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CROSS-REFERENCE TO RELATED APPLICATION
This application is a Continuation from U.S. non-provisional patent application Ser. No. 11/953,385, filed on Dec. 10, 2007 now U.S. Pat. No. 8,286,021 which claims priority under 35 U.S.C. §119 from Korean Patent Application No. 2006-126443, filed on Dec. 12, 2006, the entirety of each of which is incorporated herein by reference as if set forth in its entirety.
FIELD OF THE INVENTION
The present invention relates to semiconductor memory devices and, more particularly, to flash memory devices and memory systems that include flash memory devices.
BACKGROUND
FIG. 1 is a diagram illustrating the pin configuration of a standard 48-pin TSOP1 circuit that may be used in a general NAND flash memory device. As shown in FIG. 1 , the standard 48-pin TSOP1 includes a plurality of control pins such as /WE, ALE, CLE, /CE, /RE, and R/BB, power pins Vcc and Vss, and input/output pins I/O 0 ˜I/O 7 . As is well known, data that is to he programmed into the flash memory device is input through the input/output pins I/O 0 ˜I/O 7 in synchronization with a transition (e.g. a rising edge or a falling edge) of a control signal /WE. Data that is to be read from the flash memory device is output through the input/output pins I/O 0 ˜I/O 7 in synchronization with a transition of the control signal /RE.
The quantity of data that is input into or output from a NAND flash memory device may increase in proportion to the capacity of the NAND flash memory device. Accordingly, as the capacity of NAND flash memory devices increases, all else being equal, the time required to transfer data between the NAND flash memory device and a flash controller may increase. For example, the time required to transfer data between a flash controller and a NAND flash memory device having a 1 kilobyte page size will be twice the time required to transfer data between a flash controller and a NAND flash memory device having a 512-byte page size. Accordingly, as the capacity of NAND flush memory devices has increased, efforts have been made to reduce the data transmission time between the NAND flash memory device and the flash controller.
U.S. Patent Publication No. 2006-0023499 entitled “NON-VOLATILE MEMORY DEVICE FOR PERFORMING DDR OPERATION IN DATA OUTPUTTING PROCESS AND DATA OUTPUTTING METHOD OF THE SAME CAPABLE OF OUTPUTTING DATA AT FALLING EDGE AS WELL AS RISING EDGE OF READ CONTROL SIGNAL”, which claims priority from Korean Patent No. 10-0546418, describes one such effort at reducing the data transmission time. In particular, the above-referenced documents describe data transmission techniques in which data is transferred in synchronization with both the rising and falling edges of the control signal /RE. Both the above-referenced U.S. patent publication and the Korean patent from which it claims priority are incorporated herein by reference as if set forth in their entireties.
According to the above-referenced documents, data read out through a page buffer circuit of a non-volatile memory device is output externally in synchronization with the rising and falling edges of a clock signal (e.g., S_REB) that oscillates in a half cycle of the signal /RE. Such a data output scheme enables data to be rapidly output from the NAND flash memory device to, for example, a flash controller. However, using the signal /RE to generate a clock signal may cause problems.
In particular, as shown in FIG. 1 , in the standard 48-pin TSOP1 chip, the signal /RE is supplied through a control pin that is on one side of the chip and data is input and output through the input/output pins I/O 0 ˜I/O 7 that are on the other side of the chip. As shown in FIG. 2 , the signal /RE that is input to the chip is converted into the clock signal S_REB by a clock generator 10 (the clock generator 10 corresponds to the frequency controller 553 of the forgoing disclosure). The clock signal S_REB is applied to a data buffer circuit 20 that is adjacent to the input/output pins I/O 0 ˜I/O 7 . The data buffer circuit 20 outputs-data in synchronization with the rising and falling edges of the clock signal S_REB. As shown in FIG. 2 , the signal /RE is transferred to the data buffer circuit 20 , which is on the right side of the chip, from a pin on the left-side of the chip. With this configuration, it may be difficult to maintain a duty ratio of the signal /RE (from which the clock signal S_REB is generated) at a fixed value (e.g., 50%). As a result, setup/hold margins may be different between data output in synchronization with a rising edge of the clock signal S_REB and data output in synchronization with a falling edge of the clock signal S_REB. Thus, it may be difficult to practically implement a NAND flash memory device with a double data rate (DDR) function using the control signal /RE.
SUMMARY
Pursuant to embodiments of the present invention, NAND and other types of flash memory devices that may have improved data transmission speed arc provided, as are memory systems that include such flash memory device. These flash memory devices may also reduced numbers of pins.
Pursuant to some embodiments of the present invention, the flash memory device may include a memory cell array, a clock signal input, an input for receiving a signal designating a writing operating mode and a plurality of data input/output pads. A data input/output buffer circuit is also provided, and may be electrically connected to the clock signal input and to the plurality of data input/output pads. The data input/output buffer circuit may be configured to receive data that is to be written to the memory cell array through the data input/output pads in synchronization with a clock signal that is applied to the clock signal input in response to activation of the signal designating the writing operating mode.
In some embodiments, the input for receiving the signal designating the writing operating mode may be an input for a write-enable signal. In such embodiments, the device may further include an input for a read-enable signal, and the data input/output buffer circuit may also be configured to receive data from the memory cell array and output the data through the input/output pads in synchronization with the clock signal that is applied to the clock signal input in response to activation of the read-enable signal. Moreover, in some of these embodiments, the data input/output buffer circuit may be configured to input and output data in synchronization with both rising and falling edges of the clock signal.
In other embodiments, the input for receiving the signal designating the writing operating mode may be an input for a mode selection signal that indicates one of a reading or writing operating mode. In such embodiments, the data input/output buffer circuit may be further configured to receive data from the memory cell array and output the data through the input/output pads in synchronization with the clock signal that is applied to the clock signal input in response to the mode selection signal designating the reading operating mode. Moreover, in some of these embodiments, the data input/output buffer circuit may be configured to input and output data in synchronization with both rising and falling edges of the clock signal.
In some embodiments, the clock signal input comprises a clock signal input pad, and this clock signal input pad may be disposed between respective ones of the plurality of data input/output pads. Moreover, the device may further include a first row of pins on a first side of the device and a second row of pins on a second side of the device. In these embodiments, a pin connected to the clock signal input pad and a plurality of pins that are connected to respective ones of the plurality of data input/output pads may each be part of the second row of pins, and the pin connected to the clock signal input pad may be disposed between some of the plurality of pins that are connected to respective ones of the plurality of data input/output pads.
In sonic embodiments, the data input/output buffer circuit may receive an address and a command in synchronization with a rising or falling edge of the clock signal. In other embodiments, the data input/output buffer circuit may receives addresses in synchronization with both rising and falling edges of the clock signal. Moreover, the device may also include an input for receiving a data rate selection signal that selects one of single and double data rate modes. In such embodiments, when a data rate selection signal indicates the single data rate mode, the data input/output buffer circuit inputs and outputs data in synchronization with a rising or falling edge of the clock signal, and when the data rate selection signal indicates the double data rate mode, the data input/output buffer circuit inputs and outputs data in synchronization with both rising and falling edges of the clock signal. In still other embodiments, the device may also include a mode-register set circuit that is configured to store a data rate selection command that selects one of single and double data rate modes.
Pursuant to still further embodiments of the present invention, methods of operating a flash memory device that includes a memory cell array and a data input/output buffer circuit that is configured to receive a clock signal at a first input, a signal designating a writing operating mode at a second input, and data that is to be written to the memory cell array at a plurality of data input/output pads arc provided. Pursuant to these methods, data that is to be written to the memory cell array at the plurality of data input/output pads is received in synchronization with the clock signal in response to activation of the signal designating a writing operating mode. In some embodiments of these methods, the signal designating the writing operating mode comprises one of a write-enable signal or a mode selection signal. Moreover, the method may further include receiving data from the memory cell array and outputting the received data through the plurality of data input/output pads in synchronization with the clock signal in response to activation of a signal designating a reading operating mode. The signal designating the reading operating mode may be one of a read-enable signal or a mode selection signal. Additionally, the data may be received in synchronization with both rising and falling edges of the clock signal. The first input may be a first pin that is electrically connected to a clock signal input pad, and this first pin may be disposed between a plurality of pins that are electrically connected to respective ones or the plurality of data input/output pads.
A further understanding of the nature and advantages of the present invention herein may be realized by reference to the remaining portions of the specification and the attached figures.
BRIEF DESCRIPTION OF THE FIGURES
Non-limiting and non-exhaustive embodiments of the present invention will be described with reference to the following figures. In the figures:
FIG. 1 is a diagram illustrating a pin configuration of a standard 48-pin TSOP1 in a general NAND flash memory device;
FIG. 2 is a block diagram of the NAND flash memory device shown in FIG. 1 ;
FIG. 3 is a block diagram of a flash memory system according to first embodiments of the present invention:
FIG. 4 is a block diagram schematically illustrating the NAND flash memory device shown in FIG. 3 ;
FIGS. 5 and 6 are timing diagrams of reading and writing operations performed by the NAND flash memory device shown in FIG. 4 ;
FIG. 7 is a block diagram of a flash memory system according to second embodiments of the present invention;
FIG. 8 is a block diagram schematically illustrating the NAND flash memory device shown in FIG. 7 ;
FIGS. 9 and 10 are timing diagrams of reading and writing operations performed by the NAND flash memory device shown in FIG. 8 ;
FIG. 11 is a block diagram of a memory system according to third embodiments of the present invention;
FIG. 12 is a timing diagram illustrating operation of the NAND flash memory device shown in FIG. 11 ;
FIG. 13 is a block diagram illustrating another embodiment of the memory system shown in FIG. 11 ;
FIG. 14 is a block diagram of a memory system according to fourth embodiments of the present invention;
FIG. 15 is a timing diagram illustrating operation of the NAND flash memory device shown in FIGS. 14 ; and
FIG. 16 is a block diagram illustrating another embodiment of the memory system shown in FIG. 14 .
DETAILED DESCRIPTION
Certain embodiments of the present invention will be described below, involving a flash memory device as an example in illustrating certain structural and operational features of the invention. The present invention may, however, be embodied in many different forms and should not be constructed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art. Like reference numerals refer to like elements throughout the accompanying figures.
It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms arc only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second clement could be termed a first element, without departing from the scope of the present invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (i.e., “between” versus “directly between”, “adjacent” versus “directly adjacent”, etc.).
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” “comprising,” “includes” and/or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this disclosure and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
FIG. 3 is a block diagram of a flash memory system 1000 according to first embodiments of the present invention. As-shown-in FIG. 3 , the flash memory system 1000 may include a flash controller 1100 and a NAND flash memory device 1200 . The NAND flash memory device 1200 may be configured to conduct reading/writing operations under the control of the flash controller 1100 . The NAND flash memory device 1200 receives addresses, commands, and data in synchronization with transitions of a clock signal CLK instead of a control signal /WE (i.e., write-enable signal) or a control signal /RE (i.e., read-enable signal). In embodiments of the present invention, the signals /WE and /RE may be used as flag signals to indicate operation modes. For instance, the signal /WE is used as a flag signal for a writing mode, while the signal /RE is used as a flash signal for a reading mode. The NAND flash memory device 1200 according to embodiments of the present invention may be configured to receive and output data in synchronization with rising and falling edges of the clock signal CLK. Addresses or commands may also be input to the NAND flash memory device 1200 in synchronization with rising and falling edges of the clock signal CLK. The flash controller 1100 is likewise configured to receive data from the NAND flash memory device 1200 in synchronization with rising and falling edges of the clock signal CLK.
In this embodiment, the NAND flash memory device 1200 may communicate with the flash controller 1100 in accordance with an interface protocol for a standard NAND flash memory device.
FIG. 4 is a block diagram schematically illustrating structural features of the NAND flash memory device shown in FIG. 3 . FIGS. 5 and 6 are timing diagrams illustrating the timing of reading and writing operations performed by the NAND flash memory device 1200 of FIG. 4 . Other configurations of the NAND flash memory device 1200 may be arranged in a typical structure as well known by those skilled in this art.
As shown in FIG. 4 , the clock signal CLK provided from the flash controller 1100 is applied to an input/output buffer circuit 1220 by way of pad/pin (i.e., a pad and/or pin or other input terminal) that is adjacent to the input/output pads/pins I/O 0 ˜I/O 7 : The pad/pin to which the clock signal CLK is input may, for example, be one of the non-bonded pads/pins (e.g., 25˜28, 33˜35, 38˜40, or 45˜48) when a 48-pin TSOP1 is used. The pad/pin supplied with the clock signal CLK may be assigned to a non-bonded pad/pin that is located very close to the input/output pins I/O 0 ˜I/O 7 . As such, the transmission path of the clock signal CLK to the data input/output buffer circuit 1220 is short, and thus the duty ratio of the clock signal CLK applied to the data input/output buffer circuit 1220 can generally be maintained at a predetermined value (e.g., 50%). When this is the case, the setup/hold margins between data output in synchronization with a rising edge of the clock signal CLK and data output in synchronization with a falling edge of the clock signal CLK may be approximately the same. Consequently, a NAND flash memory device with a double data rate (DDR) function may be provided using the clock signal CLK.
Referring still to FIG. 4 , the signals /RE and /WE, as flag signals for indicating operation modes, arc transferred to the data input/output buffer circuit 1220 by way of their corresponding pads. For example, the signal /RE may be transferred to the data input/output buffer circuit 1220 as the flag signal F_DOUT which indicates the reading operation mode. As shown in FIG. 5 , the data input/output buffer circuit 1220 outputs data from memory core 1240 (i.e., a memory cell array of the device) in synchronization with rising and falling edges of the clock signal CLK during the active period of the flag signal F_DOUT. The signal /WE may similarly be transferred to the data input/output buffer circuit 1220 as the flag signal F_DIN for indicating the writing operation mode. As shown in FIG. 6 , the data input/output buffer circuit 1220 receives data from an external source in synchronization with rising and falling edges of the clock signal CLK during the active period of the flag signal F_DIN, and outputs the input data to the memory core 1240 .
FIG. 7 is a block diagram of a flash memory system according to second embodiments of the present invention. As shown in FIG. 7 , the flash memory system 2000 according to the second embodiments of the present invention includes a flash controller 2100 and a NAND flash memory device 2200 . The NAND flash memory device 2200 may be configured to conduct reading/writing operations under the control of the flash controller 2100 . The NAND flash memory device 2200 receives addresses, commands, and data in synchronization with transitions of a clock signal CLK, as is the case with respect to the NAND flash memory device 1200 shown in FIG. 3 . Thus, the NAND flash memory device 2200 may be configured to receive and output data in synchronization with rising and falling edges of the clock signal CLK. Addresses or commands may also be input to the NAND flash memory device 2200 in synchronization with rising and falling edges of the clock signal CLK. The flash controller 2100 is configured to receive data from the NAND flash memory device 2200 in synchronization with rising and falling edges of the clock signal CLK.
In the NAND flash memory device 2200 , a mode selection signal M_SEL may be used as a flag signal for indicating the operation mode instead of the signals /WE and /RE. For instance, the writing operation mode may be enabled when the mode selection signal M_SEL is set to a low level, and the reading operation mode may be enabled when the mode selection signal M_SEL is set to a high level.
In this embodiment, the NAND flash memory device 2200 may communicate with the flash controller 2100 in accordance with an interface protocol for a standard NAND flash memory device.
FIG. 8 is a block diagram schematically illustrating structural features of the NAND flash memory device shown in FIG. 7 . FIGS. 9 and 10 are timing diagrams illustrating the timing of writing and reading operations by the NAND flash memory device shown in FIG. 8 . Other configurations of the NAND flash memory device 2200 may be arranged in a typical structure as well known by those skilled in this art.
As shown in FIG. 8 , the clock signal CLK provided from the flash controller 2100 is applied to an input/output buffer circuit 2220 by way of pad/pin that is adjacent to input/output pads/pins I/O 0 ˜I/O 7 . The clock signal CLK may be input to, for example, one of the non-bonded pads/pins (e.g., 25˜28, 33˜35, 38˜40, or 45˜48). The pad/pin supplied with the clock signal CLK may be assigned to a non-bonded pad/pin that is located close to the input/output pins I/O 0 ˜I/O 7 . As in the first embodiments of the present invention discussed above, this arrangement of pads/pins facilitates maintaining setup/hold margins on the same level between data output in synchronization with a rising edge of the clock signal CLK and data output in synchronization with a falling edge of the clock signal CLK.
Referring still to FIG. 8 , the signal M_SEL, as a flag signal for indicating the operation mode, is transferred to the data input/output buffer circuit 2220 by way of its corresponding pad. For example, if the signal M_SEL that is transferred to the data input/output buffer circuit 2220 has a low level it operates as a flag signal for indicating the writing operation mode, and thus the writing operation begins. Then, the data input/output buffer circuit 2220 , as shown in FIG. 9 , receives data from an external source in synchronization with rising and falling edges of the clock signal CLK during an active period of the flag signal M_SEL, and outputs the input data to a memory core 2240 (see FIG. 8 ). On the other hand, if the signal M_SEL that is transferred to the data input/output buffer circuit 2220 has a high level it operates as a flag signal for indicating the reading operation mode, and thus the reading operation begins. Then, the data input/output buffer circuit 2220 , as shown in FIG. 10 , outputs data from the memory core 2240 in synchronization with rising and falling edges of the clock signal CLK during an active period of the flag signal M_SEL.
FIG. 11 is a block diagram of a memory system according to third embodiments of the present invention, and FIG. 12 is a timing diagram illustrating operation of the NAND flash memory device of FIG. 11 .
Referring to FIG. 11 , the memory system 3000 according to the third embodiments of the present invention may include a flash controller 3100 and a NAND flash memory device 3200 . The NAND flash memory device 3200 is similar to the NAND flash memory device 2200 of FIG. 8 , but is operable in a single data rate (SDR) mode in which data is input/output in synchronization with a rising or falling edge of the clock signal CLK, as well as operable in a double data rate (DDR) mode in which data is input/output in synchronization with both rising and falling edges of the clock signal CLK. These modes may be alternatively enabled by the selection signal SDR/DDR. If the selection signal SDR/DDR indicates the SDR mode, as shown in FIG. 12 , the NAND flash memory device 3200 receives addresses, commands, and data in synchronization with the rising or falling edges of the clock signal CLK (the rising edge is depicted in FIG. 12 ). If the selection signal SDR/DDR indicates the DDR mode, as shown in FIG. 12 , the NAND flash memory device 3200 receives addresses, commands, and data in synchronization with both the rising and failing edges of the clock signal CLK.
An alternative implementation of the memory system 3000 of FIG. 11 is depicted in FIG. 13 . As shown in FIG. 13 , in this alternative embodiment, the NAND flash memory device is implemented using the signals /RE and /WE (instead of the signal M_SEL) as flag signals for indicating the operation mode.
FIG. 14 is a block diagram of a memory system according to fourth embodiments of the present invention, and FIG. 15 is a timing diagram showing operation of the NAND flash memory device of FIG. 14 .
Referring FIG. 14 , the memory system 4000 according to fourth embodiments of the present invention may include a flash controller 4100 and a NAND flash memory device 4200 . The NAND flash memory device 4200 is similar to the NAND flash memory device 2200 of FIG. 8 , but is different in that it is operable in either the SDR or DDR mode. The mode selected may be alternatively enabled by setting a mode-register set circuit 4220 . In aiming an operation from the SDR mode to the DDR mode, as shown in FIG. 15 , the mode-register set circuit 4220 is conditioned with a command in correspondence with the DDR mode. Once the mode-register set circuit 4220 is commanded for the DDR mode, the NAND flash memory device 4200 interfaces with the flash controller 4100 in the DDR mode. For instance, if the mode-register set circuit 4220 is conditioned with a command in correspondence with the DDR mode, as shown in FIG. 15 , the NAND flash memory device 4200 receives addresses, commands, and data in synchronization with both rising and falling edges of the clock signal CLK.
An alternative implementation of the NAND flash memory device 4200 of FIG. 14 is depicted in FIG. 16 . As shown in FIG. 16 , in this alternative embodiment, the NAND flash memory device 4200 ′ is implemented using the signals /RE and /WE (instead of the signal M_SEL) as flag signals for indicating the operation mode.
As described above, pursuant to embodiments of the present invention, NAND flash memory devices having a DDR function may be provided using the clock signal CLK instead of the signals IRE and /WE.
The above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true spirit and scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description. | A flash memory device includes a memory cell array, a clock signal input, an input for receiving a signal designating a writing operating mode, a plurality of data input/output pads, and a data input/output buffer circuit that is electrically connected to the clock signal input and to the plurality of data input/output pads. The data input/output buffer circuit is configured to receive data that is to be written to the memory cell array through the data input/output pads in synchronization with a clock signal that is applied to the clock signal input in response to activation of the signal designating the writing operating mode. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a process and apparatus for treating a feed gas. In particular, the invention relates to a thermal swing adsorption (TSA) process using at least three adsorption beds for removing or at least reducing the level of a component in a feed gas to render it suitable for downstream processing and apparatus for use in the process. The invention is especially useful in removing components from a feed gas on a large scale where conventional processes and apparatus are not suitable for use.
Where a feed gas is to be subjected to downstream processing, it may often be desirable or necessary to remove certain components from the feed gas prior to such processing. As an example, high boiling materials for example water and carbon dioxide which may be present in a feed gas, for example air, must be removed where the mixture is to be subsequently treated in a low temperature, for example cryogenic, process. If relatively high boiling materials are not removed, they may liquefy or solidify in subsequent processing and lead to pressure drops, flow difficulties or other disadvantage in the downstream process. Hazardous, for instance explosive, materials are suitably removed prior to further processing of the feed gas so as to reduce the risk of build-up in the subsequent process thereby presenting a hazard. Hydrocarbon gases, for example acetylene, may present such a hazard.
In an air separation process, the gas is typically compressed using a main compressor (MAC) followed by cooling and removal of the thus condensed water in a separator. The gas may be further cooled using for example refrigerated ethylene glycol. The bulk of the water is removed in this step by condensation and separation of the condensate. The gas is then passed to an adsorption process where the components to be removed from the feed gas are removed by adsorption and then to an air separation unit. In treating air, water is conventionally removed first and then carbon dioxide by passing the feed gas through a single adsorbent layer or separate layers of adsorbent selected for preferential adsorption of water and carbon dioxide prior to feeding the treated air to a downstream separation process.
Several methods are known for removing an undesired component from a feed gas by adsorption on to a solid adsorbent including temperature swing adsorption (TSA) and pressure swing adsorption (PSA), thermal pressure swing adsorption (TPSA) and thermally enhanced pressure swing adsorption (TEPSA). Conventionally in such methods, two adsorbent beds are employed in a parallel arrangement with one being operated for adsorption while the other is off-line and being regenerated and then the roles of the beds are periodically reversed in the operating cycle. The adsorption bed is said to be “on-line” during the adsorption step.
In a TSA process, the adsorption step generates heat of adsorption causing a heat pulse to progress downstream through the adsorbent bed. The heat pulse is allowed to proceed out of the downstream end of the adsorbent bed during the feed or on-line period. After adsorption, the flow of feed gas is shut off from the adsorbent bed which is then depressurised. The adsorbent is then exposed to a flow of hot regeneration gas, typically a waste stream or other gas from the downstream process, which strips the adsorbed materials from the adsorbent and so regenerates it for further use. Regeneration conventionally is carried out in a direction counter to that of the adsorption step. The bed is then repressurised in readiness to repeat the adsorption step.
A PSA system typically involves a cycle in which the bed is on-line, and then depressurised, regenerated and then repressurised before being taken back on-line. Depressurisation involves releasing pressurised gas and leads to waste, generally known as “switch loss”. In PSA systems, the pressure of the regeneration gas is lower than that of the feed gas. It is this change in pressure that is used to remove the adsorbed component from the adsorbent. However, cycle times are usually short, for example of the order of 15 to 30 minutes, as compared with those employed in a TSA system, which may be for example of the order of 2 to 20 hours. PSA therefore has certain disadvantages including unacceptable switch loss due to the relatively high frequency of switching between on-line operation and regeneration, especially in operating large capacity plant.
U.S. Pat. No. 5,656,065 describes a PSA process that employs three beds operated in a phased cycle which aims to reduce switch loss and improve continuity of flow of the feed gas to a downstream process. The purpose of the third bed is to allow a process cycle in which a small flow of pressurised feed gas is fed to the bed undergoing repressurisation. Hence, the repressurisation step is relatively long but a reduction in the interruption of the treated gas to a downstream process is advantageously secured.
Thermal pressure swing adsorption (TPSA) is also suitable for removing components from a feed gas by adsorption. In a TPSA system an undesired component is typically adsorbed in a first zone in which an adsorption medium is disposed for example activated alumina or silica gel. A second undesired component is then adsorbed in a second zone. TPSA, utilises a two stage regeneration process in which one adsorbed component is desorbed by TSA and another is desorbed by PSA. A TPSA process is described in U.S. Pat. No. 5,885,650 and U.S. Pat. No. 5,846,295.
In thermally enhanced PSA (TEPSA), desorption occurs by feeding a regeneration gas at a pressure lower than the feed gas and at a temperature greater than it and subsequently replacing the hot regeneration gas by a cold regeneration gas. The heated regeneration gas allows the cycle time to be extended as compared to that of a PSA system so reducing switch losses as heat generated by adsorption within the bed may be replaced in part by the heat from the hot regeneration gas. A TEPSA process is described in U.S. Pat. No. 5,614,000.
TSA, TPSA and TEPSA systems require the input of thermal energy and may require the use of insulated vessels, a regeneration gas preheater and an inlet end precooler and generally the high temperatures impose a more stringent and costly mechanical specification for the system. In operation, there is extra energy cost associated with using the preheater.
By the term “thermal swing adsorption” we mean adsorption processes and apparatus for operating the process in which thermal energy is input to regenerate the adsorbent and includes TPSA and TEPSA processes in addition to TSA unless otherwise stated.
TSA apparatus typically comprises a pair of adsorber vessels, both containing adsorbent. The vessels may be of any conventional type including the vertical, horizontal and radial type.
Conventional purification in a TSA process, especially where larger vessels are employed, may be problematic because the flow characteristics of the gas being processed may place limitations due to the need to avoid undue fluidization of the adsorbent bed and unacceptable pressure drop. In addition complex design of vessel geometry to address these issues, especially to accommodate large flows, may themselves introduce further problems. Accordingly, large vessels present certain problems and there are practical limits for their use.
Radial flow adsorbers have been employed to reduce problems with flow but they are typically more expensive than vertical and simple horizontal vessels. For radial beds, a higher ratio of bed height to bed diameter is required to gain a higher flow. In addition the bed's effective thickness is typically limited by the diameter which may itself be limited by constraints in transporting the adsorption vessel in manufacture and assembly of the plant. Moreover, the bed size is limited by the need to avoid a large pressure drop and lack of uniformity of flow.
In a horizontal bed, a reduction in bed thickness and increase in the ratio of effective bed length to diameter also has practical limits and long horizontal beds are therefore undesirable.
To increase capacity, a “four bed” configuration may be used in a TSA process in which two beds are on line with two beds being regenerated at the same time and the regenerated beds then being placed on-line and the other, exhausted beds being regenerated to provide a high throughput. The four beds are typically operated as two pairs of beds and the phasing of the adsorption/regeneration cycle of the two pairs need not be co-ordinated. In this way four simple vessels having a conventional geometry and design may be used to avoid difficulties of pressure drops and transportation which could be encountered if larger scale equipment were to be employed. This approach however requires significant capital investment and adds to the complexities of design of a large scale separation unit.
U.S. Pat. No. 5,571,309 describes an adsorption process in which a high pressure and a low pressure feed stream are passed to each of a plurality of adsorption beds. The beds are operated in an out of phase cycle. The feed for any given bed is fed sequentially at low and high pressure during a single adsorption cycle and it is necessary to utilise a repressurisation stage just prior to the high and low pressure feed stages. This process seeks to address the problem of providing a product stream at high and low pressure from a single adsorption unit.
The process of U.S. Pat. No. 5,571,309 does not disclose a process for treating a feed gas on a large scale without introducing undue complexity or cost in order to avoid or address the technical difficulties of unacceptably high pressure drop and feed gas flow distribution which are associated with operation of a conventional TSA process on a large scale.
BRIEF SUMMARY OF THE INVENTION
We have now found that technical problems such as undesirable fluid flow, bed fluidisation and unacceptable pressure drop and economic and practical problems including cost, design complexity and difficulties in transporting large-scale apparatus may be reduced or avoided by operating a TSA process using at least three adsorption zones in which, in use, at least two of the zones are always on-line and in which the feed gas is fed to the process continuously at a pressure which is generally constant in the adsorption step of the process. Each of the zones repeatedly passes through the cycle of adsorption and regeneration, the each zone being at a point on the cycle which is out of phase with the other zones so that at any given time at least two zones are adsorbing a component of the feed gas and a third zone is being regenerated and is brought on-line as or before one of the zones in the adsorption phase is taken off-line to be regenerated. By employing a TSA process, characteristics inherent in a PSA process are also avoided.
A first aspect of the invention provides a process for the reduction of the level of a component in a feed gas comprising passing the feed gas to at least three parallel thermal swing adsorption zones, each zone containing an adsorbent and being operated in an adsorption cycle which comprises an adsorption step to remove or to reduce the level of the component from the feed gas and in which the feed gas is fed continuously to the adsorption zone during the adsorption step, depressurisation of the adsorption zone, a regeneration step to desorb the adsorbed component and repressurisation of the adsorption zone, wherein the adsorption cycle of each zone is phased with respect to that of the other zones so that at any point during the adsorption cycle, the number of zones in the adsorption step is greater than the number of zones not in the adsorption step.
Suitably, the pressure of the gas being fed to the adsorption step is substantially constant in a given adsorption cycle. The pressure of the feed gas suitably is not varied discretely during the adsorption step in a given adsorption cycle. The adsorption cycle preferably does not contain more than one adsorption step but if it does, then the pressure of the feed gas in each more than one step is desirably the same as in the other steps of that cycle.
Preferably, the pressure of the feed gas is not varied from one adsorption cycle to another, but, as desired, a feed gas of different pressure to that in a subsequent or prior adsorption cycle in the same or a different adsorption zone may be employed,
The feed gas is suitably split upstream of the adsorption zones to produce multiple streams of feed gas for feeding to the at least two adsorption zones that are on-line at any given time.
In the regeneration step, a regeneration gas is suitably fed to the adsorption zone being regenerated so as to desorb the adsorbed component thereby regenerating the zone for a subsequent adsorption step in a new adsorption cycle.
Advantageously, a high process throughput may be secured as compared to prior art processes for a given scale of apparatus and avoids the disadvantage of higher cost, flow fluctuations and pressure drop associated with the use of larger scale equipment to achieve a comparable throughput.
The invention provides in a second aspect, thermal swing adsorption apparatus for conducting thermal swing adsorption of a component in a feed gas, the apparatus comprising at least three parallel thermal swing adsorption zones adapted to receive an adsorbent bed and means for controlling the flow of the feed gas through the at least three zones such that each bed undergoes repeated adsorption cycles which cycle comprises an adsorption step to remove or to reduce the level of the component from the feed gas and in which the feed gas is fed continuously to the adsorption zone during the adsorption step, depressurisation of the zone, a regeneration step to desorb the adsorbed component and repressurisation of the adsorption zone, and wherein the adsorption cycle of each zone is phased with respect to that of the other zones so that, in use, the number of zones in the adsorption step is greater than the number of zones not in the adsorption step.
The regeneration step suitably comprises feeding a regeneration gas to the adsorption zone undergoing regeneration. The apparatus according to the invention also suitably comprises means for controlling the flow of a regeneration gas such that the regeneration step may be successively performed for each of the adsorption zones and a heater for heating the regeneration gas.
The means for controlling the flow of feed gas may comprise conduits for gas flow in or connecting the zones and connecting each bed to a source of the feed gas and to an outlet from the apparatus for the gas treated by removal or reduction of the undesired component, valve means in the conduits operable to open and close respective ones of the conduits. It is especially preferred that the means for controlling the flow of gas comprises valve control means programmed to operate the valve means in sequence to produce the required adsorption cycles of operation.
The apparatus also suitably comprises means to control the flow of gas for regeneration, depressurisation and repressurisation.
In a preferred embodiment, the adsorption zone is defined by a conventional adsorption vessel. Preferably the apparatus comprises three adsorption vessels.
As a practical advantage, the use of three adsorption vessels each having half the capacity of each of two larger vessels requires about 25% less adsorbent than the two vessels of twice the capacity. In operating the two bed, large vessel system conventionally, one bed at a time would be on-line. However, in operating the three vessel system, two of the three vessels would be on-line at a given time providing a comparable throughput. Moreover, by virtue of splitting the feed gas into two streams to feed both vessels, the size of tubing and valves required in the plant will be smaller and provide significant cost benefits as compared to conventional apparatus because typically the cost of valves increases greatly with size.
Preferably, the process according to the invention is carried out in the apparatus according to the invention.
Suitably, at least two zones are in the adsorption step and at least one is in the regeneration step at any point during the adsorption cycle. Preferably, the number of zones in the adsorption step at any point during the adsorption cycle is constant so as to provide advantageously a relatively constant throughput of the feed gas and reducing fluctuations in flow volume in a downstream process. Optimally, the number of zones in the adsorption step at any point during the cycle is one fewer than the total number of adsorption zones so that, at any point only one zone is in the regeneration step so as to maximise throughput of the feed gas.
In a preferred embodiment the adsorption cycle of each zone commences at a different time to the commencement of the adsorption cycle of the other zones and for all the adsorption zones is substantially the same duration. More preferably, in addition, the adsorption step for each zone is substantially the same duration as that for the other zones. More preferably, the ratio of the duration of the adsorption step to the adsorption cycle is not less than the ratio of one less than the number of adsorption zones to the number of adsorption zones.
For reference, the adsorption cycle herein is considered to start with the adsorption step and then to be followed by depressurisation, the regeneration step and repressurisation.
The feed gas comprises a desired component and a component to be removed from the feed gas by adsorption. For example the feed gas may contain carbon dioxide and water. The feed gas may be natural gas or synthetic gas and in a preferred embodiment, the feed gas is air. After treatment, the gas is suitably subjected to a downstream process of cryogenic separation especially for the recovery of oxygen and/or nitrogen.
Where the feed gas contains carbon dioxide and water, it is suitably treated by contacting with a first adsorbent so as to remove the water prior to removal of carbon dioxide suitably on a second adsorbent. Suitable adsorbents include alumina, silica gel, activated alumina, impregnated alumina, and molecular sieves, for example zeolite of the X type, A type and LSX. Preferably the zeolite has a silicon to aluminium ratio of 1.0 to 1.25. The water adsorbent material is preferably silica gel, activated alumina or impregnated alumina and the carbon dioxide adsorbent material may be a molecular sieve for example, a zeolite. The zeolite may be bound or binderless. Preferably, the zeolite is sodium exchanged zeolite X, sodium exchanged zeolite Y or calcium exchanged zeolite X. More than one adsorbent may be employed in a single bed, for example as separate layers, as desired.
Preferably, the water adsorbent and carbon dioxide adsorbent are arranged in a composite bed with the carbon dioxide adsorbent downstream of the water adsorbent although separate beds may be employed if desired.
The TSA process according to the invention is preferably operated using at least three parallel flow paths and optimally the same number of flow paths as adsorption zones, so as to allow the process to be operated in a cyclical manner comprising adsorption and desorption with the separate flow paths being cycled out of phase to provide a pseudo-continuous flow of feed gas from the process through the at least three adsorption zones. This arrangement is also beneficial in reducing cost and complexity of the process design.
The feed gas is suitably fed to the adsorption step at a temperature of −50 to 80° C. and preferably 0 to 60° C., especially 5 to 50° C. Suitably the pressure of the feed gas is at least 100000 N/m 2 , preferably 200000 to 4000000 more preferably 200000 to 3000000 and desirably 200000 to 2000000 N/m 2 . The feed gas is fed in a continuous manner to the adsorption zone during the adsorption step.
In the process, the feed gas is introduced into an adsorption zone and contacted with the adsorbent, suitably in the form of a bed. As the mixture passes through the adsorbent, the component(s) to be adsorbed are adsorbed and the remaining gas then passes out of the adsorption zone. During the process a front of the gas to be adsorbed forms in the adsorbent and passes through it. As desired, the adsorption step is then terminated and the adsorption zone is then heated and optionally subjected to a reduced pressure and is purged of the adsorbed gas during regeneration by feeding a regeneration gas to the zone.
The adsorption step is suitably operated in a conventional manner known to those skilled in the art.
Preferably, the regeneration gas comprises a gas recycled from a downstream process, for example a nitrogen-rich waste gas stream from an air separation plant which is dry and free of carbon dioxide. Preferred regeneration gases include oxygen, nitrogen, methane, hydrogen and argon and mixtures thereof.
The regeneration of the adsorbent is suitably carried out using a regeneration gas at a temperature above the bed adsorption temperature, suitably at a temperature of 0 to 400° C., preferably from 40 to 200° C.
Suitably, the regeneration pressure is 10000 to 2000000 N/m 2 and preferably 20000 to 1500000 N/m 2 . It is especially desirable that the regeneration pressure does not exceed 50 percent of the pressure of the feed gas.
Repressurisation may be effected by passing upstream, feed gas or downstream, treated gas through the bed to be regenerated. The repressurisation gas is at a higher pressure than the adsorption zone.
Preferably, the process is operated with a molar flow of regeneration gas to the feed gas of 0.05 to 0.8 more preferably 0.1 to 0.5.
Suitably, in a TSA process and a TPSA process, the feed gas is fed to the adsorption zone for a period of 6 to 1000 minutes and preferably 70 to 300 minutes. In a TEPSA process the feed gas is suitably fed to adsorption unit zone for a period of 10 to 150 minutes and preferably 20 to 80 minutes.
Advantageously, in use, where the adsorbent is free standing in a horizontal or vertical vessel, the fluid flow is suitably not more than 90% and desirably not more than 70% of the flow at which fluidisation of the bed occurs.
The present invention also allows independent feed gases which have a different characteristic to the other gases. Each feed gas may be of different composition or have different properties, for example flow, pressure, temperature and rate, on being fed to the adsorption cycle. In these circumstances, each adsorption zone is designed to take account of the most extreme conditions of the different feed stocks thereby enabling the different feeds to be cycled between each bed with regeneration in between. Whilst the feed gas composition or properties may be different from one adsorption cycle to another, within a given adsorption cycle, the feed gas composition and properties are not altered and the gas is fed to the adsorption zone continuously.
The invention also provides in a preferred embodiment a thermal swing adsorption apparatus comprising at least three adsorption vessels, a feed gas inlet assembly in fluid communication with each vessel, an outlet assembly in fluid communication with the at least three vessels being arranged in parallel paths, flow control means to permit the feed gas to pass through each vessel and to the outlet assembly, a regeneration assembly comprising a conduit in fluid communication with the outlet assembly whereby a regeneration gas is able to be passed into each vessel and a heater to heat the regeneration gas, the flow control means and the regeneration assembly being arranged so that each vessel, in use, repeatedly undergoes an adsorption cycle comprising an adsorption step, depressurisation, a regeneration step and repressurisation and the adsorption cycle for each vessel is out of phase with the cycle for all the other vessels provided that, in use, at least two vessels are in the adsorption step at any time and the flow control means feeds the feed gas continuously to the adsorption zone during the adsorption step.
The present invention may be employed in combination with otherwise conventional air separation plant and other apparatus for gas separation. The invention also has applicability in other fields including remote applications, for example shipboard applications, where oxygen storage may be subject to safety scrutiny. The invention provides advantage in applications where continuous supply of a gas to a downstream process is important for economic, safety or other masons. For example the need for reliability of supply of oxygen for a downstream Fisher Tropsch or methanol production process is important and the present invention provides a safety benefit by being operable in a conventional mode, that is using a pair of beds in the event that the third vessel is inoperative for example in an emergency or due to scheduled process down-time.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 shows a conventional cycle for the operation of a prior art two bed TSA process.
FIG. 2 is a schematic illustration of apparatus according to the invention.
FIG. 3 shows the cycle of operation of a process according to the invention and the apparatus of FIG. 2 .
In FIGS. 1 and 3 , “D” denotes depressurisation, “R” denotes repressurisation and “REGEN” denotes regeneration. In FIG. 1 , a conventional TSA process cycle is shown in which the adsorbent in a first bed is on-line, receiving a feed gas and adsorbing at least one undesired component of the gas and the treated feed is then passed downstream, optionally for further processing. While the first bed is on line, the second bed is sequentially depressurised, regenerated by passing a regeneration gas through the bed counter-current to that of the feed gas when on-line and then repressurised. The regeneration gas is heated for at least the initial period of regeneration to provide a heat pulse which passes through the second bed and desorbs the adsorbed, undesirable component. Repressurisation of the second bed is then carried out. After repressurisation, the second bed is then switched to on-line operation and the first bed is taken off-line and subjected to the depressurisation, regeneration and repressurisation process.
DETAILED DESCRIPTION OF THE INVENTION
A conventional TSA process typically has a cycle time of some hours whereas a conventional PSA process has a cycle time of the order of tens of minutes. Accordingly, use of downstream, treated gas to repressurise the bed undergoing regeneration does not adversely affect the continuity of the downstream flow to the same extent as in a PSA process.
Apparatus for use in accordance with the present invention shown in FIG. 2 comprises three beds of adsorbent 1 , 2 and 3 arranged in parallel. Each is connected via a respective inlet valve 4 , 5 and 6 to an inlet manifold 7 connected to a source 8 of feed gas. The inlet end of each of the beds 1 , 2 and 3 is also connected to a first venting manifold 9 via respective venting valves 10 , 11 and 12 . The outlet from each of the beds 1 , 2 and 3 is connected via a respective outlet valve 13 , 14 and 15 to an outlet manifold 16 which is connected to a downstream processing apparatus such as the cold box of an air separation unit 17 . Regeneration gas for example from an air separation unit is supplied to the apparatus of FIG. 2 at an input 18 via a heater 19 which is periodically switched on to provide a heated pulse of regeneration gas and is connected to the outlet end of each bed 1 , 2 and 3 for counter-current purging flow via a respective inlet valve 20 , 21 and 22 . The outlets of the beds 1 , 2 and 3 are interconnected amongst themselves via valves 23 , 24 and 25 to allow flow of repressurisation gas from outlet manifold 16 . The operation of the control valves is controlled in a known manner by appropriate control means, not illustrated, but in a novel sequence to provide the phased adsorption cycles for the beds 1 , 2 and 3 .
The phasing of the operations of the beds 1 , 2 and 3 is illustrated in FIG. 3 which shows one adsorption cycle. It is this cycle which is repeated. In FIG. 3 it can be seen that during the on-line or feed period of each bed, at least one of the other beds and is also on-line. Each bed is sequentially operated on-line, depressurised (D), regenerated and then repressurised (R). As the first bed 1 is taken off-line at t a , the regenerated bed 2 is brought on-line, having been depressurised at t c , regenerated and repressurised. During this time, the third bed 3 is on-line having been brought on-line at t c during the adsorption step of the first bed 1 and is then taken off-line during the adsorption step of the second bed 2 at t b after the first bed 1 is brought on-line. On being taken off-line, the first bed is then depressurised, regenerated and then repressurised and brought on-line at t b at which time, the third bed is taken off-line and subjected to depressurisation, regeneration and repressurisation.
As one bed is taken off-line and another is brought on-line, a short period of overlap during which the two beds are both on-line is provided to allow for the mechanical opening and closing of valves.
The cycles of the beds suitably are phased so that there are overlaps for example of 10 to 20 seconds between the on-line periods of the beds. During such overlap periods, venting may be carried out to maintain a constant output of treated gas.
It will readily be appreciated that further beds may be included in parallel in a modified version of the apparatus shown in FIG. 2 .
The invention is illustrated by reference to the following non-.limiting examples and the accompanying drawings.
EXAMPLES 1 TO 6 AND COMPARATIVE EXAMPLES A1 TO A12
The effectiveness of a TSA system according to the invention as shown in FIG. 2 with adsorption cycles phased as shown in FIG. 3 and employing vertical beds was assessed by simulation.
Conventional processes were simulated according to the conventional TSA cycle shown in FIG. 1 for operation with two beds and two pairs of beds where the beds are alternately on-line and off-line for comparative purposes.
Three sets of runs were simulated, at 1000000 Nm −2 , 600000 Nm −2 and 300000 Nm −2 .
Zeolite 13X of density 640 kg/m 3 , was used as the adsorbent. Runs were simulated using small adsorbent beads and large adsorbent beads, altered, small beads being 1.0 to 2.4 mm in diameter and large beads being 2.4 to 5 mm.
The molar purge to air ratio (P/A) was 0.15, contact time was set at 7 seconds and the temperature of the feed gas at 15° C. The beds were taken to be 5 m diameter. The approach to fluidisation of the bed was constant for runs at a given pressure and was less than 70%. A maximum regeneration temperature of 140° C. was used.
The results are shown below in Tables 1 to 3.
TABLE 1
Vertical bed at 1000000 Nm −2
Bead
No of
Bed Height
Air Flow
DP, Pa/m
DP, Pa/m
Eg
Size
Beds
(m)
(Nm3/h)
(air)
(hot purge)
A1
SMALL
2
1.06
100,000
3533
2755
1
SMALL
3
1.06
200,000
3533
7073
A2
SMALL
4
1.06
200,000
3533
2755
A3
LARGE
2
1.06
150,0000
3509
1687
2
LARGE
3
1.06
300,000
3509
5143
A4
LARGE
4
1.06
300,000
3509
1687
DP (air) refers to the pressure drop when operated on line and DP (hot purge) to the pressure drop during the regeneration step.
TABLE 2
Vertical bed at 600000 Nm −2
Bead
No of
Bed Height
Air Flow
DP, Pa/m
DP, Pa/m
Eg
Size
Beds
(m)
(Nm3/h)
(air)
(hot purge)
A5
SMALL
2
1.4
80000
4000
2100
3
SMALL
3
1.4
160000
4000
5158
A6
SMALL
4
1.4
160000
4000
2100
A7
LARGE
2
1.4
120000
3830
1200
4
LARGE
3
1.4
240000
3830
3568
A8
LARGE
4
1.4
240000
3830
1200
TABLE 3
Vertical bed at 300000 Nm −2
DP, Pa/m
Bead
No of
Bed Height
Air Flow
DP, Pa/m
(hot
Eg
Size
Beds
(m)
(Nm3/h)
(air)
purge)
A9
SMALL
2
2.47
50000
3619
1183
5
SMALL
3
2.47
100,000
3619
2755
A10
SMALL
4
2.47
100,00
3619
1183
A11
LARGE
2
2.47
70,0000
2808
562
6
LARGE
3
2.47
140,000
2808
1518
A12
LARGE
4
2.47
140,000
2808
562
From the above results It can be seen that in Examples 1 to 6, by adding a third bed and operating the adsorption cycles out of phase a much higher air flow than a conventional two bed system and a comparable air flow as a conventional four bed system may be achieved. With three beds rather than four, major savings in capital and variable cost may be achieved.
EXAMPLES 7 AND 8 AND COMPARATIVE EXAMPLES B1 AND B2
A series of simulations were carried out under the same conditions as set out under Examples 1 to 6 and A1 to A12 for a horizontal bed of 5 m diameter and 2 m depth. The pressure is 600000 Nm −2 .
The results are shown in Table 4.
TABLE 4
Bead
No
Air Flow
Bed Length
DP, Pa/m
DP, Pa/m
Eg
Size
Beds
(Nm3/h)
(m)
(air)
(hot purge)
B1
SMALL
2
1000,000
34
3711
1515
7
SMALL
3
1000,000
16
3711
4379
B2
LARGE
2
1000,000
34
1711
571
8
LARGE
3
1000,000
17
1700
5391
Operating according to the present invention for a given air flow enables a horizontal bed of much shorter length to be employed than would be usable in a conventional process. Alternatively, for a given bed length, the present invention allows a significantly higher throughput to be achieved than a conventional process.
EXAMPLE 9 AND COMPARATIVE EXAMPLE C1
A series of simulations were carried out under the same conditions as set out under Examples 1 to 6 and A1 to A12 for a radial bed of 5 m diameter and 1.2 m depth with a small bead size adsorbent. The pressure is 600000 Nm −2 .
The results are shown in Table 5.
TABLE 5
Air Flow
Bed Length
No
DP, Pa/m
DP, Pa/m (hot
Eg
(NM3/h)
(m)
Beds
(air)
purge)
C1
1000,000
30
2
4180
2618
9
1000,000
15
3
4180
6828
Operating according to the present invention for a given air flow enables a radial bed of much shorter length to be employed than would be usable in a conventional process. Alternatively, for a given bed length, the present invention allows a significantly higher throughput to be achieved than a conventional process. | A process and an apparatus related to the reduction of the level of a component in a feed gas such as air involving passing the gas to at least three parallel thermal swing adsorption zones charged with an adsorbent and operating according to an adsorption cycle, wherein the cycle of each zone is phased with respect to that of the other zones so that at any point during the cycle, the number of zones in the adsorption step is greater than the number of zones not in the adsorption step. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of Ser. No. 10/277,509 filed 22 Oct. 2002 (now U.S. Pat. _______) and based upon provisional application 60/331,092 filed 22 Oct. 2001.
FIELD OF THE INVENTION
[0002] This invention pertains to electronic devices that can be used on the lap of a seated user, such as a laptop computer, and more particularly to maintaining such devices in a secure and stable condition while on the lap, and to preventing the devices from falling to the floor.
BACKGROUND DISCUSSION OF PRIOR ART
[0003] Inventors of relevant prior art have pointed to, and attempted to remedy, practical problems involved in the use of the laptop computer. For example, it has been previously noted that when a laptop computer is being used while on the lap it is at risk of slipping off the lap and falling onto the floor, being damaged as a result (e.g., Bourque, U.S. Pat. No. 5,667,114, contains a discussion of this problem; see especially paragraph 4 of Bourgue's Background section). The current invention also serves to remedy practical problems associated with use of the laptop computer, as well as other electronic devices that can be used on the lap, but it differs from the prior art in important ways.
[0004] Scrutiny of prior art reveals seven specific structural and functional characteristics that frequently recur and which typically differ between the prior art and the invention disclosed in this application. Because awareness of these differentiating characteristics can help one appreciate the novelty and non-obviousness of the current invention, these characteristics will be enumerated before specific prior art patents are discussed. The seven characteristics are:
1. Prior art is designed to be used primarily, and in many cases exclusively, in a standing or walking position; in contrast, the invention being disclosed here is designed to be used by a person who is working in a seated position. As a result, the problems addressed by the prior art are frequently not the same as those addressed by the current invention. 2. Prior art generally provides a flat physical surface—such as a tray, desk, or platform—which the laptop computer rests; in contrast, the invention being disclosed here allows the laptop computer to rest directly on the user's lap. 3. Prior art generally includes means that transfers the weight of the laptop computer to the shoulders or other parts of the body; in contrast, the invention being disclosed here allows the weight of the laptop to be borne and carried by the lap itself. 4. Prior art establishes a predetermined and non-adjustable working distance between the laptop computer and the user, thus setting the degree to which the arms must be extended to reach the keyboard; further, the prior art maintains the computer in a square position with respect to the body, so that the left and right arms are extended equally when resting on the keyboard, but does not allow the user the option of positioning the laptop off-square (angled). In contrast, the current invention allows the user to adjust the working distance between the laptop and the user, as well as to determine whether the laptop will be square or off-square with respect to the user's is body. 5. Prior art immobilizes the laptop against a specific part of the abdomen or thigh; in contrast, the invention disclosed here does not immobilize the laptop computer against a part of the body. In fact, in the invention disclosed here, the laptop can be easily moved about on the lap. This freedom of movement is inherent in the notion of a “tether”. The notion of tethering is essential to our invention and a central point of differentiation between our invention and the prior art. 6. Prior makes use of straps and similar flexible members for the function of “support”, or to pull the laptop into direct apposition against the body of the user; in contrast, in the invention being disclosed here, flexible members function to tether the laptop in a manner that does not carry the weight of the laptop while it is in use and does not pull the laptop against the body. 7. Prior art tend to be relatively bulky, heavy, and to have one or more parts that cannot easily be folded or compressed into a small space, for transport or storage; in contrast, the invention disclosed here is small and light, with its non-compressible parts being very small and thus allowing the user to more easily fit the invention into a small space.
[0012] An awareness of these above seven characteristics can help one differentiate the invention disclosed in this application from prior art patents. These differences are apparent in the following prior art patents, which are the most relevant uncovered in a careful search:
[0013] Cobbs (U.S. Pat. No. 4,715,293) provides a “desk” to support the laptop computer, and a rigid support system with shoulder frames to transfer the weight of the laptop to the shoulders of a standing user.
[0014] Bourque (U.S. Pat. No. 5,667,114) provides a “platform” that supports the laptop computer, as well as shoulder straps that transfer the weight to the shoulders. The dimensions of the platform, which rests directly against the front of the user's body, determines the working distance between the user and the laptop computer.
[0015] Boyer et al. (U.S. Pat. No. 5,713,548), although designed to be used by a seated user and to let the weight of the laptop be carried by the lap, does not tether the laptop computer to the user, but instead provides a thick Velcro band that is wrapped around the upper legs; this Velcro band adheres to Velcro pads that are attached to the bottom of the laptop computer, the result being that the laptop computer “sticks” to the lap.
[0016] Hrusoff et al. (U.S. Pat. No. 5,724,225) provides a “tray” that supports the laptop computer, and a system of straps that transfers weight from the tray to the shoulders.
[0017] Myles et al. (U.S. Pat. No. 5,887,777) provides a shoulder strap that supports the weight of the laptop computer, for use in the standing position.
[0018] Sauer et al. (U.S. Pat. No. 5,938,096) provides a platform-like bottom panel that carries the weight of the laptop, for use in the standing position. Also included are straps to transfer weight from the panel to the shoulders, and also a waist strap that pulls the laptop against the user's body.
[0019] Piatt (U.S. Pat. No. 6,006,970), for use while standing or walking, provides both a harness and a leg, which extends to the floor, to support the weight of the laptop, and a belt mechanism that holds the laptop immobile in fixed relation to the front of the body.
[0020] Svegliato (U.S. Pat. No. 6,062,522) provides a platform-like “flat planar surface”, which is belted at a fixed distance from the user, for use with a computer “mouse”.
BACKGROUND PROBLEMS ADDRESSED BY THE INVENTION
[0021] When a laptop computer rests on the lap of a seated user, there is a tendency for the laptop to slip off the user's lap or to move in other unwanted and problematic ways. First, there is a tendency for the laptop to move far forward or far to the sides, or between the user's legs, thus falling off the lap and striking the floor. In fact, many laptops are damaged by this type of fall. Second, there is a tendency for the laptop computer to slide forward on the lap so that, even without falling off the lap, it is positioned a greater distance from the user's hands, arms, and upper body than is comfortable or ergonomic. Third, there is a tendency for the laptop computer to rotate on the lap surface, in a clockwise or counter-clockwise direction, such that the laptop is not “square” with respect to the user's upper body but instead rests in such a position that the right arm and left arm must be unequally extended from the body in order to reach the keyboard of the laptop. These and other untoward movements of the laptop computer can be induced by gravity or by inadvertent body movements.
[0022] To prevent or minimize these untoward movements of the laptop computer, or to correct them once they occur, takes ongoing attention and effort by the user. For example, when a person sits with feet flat on the floor, the knees may be lower than the thighs and this creates a downward-sloping lap surface, which can cause the laptop to slide forward and fall off the lap. To correct this slope, many users attempt to elevate the knees by raising their heels off the ground, in a manner that is awkward and uncomfortable. As another example, concern about the laptop falling between the legs leads some users to pull the knees together into an awkward and uncomfortable position.
[0023] Because inadvertent movements of the leg, torso, or virtually any part of the body can cause the laptop to move or fall, the user must remain constantly vigilant against all body movements, however minor. The user is thus constrained in all physical movements, be they subtle or gross. The user necessarily exists in a condition of subtle vigilance and even stress and tension, because of concern about what will happen if attention to the disposition of the laptop is momentarily relaxed. Further, the efforts and postures undertaken to prevent the laptop from moving or falling produce in the user a state of discomfort. The user must never stand or stretch without giving careful thought to the disposition of the computer; a user who stands or stretches carelessly may eject the laptop onto the floor. The need to carefully attend to these untoward possibilities distracts the user from work being carried out on the laptop.
BRIEF SUMMARY OF THE INVENTION
[0024] It is an object of the present invention to overcome the aforementioned problems by providing a tether arrangement that helps retain the laptop computer on the lap of a seated user, that prevents the laptop from falling to the floor, and that helps stabilize the laptop in a comfortable and ergonomic position.
[0025] It is another object of the present invention to allow the laptop computer to rest directly on the lap, without the need for a platform or other supporting structure interposed between the user and the laptop, and without the need to transfer the weight of the laptop computer off the lap and onto the shoulders or other part of the body.
[0026] It is an another object of the present invention to provide ergonomic customization by allowing the user to easily, rapidly, and conveniently adjust and change the distance between the laptop computer and the body of the user and hence to change the extent to which the arms must be extended to reach the keyboard.
[0027] It is an another object of the present invention to allow the user to adjust the position of the laptop so that it is square with respect to the upper body, thus allowing the extension of the left and right arms to be equal when resting on the keyboard, but also to allow users who desire it to position the laptop in a non-square position, that is, so that their left and right arms are unequally extended when resting on the keyboard.
[0028] It is an another object of the present invention to stabilize the laptop on the lap in a manner that does not bind the laptop computer to, or otherwise immobilize the laptop computer against, a specific part of the body, such as against a specific point on the abdomen or thigh, but which instead allows the laptop to be moved on the lap surface, or even momentarily lifted off of the lap surface, in whatever manner is desired by the user.
[0029] It is an another object of the present invention to provide such a tether arrangement that is small and which adds very little bulk or weight to the computer, and which tends to be easily foldable or otherwise compressible into a small space, thereby allowing for convenient transport or storage.
[0030] It is another object of the invention to provide such a tether arrangement that can be provided as original equipment with a laptop computer especially constructed or modified to cooperate with the tether arrangement.
[0031] It is another object of the present invention to provide such a tether arrangement that can be used with existing laptop computers, including those which have previously been sold and are already in use; that is, to provide a tether arrangement that can be “retrofit” onto existing computers.
[0032] It is another object of the invention to provide such a tether arrangement that is inexpensive to produce and incorporate with new laptops and with existing laptops.
[0033] Additional objects of the present invention are to provide such a tether arrangement that is simple to use; that allows the user greater freedom of movement and greater freedom with regard to the placement of the legs, arms, and hands, and with regard to body positioning and posture; that allows freedom from worry and anxiety over the possibility of having the laptop fall off the lap and therefore allows greater freedom to concentrate on the work being carried out on the laptop; that affords a general sense of ease in operation of the laptop; and that allows the user to safely stand or stretch during a break from work without causing the laptop to fall and strike the floor.
[0034] Other objects and advantages of the present invention will become apparent later in this application, especially in the detailed descriptions of the preferred embodiments.
DEFINITIONS
Definition of the Essential Concept: a Tether
[0035] The essence of this invention is that it provides a tether. Because of the centrality of the concept of a tether, we have included a brief discussion to aid in transparency. The American Heritage Dictionary (fourth edition) says a tether is “a. A rope, chain, or similar restraint for holding an animal in place, allowing a short radius in which it can move about. b. A similar ropelike restraint used as a safety measure, especially for young children and astronauts.” Similarly, the Random House Unabridged Dictionary (second edition) defines tether as “A rope, chain, or the like, by which an animal is fastened to a fixed object so as to limit its range of movement.” (Figurative phrases like being at “the end of their tether” are based directly on the literal meaning of the term tether; this phrase means “they can go no further”—as if their tether is already stretched to the limit.)
[0036] To see clearly how a tether works, consider an animal that is tethered to a fixed object. This animal can move to a certain distance from the fixed object, until the tether is pulled taught. The fully extended tether thus forms what is, in essence, the radius of a circle, and the animal is free to roam within that circle but not beyond the circle's diameter. If the animal walks out to the diameter of the limiting circle, and walks along that diameter, the tether, which is the radius of the circle, sweeps over a pie-wedge-shaped area.
[0037] It is an obvious fact, but still important to emphasize, that a tether does not “support” an animal, person, or object that is tethered. That is, the tether does not, as part of its normal function, bear weight. That weight is borne by the ground. Thus, the tether restricts movement but does not bear weight. However, if there is a steep drop within the area in which the animal can freely roam, and the animal falls into the fissure, the tether will reach its full extent as the animal falls, and when the tether becomes taught it will then bare the weight of the animal. As this example suggests, the only time a tether bares weight is if the tethered animal or object falls from the normal ground level.
[0038] More than one tether can be used to restrain the same animal or object. The result of using two tethers is similar to that obtained from a single tether, except that the domain in which the object is constrained is not a simple pie-wedge-shaped area, but instead is a more complex shape. The shape will be determined by a many variables, including, for example, the relative lengths of the two tethers. Mention of a two-tether system is relevant because in some of the preferred embodiments of the invention disclosed herein, a laptop is attached to the user by two separate tethers, each of which may originate from different points on the user and each of which may terminate at different points on the laptop.
[0039] A variant of the two-tether arrangement just described is a single, long tether that both originates and terminates on the object being restrained, but which is long enough so that some intermediate region of the tether can pass around and behind an immobile object. This arrangement creates two functional tethers out of a single piece of rope or other tether material. For example, if both ends of a long piece of rope are tied to an animal, and an intermediate portion of that rope is tossed over a fixed object, such as a post, the animal will effectively be tethered to the post by two tethers. As will become clear in the discussion of preferred embodiments, some embodiments of the current invention make use of a single piece of tether material passed behind the back of the user, with both free ends attached to the laptop.
[0040] While a tether often consists of a single piece of material, such as a single continuous length of cord, it is also possible to construct a single tether out of several pieces of tether material that are connected end to end. Thus, a single tether may be either uni-segmental or multi-segmental in construction. Also, a tether, while generally attached at its ends, may also be attached at any two intermediate points, so long as there is some space between these points. Although not especially convenient, one can even make a tether out of a closed loop of material, such as a cord that has been tied into a closed loop; in this situation, one can form a tether by designating any two spaced-apart points on the loop, connecting one designated point to one object and the other designated point to another object.
Lexicon of Specific Terms and Phrases Used in This Application
[0041] Consider a situation in which a laptop computer is resting on the lap of a seated user, and is tethered by a cord to a belt loop on the user's trousers. In this application, and in the Claims in particular, we have found it useful to refer to the physical material that extends between the two tethered objects, and which effects the tether connection (such as a cord) as a “tethering element.”
[0042] The term “tethering element” is broad and does not specify any particular embodiment or material. It may pertain, for instance, to a system where a cord is attached at its two ends to the tethered objects, or a system where the cord is attached some distance from its ends to the objects; or even to a closed loop of cord that is attached at two-spaced apart points to the tethered objects. It should also be emphasized that a tethering element may be composed of a single, unified, and undivided piece of material, such as a single length of cord, or it may be composed of a number of pieces of material that are aligned in series, that is end to end, and connected with each other.
[0043] Consider a laptop computer tethered to a user. We have found it convenient to speak of “connector means,” “means of connecting” or “means of securing.” Using this means terminology allows for the possibility of specific pieces of hardware that facilitate the connection, such as male-female couplers, but it also allows for the possibility that the tethering element itself be modified to effect the connection.
[0044] We also must address the question of how to speak of the tethering situation as a whole. In this application, and in the claims in particular, we have found it useful to speak of the tethering element, along with the means of connecting this element to both the user and the electronic device in question, as the “tether arrangement”. In addition, in some situations, for example, when the means of connecting the tether to a laptop computer is built into the laptop computer as original equipment, we may also include the laptop computer or other electronic device as part of the “tether arrangement.” The term “tether arrangement” may also include other elements associated with the tethering element or the means of connection. For example, if a mechanism for adjusting the effective length of the tethering element is described, this mechanism will be considered part of the tether arrangement.
[0045] This invention pertains to a broad category or class of electronic devices that can, either currently or potentially (e.g., through modification or redesign), be used on the lap of a seated user. We have found it convenient to designate this entire class or category with the term “lap-usable.” The most common and readily identified member of this class or category is the laptop computer, which because of its design, portability, and small size is ideally suited for use on the lap. However, the term “lap-usable” is broad, and encompasses many other electronic devices, some of which are not even fully portable. For example, electronic keyboards or other types of data-entry terminals may be usable on the lap even though they may be attached by wires of limited length to a large, immobile computer or instrument panel; such devices are encompassed by the term “lap-usable” and are therefore suitable for use with the invention disclosed here, although they are not fully portable in the same way a laptop computer is. Although we use the term “lap-usable” in the claims, it is more convenient to use a specific example when describing preferred embodiments, and for this reason we will discuss the laptop computer. But it should be understood that this focus on the laptop computer does not limit the intended scope of the invention in any way.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] FIG. 1 is a fragmentary perspective view of a seated person using a laptop computer on the lap and employing a tether arrangement according to the present invention.
[0047] FIG. 2A is a perspective view of the laptop computer and tether arrangement of FIG. 1 , on an enlarged scale, showing the tether arrangement on one side of the computer.
[0048] FIG. 2B is a view of the length-adjuster/cord-lock mechanism of the tether.
[0049] FIG. 3 is a view of the laptop computer in perspective and a fragmentary horizontal cross sectional view of the user, showing clips attached to user's belt loops.
[0050] FIG. 4 is a perspective view of the laptop computer user showing an alternative embodiment of the tether arrangement.
[0051] FIG. 5 is a view of a portion of the tether arrangement of FIG. 4 .
[0052] FIG. 6 is a perspective view of a laptop computer showing another alternative embodiment of a tether arrangement, with tether arrangement on one side of computer shown.
[0053] FIGS. 7-9 are views of three alternative connection terminals which may be built into or onto the laptop computer as part of the tether arrangement. FIG. 9 shows a combined length adjuster and connection terminal.
[0054] FIG. 10 is a perspective view of a laptop computer showing some alternative sites for connection terminals for the tether arrangement.
[0055] FIG. 11 is a perspective view of a laptop computer showing another tether arrangement, with retractable tethers built into the computer.
[0056] FIG. 12 is a perspective view of a tether arrangement showing an alternative length-adjusting mechanism, with retractable tethers. Two are shown.
[0057] FIG. 13 is a perspective view of a laptop computer showing another alternative tether arrangement for use with an existing computer.
[0058] FIG. 14 is a diagrammatic perspective view showing another tether arrangement using a belt capable of encircling the waste of the user, tethers which can be provided with any of the attachments to the laptop computer which have previously been described and lockable length adjusters or retractors as also have been described. The laptop computer has not been shown in this figure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0059] For this invention, no single embodiment is truly “preferred” because the desirability of any particular embodiment will be determined by multiple factors, including the type of electronic device it is used with, the weight of the electronic device and how it balances on the user's lap, and other technical and aesthetic considerations. Nonetheless, it is possible to show one embodiment in detail and then to discuss alternative embodiments with reference to it.
[0060] FIG. 1 shows a user 29 of a laptop computer 22 . The laptop computer is tethered to the left side of the user 29 by means of a cord 24 , which has at one end a peg 25 with two splines, which is inserted into and turned in the receiving hole 23 of the laptop computer, and thus locked in place by a conventional locking mechanism (not shown). At the other end of the cord 24 is a carabiner-style clip 26 , which is clipped to the belt loop 28 of the user 29 . A length-adjuster/cord-lock 27 (henceforth simply “length adjuster”) makes it possible to adjust the effective length of the cord 24 . On the right side of the user, a cord 24 and a length adjuster 27 is also shown, thereby indicating that the arrangement on the right side of the user 29 is a symmetrical duplication of the arrangement on the left side on the user 29 . FIG. 2A provides a more detailed view of one tether in FIG. 1 . FIG. 2B is a detailed view of the length-adjuster 27 in FIG. 1 .
[0061] FIG. 3 shows the peg 25 having been inserted into and turned in the receiving hole 23 of the laptop and thus locked in place by the conventional locking mechanism (not shown). The carabiner-style clip 26 at the other end of the cord 24 is clipped to the belt loop 28 of the pants of the user 29 . This Figure shows the tethering arrangements on both sides of the computer.
[0062] In operation ( FIGS. 1 and 3 ) the user sits and places the laptop computer 22 on the lap, and then attaches the cord 24 to the laptop 22 on the left side by inserting the end of the cord 24 that has the peg 25 with splines into the receiving hole 23 , and turning the peg 25 within the hole so that it is locked in place by the mechanism inside the receiving hole 23 . The user 29 then attaches the cord 24 to the left side of the user 29 by clipping the carabiner-style clip 26 to a belt loop 28 on the left side of the user 29 . The user then duplicates these operations on the right side, so that a cord is connected to both the user and the laptop on the right side, and a second cord is connected to both the user and the laptop on the left side. With both cords attached, the user then adjusts the effective length of first one cord, then the other cord, to user's preference by means of the length adjusters 27 .
[0063] This tether arrangement allows the laptop 22 to rest on the lap of the user 29 , secure from falling off and, due to this security, allows the user 29 greater freedom with regard to leg placement, body posture, and position, and freedom from worry and anxiety over the possibility of having the laptop 22 fall off the lap. Thus, a general ease in operation of the laptop 22 is afforded.
[0064] Further, the presence of two cords, on opposite sides of the computer, serves to stabilize the computer in a position wherein it sits square on the user's lap, such that the user's right and left arms are equally extended from the user's body while using the keyboard; in other words, the two cords act to inhibit the lateral rotation (clockwise or counter-clockwise) of the laptop 22 on the lap surface. However, if a user should wish for the laptop to rest in a position on the lap that is not square, such that one arm is more extended than the other, this can be accomplished by deliberately adjusting the effective lengths of the tethers unequally.
[0065] Further, the adjustments made by the user in the effective lengths of the cords 24 , by means of the length adjusters 27 , sets the maximum distance between the laptop and the waist area of the user (it also sets the maximum distance between the laptop and the upper body, including the arms). This limits the maximum extension of the arms that the user must accomplish when working with the computer, which is an important determinant of comfort and ergonomic operation.
[0066] Further, although the tethers do not support the laptop computer or carry its weight when the laptop is being used, the tethers do allow the user, during a break from work, to stand if necessary without having to hold the laptop in the hands. Specifically, if a user stands, the laptop, which during work is resting atop the upper surface of the thighs, remains against the thighs even though the thighs are now vertical, that is, perpendicular with respect to the floor. In this position, the laptop hangs freely, with the tethers having taken up the weight and preventing it from falling to the floor.
[0067] Thus, the invention described here serves several functions, including preventing the lap top from falling off the lap and onto the floor where it might be damaged, inhibiting rotational movement of the laptop on the lap surface and thus stabilizing the laptop in a square position with respect to the upper body and arms, and setting the maximum working distance between the laptop, on the one hand, and the waist area and upper body of the user, on the other hand, and thereby limiting the maximum extension of the user's arms during work.
Multiple Embodiments
[0068] The invention described here can be modified in numerous ways to meet functional, technical, and aesthetic considerations relevant to the particular device being used. Some of the possible modifications are described here. As noted previously, variants are discussed with respect to a laptop computer, but all comments may apply to the use of the invention with other lap-usable electronic devices. These variants are discussed under the following twelve headings:
Means of Connecting Tether to Laptop Means of Connecting Tether to User Means of Adjusting Length of Tether Behind-the-Back Tethers Flexible and Inflexible Tethers Materials and Styles Number of Tethers Segmentation of Tethers Tether Configuration Consolidation of Functions Practical Applications of the Invention Possibility of Numerous Variants
[0081] Means of Connecting Tether to Laptop. Numerous means of connecting the tethers to the laptop computer are possible. Some of these means will make use of two parts that can mate with each other, one such part attached to the tether and the other such part attached to the laptop, such that the mating of these two parts effectively connects the tether to the laptop. This pair of mating pieces may be male and female in construction, such as the peg-and-splines arrangement described previously and illustrated in FIG. 2B and elsewhere. Alternatively, the two mating pieces may consist of, as one mating piece, a clip that is permanently attached to the tether, and as the other mating piece, a post, ring, eyelet, or similar structure mounted to the laptop, with the clip capable of attaching to the post, hook, eyelet or similar device. One embodiment of this type is shown in FIG. 6 , which shows a recess 33 in the housing of the laptop, with a post 32 extending across the recess, with clip 26 capable of attaching to the post 32 . Two of many other types of pieces that are capable of mating with such a clip are shown in FIGS. 7 and 8 ; these pieces could be mounted onto a laptop computer, and the clip that is attached to the tether could be mated with them. FIG. 7 shows a hinge arrangement, which could be mounted to the laptop computer, with the distal portion 40 of the piece, which contains the hole, swung flush with the computer, perhaps into a shallow recess, when the tether arrangement is not engaged; when establishing the tether connection is desired, the distal portion 40 could be swung away from the computer, allowing a clip to attach to it. FIG. 8 shows a screw with eyelet 41 , which could be screwed into a threaded hole in the housing of a laptop computer; the eyelet 41 , which would protrude from the side of the laptop, would provide a convenient element for a clip to attach to. Many other conventional means of attachment between the tether and the laptop are possible, and the invention described in this application is not limited to those few conventional means that are discussed explicitly or illustrated.
[0082] The invention described here could be sold as original equipment that is integrated with the electronic device, such as would be found with a permanent connection terminal (for the tether) built into or onto the device; such connection terminals could be recessed in the laptop, protruding from the laptop, or flush with the laptop. Alternatively, the invention could be sold as a stand-alone invention that could be added, or “retrofitted”, to an electronic device that was not previously modified or designed to be used with a tether system. This retrofit could be permanent, so that once attached it effectively becomes part of the laptop and can not be removed easily, or it could be a temporary or detachably retrofit, which could easily be removed so that the laptop is not permanently altered by the use of the retrofit.
[0083] A few of many possible examples of retrofits include connection terminals that can be attached, or added on, to the laptop by C-type clamps, or by epoxy, or by being strapped on to the laptop with bands made of plastic, nylon, rubber, or other materials. These add-on connection terminals could be removable or could be constructed so that once added on would become a permanent part of the laptop. Other arrangements could make use of cords or other materials that encircle, loop around, or slip over part of the laptop, such as a loop of cord, to which tethers are permanently attached or temporarily mated; an example of this type of retrofit device is shown in FIG. 13 . FIG. 13 shows a continuous loop of cord 35 , which can be slid over the screen so that it comes to encircle the hinged area that lies between the base of the screen and the rear of the laptop body. Once positioned so that it encircles the hinge area, the loop could be tightened, like a noose, by means of a length adjuster 27 located on the loop 35 . With the loop tightened snugly around the hinge area, the tether connection with the user is established by connecting the carabiner-style clips 26 to the belt loops of the user. Once the carabiner clips 26 are attached to the belt loops, the tethers are adjusted by means of the length adjusters 27 .
[0084] Another example, not shown, of a retrofit method that makes use of an element that encircles a portion of the laptop would make use of a sleeve or “glove” made of fabric or other suitable material; this sleeve or glove could be slid over the base is of the laptop, and could be designed with an opening so as not obstruct the keyboard and other buttons on the laptop surface; tethers could be attached to connection points on the sleeve or glove, or the ends of the tethers could be permanently attached to the sleeve or glove. Another type of retrofit variation could connect the tether or tethers to the laptop by means of a length of cloth or stretchable fabric or other suitable material, which could be wrapped or form-fit around the rear corners of the laptop base; or such material could be wrapped around all four corners, or hooked over corners.
[0085] These are just a few of many possible variations in which a suitable cord, fabric, or other material surrounds all or part of the laptop, with extension cords or straps extending from this material and functioning as tethers. This basic patter could be modified to function with an around-the-back tether arrangement (see below). Many other conventional means of retrofit attachment between the tether and the laptop are possible, and the invention described in this application is not limited to those few conventional means that are discussed explicitly or illustrated.
[0086] Means of Connecting Tether to User. Various means can be used to connect one end of the tether to the user or the user's clothing. These include clips such as the carabiner-style clips described previously and illustrated in FIG. 2A and elsewhere, which may clip onto a belt loop, belt, or other piece of clothing; other kinds of clips designed to attach to clothing; devices designed to attach by squeezing, such as clips designed to attach to a waist band of a pair of trousers or a skirt; pieces of fabric attached to the end of the tether that fold back on themselves and connect to themselves by means of Velcro or snaps and thus form a loop that can be used to attach to a belt loop or belt. Clothing could also be modified in ways that permit novel means of attachment; for example, a pair of slacks or skirt might be modified with reinforced loops added above the pockets, to which the tether could be connected by means of a carabiner-style clip; other modifications of clothing are also possible, such as a hole in the clothing through which a button or other elements attached to the tether could be passed. Many other conventional means of attachment between the tether and the user are possible, and the invention described in this application is not limited to those few conventional means that are discussed explicitly or illustrated.
[0087] Means of Adjusting Length of Tether. Various means are available to adjust the effect length of the tethers. These include means that take up the excess length of a flexible tether in the form of a loop, and means that retain the excess length within a confined space, such as by causing the length of excess tether to be wound upon a reel, such as a reel having a retractor spring configured so that the reel tends to constantly wind the cord around the reel. A loop-forming length-adjuster is shown in FIG. 2B . A reel-type, or retractor-type, length adjuster is shown in FIG. 12 . ( FIG. 12 also shows carabiner style clips on both ends of the adjustable tether, one clip for attachment to a belt-loop or belt, the other clip for attachment to a post mounted on the laptop.)
[0088] Retractable length adjusters could also be built into the laptop itself, as a permanent and original part of the laptop, or could be built into other parts. Some of these length-adjusting mechanisms, such as the reel mechanism just mentioned, also would provide a convenient means to store the tethers while the tether arrangement is not being used; for example, the tethers could be wound onto the reel and stored in the wound position. A free-standing retractor mechanisms could also be constructed so that the mechanism was combined with a mating piece, which mating piece could mate with a connection terminal built into the laptop; this retractor mechanism could be mated with the laptop, then the tether could be extended, and either attached to the user's clothing or passed behind the back of the user, thus forming an around-the-back tether (see below). A retractor mechanism could also be associated with a C-clamp or other means that would allow the retractor to be attached to a laptop that was not equipped with a connection terminal; the tether of such a retractor mechanism could be extended and attached to the user's belt loop or another piece of the user's clothing. Many other variants of retractor mechanisms are possible, which could be either free-standing or built into the laptop, or which could be added onto the laptop either permanently or detachably.
[0089] Many other conventional means of adjusting the effective length of the tether are possible, and the invention described in this application is not limited to those few conventional means that are discussed explicitly or illustrated.
[0090] Behind-the-Back Tethers. One means of securing a tether or tethers to the user makes use of arrangements in which a tether or other material is passed around the back of the user. Many embodiments of this basic pattern are possible.
[0091] One such embodiment is illustrated in FIGS. 4 and 5 . These figures show a strap 30 that has an end ring 31 on each end. In this embodiment, the carabiner-style clips 26 are not clipped to the belt loops 28 , as in FIGS. 1 and 3 . Instead, the strap 30 is positioned around the back of the waist of the user 29 , with the end rings 31 on the left side of the user 29 attached to the carabiner-style clips 26 on the left side of the user 29 , and the end ring 31 on the right side of the user 29 attached to the carabiner-style clip 26 on the right side of the user. This arrangement forms an around-the-back retaining system, which secures the laptop to the user without the need for a direct mechanical connection between one end of the tether and the user or the user's clothing. Such an arrangement may be suitable for various users, including those wearing dresses or other garments that do not have either belt loops, belts, or waist bands. The behind-the-back strap could be adjustable in length, or it could be non-adjustable, relying on the adjustments made in the tether cords to set the total length of the tether-plus-strap arrangement. A length-adjuster is shown on the strap in FIG. 5 . Many other conventional means of attaching the behind-the-back strap to the tethers, and many other conventional means of adjusting the effective length of the strap, are possible. For example, the strap could be attached to the tether not by clip and ring, but by male-female mating pieces. Further, material other than a strap could be used for example, a strip of plastic could serve the same function-and for this reason we will, in the Claims, speak of a “spanning member” instead of a strap. Therefore, the invention described in this application is not limited to those few conventional means that are discussed explicitly or illustrated.
[0092] Many other behind-the-back variants are possible. One such variant uses two tethers, each with two ends, with one end of each tether attaching to the electronic device, and the other end of each tether having means capable of mating with each other, thus forming a continuous loop that passes around the body of the user. For example, the free ends (i.e., the end not attached to the laptop) of the two tethers could have male-female mating pieces attached, which pieces are capable of mating with each other behind the user's back. In another embodiment, the caribiner clips shown in FIG. 3 could clip directly onto each other, behind the user's back, thus forming a continuous loop behind the users back and securing the laptop to the user.
[0093] Another behind-the-back variant makes use of a single long tether having two ends, with each end connected to a point on the laptop, and the intervening length of tether passed behind the back of the user. A variant of this embodiment would include a retractor mechanism built into or added onto one side of the laptop, with a mating piece on the free end of the tether; this free end would be passed behind the user's back and mated with a compatible mating terminal on the other side of the laptop, thus forming a continuous loop around the user's back and securing the laptop to the user by means of this loop; further, the retractor mechanism could be associated with a cord-lock mechanism, that would maintain the tether at the desired length.
[0094] Another behind-the-back variant uses a tether having two ends, which is connected at one end to the electronic device and at the other end to the tether itself, thus forming a closed loop; this closed loop can encircle part of the user's body, effectively forming a lasso around the body, and securing the laptop to the user by means of this lasso. As an alternative to going around the waist, tethers might be passed around the upper body, such as around the upper back, shoulders or neck. Many other conventional means for securing a laptop to a user by means of a tether passed behind the back are possible, and the invention described in this application is not limited to those few conventional means that are discussed explicitly or illustrated.
[0095] Flexible and Inflexible Tethers. Although most tethers have been described in this application as cords, various tethering means can be used to tether the laptop to the user. These include fully flexible tethers such as nylon cords or straps, semi-flexible tethers such as elongated thin plastic strips made of bendable plastic, and rigid tethers such as rods made of hard plastic or metal. Flexible tethers composed of intrinsically inflexible materials, for example a chain made of metal links, may also be used. Means of adjusting the effective length of inflexible or semi-flexible tethers are possible. For example, for a rigid tether, the effective length can be adjusted by a telescoping arrangement. Many other conventional means of constructing tethers are possible, and the invention described in this application is not limited to those few conventional means that are discussed explicitly or illustrated.
[0096] Materials and Styles. The components of this invention can be made of any suitably strong and durable material, natural or synthetic or composite, including but not limited to nylon, leather, cloth, rubber, plastic, metal. The styles and mechanisms portrayed above are also variable, and the illustrations in the text and the Figures are not intended to limit the embodiments.
[0097] Number of Tethers. Depending on the electronic device being tethered, and the aesthetic and functional objectives of the manufacturer of the tether system, the number of tethers can range from one to many. For example, a small electronic device such as a personal organizer might be tethered with a single tether. In contrast, a large electronic device might require more than two tethers. In addition, tethers could split or consolidate along their path between the electronic device and user. Thus, for example, two tethers attached at two different points on an electronic device could, en route to the user, come together and merge into a single tether, in a “Y” configuration, and then attach to the user at a single point; or this single consolidated tether might, for instance, split and re-form two tethers. These are just two of many possible examples by which tethers could split or consolidate during their paths between electronic device and user.
[0098] Segmentation of Tethers. Tethers may be composed of a single piece of material, or may be made in such a way that they are composed of multiple contiguous segments of material that are attached to each other. In accordance with the possibility of tethers being composed of multiple segments, for the purpose of this application the term “tether” shall be defined such that it includes not only elongated members made of a single piece of material, but also elongated attachment members that are composed of a plurality of members that are designed to be fitted together to form a single functional elongated attachment member.
[0099] Tether Configuration. Tethers could be attached to any surface of the electronic device, including the front surface (i.e., the surface perpendicular to the plane of the lap and thus facing the abdomen of the user), the bottom surface (i.e, the surface in contact with the user's lap), the side surfaces or the top surface (i.e., keyboard surface) of the device, or even the back surface, with the tethers passing around the back corners of the laptop and extending towards the user. Further, tethers could emanate from opposite sides of the machine (e.g., one tether coming from each side of the electronic device), from spaced-apart points on the same surface (e.g., both coming from the front of the device, one from the left side and the other from the right side of this surface), symmetrically or asymmetrically (e.g., one tether from the right side, the other tether from the left front of the electronic device). Several of these variants are suggested in FIG. 10 , which shows a number of alternative locations for receiving holes.
[0100] Consolidation of Functions. Many functional aspects of the invention can be consolidated into unified mechanical elements. For example, a length adjuster that acts to retract a tether cord can be built into or onto the electronic device. FIG. 11 is a view of a laptop computer 22 furnished with a retractable cord 34 with one carabiner-style clip 26 on the free end. The retractable mechanism, which in this case may be considered a connection terminal, is located within the laptop housing. When in the retracted position the clip 25 rests in the cavity 33 in the computer 22 . The retractable mechanism would allow for the cord 34 to be locked at any given length (cord lock for retractable mechanism is conventional and, hence, not shown in FIG. 11 ). Arrangements are symmetrical on the right and left sides of the user 29 .
[0101] Alternatively, the length adjuster may be consolidated with a connection terminal built into or onto the device, to which the tether could be attached. For example, FIG. 9 shows a naked (i.e, unmodified, with no mating piece attached) tether passes through a length-adjuster/cord-lock 42 attached to the housing of the electronic device; such an arrangement would allow the length-adjuster/cord-lock itself to function as a connection terminal for an unmodified tether end. Alternatively, the length-adjuster/cord-lock could be combined with a carabiner that clips onto a user's belt. Alternatively, the length adjuster could be built into a mating piece on the end of the tether that attaches to a connection terminal on the device. Such combinations might be especially convenient if they included means to sequester the excess tether, such as a length adjuster that winds a flexible tether around a reel. Many other ways of consolidating functions of this invention are possible, and the possibilities for consolidation should not be limited to those few means that are discussed explicitly or illustrated.
[0102] Practical Applications of the Invention. As noted, this invention can be applied not only to laptop computers but towards all electronic devices that are “lap-usable” that is, to all devices which are currently or potentially capable of being used on the lap of a seated user. A few of many possible examples include keyboards and other data entry devices that are either wireless or attached by wires to a computer system, electronic drawing pads, control units for gaming or entertainment centers, small e-mail or personal organizer units, communication systems such as organizer-cell phone units, industrial control systems and vehicular control or navigation systems suitable for use on the lap. Some of these lap-usable electronic devices may not currently exist, and may in fact be brought into existence in response to the possibility of a stable lap working environment created by the invention discussed in this application.
[0103] Tethers can also be connected to user by means of a closable and adjustable encircling waist belt to which tethers are secured, such as in FIG. 14 (detailed below), in which tethers are illustrated as secured to left and right side of the belt. The adjuster and closure mechanism of the belt are conventional and can take many forms. Tethers may be permanently attached to the belt or can be detachable from it. Tethers may be retractable, that is, associated with a retraction mechanism such as a spring-loaded spool; this retraction mechanism may be associated with, or even mechanically combined with, the locale length-adjusting mechanism of the tether. The belt itself may also be associated with a retraction mechanism capable of storing the belt in a retracted state; this belt-retraction mechanism may be combined with, or built adjacent to, other features, such as the closure mechanism, the belt-length-adjusting mechanism, and tether retractors. Features may be combined structurally in various combinations; for example, belt retractor, belt length adjuster, belt closure mechanism and one or both tether retractors could all be integrated into a single unit.
[0104] FIG. 14 shows belt 101 , belt length adjuster 102 combined with female end 103 of belt closure mechanism, excess belt piece 104 that remains after adjusting belt length, belt retractor 105 , flexible tethers 106 , tether-retractors with built-in length-adjuster/cord locks 107 , and male end 108 of belt closure mechanism. Means of connecting extended ends of tethers to laptop computer case are not illustrated in this figure.
[0105] In operation, the user extends the belt by holding one end of the belt with each hand. If a belt retraction mechanism is present, the user operates this retractor so that the belt extends from its retracted state. The user then encircles waist with belt, which may pass through or attach to belt loops or other clothing structure, or may pass around the waist irrespective of such loops or structures. The user then closes the belt with the belt-closure mechanism and adjusts length and thereby tightness of the belt. If the user desires, the portion of the belt that passes across the back of the user can be pushed down over the tops of the buttocks so that belt is at waist level in front and across the buttock in the rear of the user. Both tethers are extended to the laptop computer and attached to case of said computer by conventional means such as by clips, hooks, Velcro, male-female couplers, etc. The lengths of the tethers are adjusted us user preference.
[0106] The belt exerts an inward-directed pressure on the waist of the user and is held in a stable position against the user's body by a combination of compressive and frictional forces. The belt may be equipped with a frictional surface to increase friction along the zone of contact with the user's waist. The compressive pressure exerted by the belt on the user's waist can be varied by tightening or loosening the belt. This encircling belt, by providing a stabile structural element along the user's body, allows the flexible tethers to be securely connected to the user without the need to attach free-ended to belt loops or other structures, such as by carabineer or other means. Because some users do not wear pants with belt loops, because some users wear pants with belt loops that are fragile, and because some users do not wish to attach tethers directly to belt loops or other clothing structures, this encircling belt variant provides in some settings an improved means of connecting tethers to the user.
[0107] Possibility of Numerous Variants. With this invention, numerous variations on the embodiments described are possible: variations in size, shape, color, and material composition of components, and of design and mechanisms of components, and variations in the arranging and combining of components. The choice of preferred embodiment would be dependent upon the particular electronic device being tethered: its shape, weight, how it balances (i.e., the internal distribution of this weight within its own housing); considerations of aesthetics and style, and individual preferences of the manufacturers. Thus, the scope of the invention should not be limited to the specific embodiments and variants discussed or illustrated in this application, as other variants are possible. | A laptop computer assembly has a belt which is adapted to encircle the waste of a user, a fastener for releasably joining the ends of hte belt togetehr around the user and two tethers running from the belt to the laptop computer. Lockable length adjusters are provided for the tethers. | 6 |
This is the national phase application, under 35 USC 371, for PCT/US2004/039763, filed 13 Dec. 2004, which, claims the benefit, under 35 USC 119(e), of U.S. provisional application 60/532,247 filed 23 Dec. 2003.
BACKGROUND OF THE INVENTION
Marijuana ( Cannabis sativa L.) and its derivatives have been used for centuries for medicinal and recreational purposes. A major active ingredient in marijuana and hashish has been determined to be Δ 9 -tetrahydrocannabinol (Δ 9 -THC). Detailed research has revealed that the biological action of Δ 9 -THC and other members of the cannabinoid family occurs through two G-protein coupled receptors termed CB 1 and CB 2 . The CB 1 receptor is primarily found in the central and peripheral nervous systems and to a lesser extent in several peripheral organs. The CB 2 receptor is found primarily in lymphoid tissues and cells. Three endogenous ligands for the cannabinoid receptors derived from arachidonic acid have been identified (anandamide, 2-arachidonoyl glycerol, and 2-arachidonyl glycerol ether). Each is an agonist with activities similar to Δ 9 -THC, including sedation, hypothermia, intestinal immobility, antinociception, analgesia, catalepsy, anti-emesis, and appetite stimulation.
Excessive exposure to Δ 9 -THC can lead to overeating, psychosis, hypothermia, memory loss, and sedation. Specific synthetic ligands for the cannabinoid receptors have been developed and have aided in the characterization of the cannabinoid receptors: CP55,940 (J. Pharmacol. Exp. Ther. 1988, 247, 1046-1051); WIN55212-2 (J. Pharmacol. Exp. Ther. 1993, 264, 1352-1363); SR141716A (FEBS Lett. 1994, 350, 240-244; Life Sci. 1995, 56, 1941-1947); and SR144528 (J. Pharmacol. Exp. Ther. 1999, 288, 582-589). The pharmacology and therapeutic potential for cannabinoid receptor ligands has been reviewed (Exp. Opin. Ther. Patents 1998, 8, 301-313; Ann. Rep. Med. Chem., A. Doherty, Ed.; Academic Press, NY 1999, Vol. 34, 199-208; Exp. Opin. Ther. Patents 2000, 10, 1529-1538; Trends in Pharma Sci. 2000, 21, 218-224). There is at least one CB 1 modulator characterized as an inverse agonist or an antagonist, N-(1-piperidinyl)-5-(4-chlorophenyl)-1-(2,4-dichlorophenyl)-4-methylpyrazole-3-carboxamide (SR141716A), in clinical trials for treatment of eating disorders.
Hitherto, several classes of CB 1 modulators are known. U.S. Pat. Nos. 5,624,941 and 6,028,084, PCT Publication Nos. WO98/43636 and WO98/43635, and European Patent Application No. EP-658546 disclose substituted pyrazoles having activity against the cannabinoid receptors. PCT Publication Nos. WO98/31227 and WO98/41519 also disclose substituted pyrazoles having activity against the cannabinoid receptors. PCT Publication Nos. WO98/37061, WO00/10967, and WO00/10968 disclose diaryl ether sulfonamides having activity against the cannabinoid receptors. PCT Publication Nos. WO97/29079 and WO99/02499 disclose alkoxy-isoindolones and alkoxy-quinolones as having activity against the cannabinoid receptors. U.S. Pat. No. 5,532,237 discloses N-benzoyl-indole derivatives having activity against the cannabinoid receptors. U.S. Pat. No. 4,973,587, U.S. Pat. No. 5,013,837, U.S. Pat. No. 5,081,122, U.S. Pat. No. 5,112,820, and U.S. Pat. No. 5,292,736 disclose aminoalkylindole derivatives as having activity against the cannabinoid receptors. PCT Publication No. WO03/027076 discloses 1H-imidazole derivatives having CB 1 agonist, CB 1 partial agonist or CB 1 antagonist activity. PCT Publication No. WO03/026648 discloses 4,5-dihydro-1H-pyrazole derivatives having potent CB 1 -antagonist activity. US Publication No. US 2003/0114495 discloses substituted imidazoles as cannabinoid receptor modulators. US Publication No. US 2003/0119810 discloses pharmaceutical compositions containing 3-aminoazetidine derivatives possessing a high affinity for CB 1 receptors.
[4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-(4-phenyl-piperazin-1-yl)-methanone RN 439128-75-3, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-morpholin-4-yl-methanone RN394228-83-2, and [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone RN 394228-85-4 are found in the CA database.
There still remains a need for potent low molecular weight CB 1 modulators that have pharmacokinetic and pharmacodynamic properties suitable for use as human pharmaceuticals.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides compounds of formula I
wherein:
is a 6,5-bicyclic ring selected from the group consisting of:
R 1 is selected from the group consisting of:
(a) hydrogen, (b) alkylcarbonyl optionally substituted with heterocyclyl, (c) heterocyclylcarbonyl optionally substituted with alkyl or acetyl, (d) alkyl or haloalkyl, (e) cycloalkyl optionally substituted with one or two substituents independently selected from the group consisting of alkyl, halo, oxo, hydroxy, alkoxy, amino, alkylamino and dialkylamino, (f) heterocyclyl selected from the group consisting of:
(g) aryl optionally substituted with halo, alkyl, alkoxy, cyano, amino, alkylamino, or dialkylamino, and
(h) heteroaryl selected from the group consisting of:
R 2 is hydrogen, alkyl, heterocyclyl or, together with R 1 and the carbon to which they are attached, forms a saturated ring substituent selected from the group consisting of:
(a) cycloalkyl, and (b) heterocyclyl selected from the group consisting of: tetrahydrofuranyl, tetrahydropyranyl and piperidinyl optionally N-substituted with alkyl, acetyl or aryl,
X is —NR 13 R 3 or
R 3 is selected from the group consisting of:
(a) hydrogen, (b) alkyl optionally substituted with one or two substituents independently selected from the group consisting of hydroxy, alkoxy, halogen, amino, alkylamino, and dialkylamino, (c) cycloalkyl optionally substituted with one or two substituents independently selected from the group consisting of hydroxy, alkoxy, halo, amino, alkylamino, and dialkylamino, (d) heterocyclyl selected from the group consisting of:
(e) cycloalkylalkyl selected from the group consisting of:
(f) heterocyclylalkyl selected from the group consisting of:
(g) arylalkyl selected from the group consisting of:
(h) heteroarylalkyl selected from the group consisting of:
is a heterocyclic ring selected from the group consisting of:
R 4 is hydrogen, phenyl, halophenyl, acyl, or alkoxycarbonyl;
R 5 is hydrogen, hydroxy or alkoxy;
each of R 6 and R 7 is independently selected from hydrogen, halo, cyano, alkyl, alkoxy, haloalkyl, haloalkoxy, amino, alkylamino, dialkylamino, alkoxycarbonyl, dialkylaminocarbonyl, aryl, and aryloxy;
R 8 is hydrogen, hydroxyalkyl, acyl, oxo, aryl, pyridinyl, alkyl-SO 2 —O—, R b —NH—CH 2 —, arylalkyl, or R c 2 N—CO—O—;
R 9 is hydrogen, hydroxy, hydroxyalkyl, acyl, halo, dihalo, oxo, aryl, haloarylalkyl, pyridinyl, alkyl-SO 2 —O—, R a —NH—, R b —NH—CH 2 —, arylalkyl,
R c 2 N—CO—O—;
R 10 is hydrogen, alkyl, alkoxycarbonyl, aryl or haloaryl;
R 11 is hydrogen, alkyl or aryl;
R 12 is hydrogen or aryl;
R 13 is hydrogen or alkyl;
R 14 is hydrogen, alkyl, aryl or acyl;
R a is hydrogen, alkoxycarbonyl or halophenyl;
R b is hydrogen, alkoxy, phenyl, halophenyl, halophenylalkyl, halopyridinyl, pyrimidinyl, alkoxycarbonyl, dialkylaminocarbonyl or dialkylaminothiocarbonyl; and
R c is hydrogen or alkyl;
and all salts, solvates, optical and geometric isomers, and crystalline forms thereof with the proviso that the compound of formula (I) is other than [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-(4-phenyl-piperazin-1-yl)-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-morpholinyl-methanone, and [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone.
In a preferred embodiment,
is a 6,5-bicyclic ring selected from the group consisting of:
R 1 is selected from the group consisting of:
(a) hydrogen, (b) alkylcarbonyl optionally substituted with heterocyclyl, (c) heterocyclylcarbonyl optionally substituted with alkyl or acetyl, (d) methyl, propyl, t-butyl or trifluoromethyl, (e) cycloalkyl optionally substituted with oxo, hydroxy, methoxy, difluoro or methyl, (f) heterocyclyl selected from the group consisting of:
(g) phenyl optionally substituted with halo, methyl, methoxy, cyano or dimethylamino, and
(h) heteroaryl selected from the group consisting of:
R 2 is H, methyl, ethyl, or together with R 1 and the carbon to which they are attached, forms a saturated ring substituent selected from the group consisting of:
(a) cycloalkyl, and (b) heterocyclyl selected from the group consisting of: tetrahydropyranyl and N-methylpiperidin-4-yl;
X is —NR 13 R 3 or
R 3 is selected from the group consisting of:
(a) hydrogen, (b) (C 1 -C 2 ) alkyl optionally substituted with (C 1 -C 2 ) alkoxy, (c) (C 4 -C 6 ) cycloalkyl optionally substituted with one or two substitutes independently selected from hydroxy, methoxy, amino, alkylamino, and dialkylamino, (d) heterocyclyl selected from the group consisting of:
(e) cycloalkylalkyl selected from the group consisting of:
(f) heterocyclylalkyl selected from the group consisting of:
(g) arylalkyl which is
(h) heteroarylalkyl selected from the group consisting of:
is a heterocyclic ring selected from the group consisting of:
R 4 is hydrogen, phenyl, fluorophenyl, t-butyloxycarbonyl or methoxycarbonyl;
R 5 is hydrogen, hydroxy or methoxy;
each of R 6 and R 7 is independently selected from the group consisting of hydrogen, alkyl, fluoro, chloro, trifluoromethyl, cyano, methoxy, amino, monomethylamino, dimethylamino, methoxycarbonyl and dimethylaminocarbonyl;
R 8 is hydrogen, hydroxyalkyl, acyl, oxo, aryl, pyridinyl, alkyl-SO 2 —O—, R b —NH—CH 2 —, arylalkyl or (CH 3 ) 2 N—CO—O—;
R 9 is hydrogen, hydroxy, hydroxymethyl, acetyl, fluoro, difluoro, oxo, phenyl, benzyl, pyridinyl, CH 3 —SO 2 —O—, R a —NH—, R b —NH—CH 2 —,
(CH 3 ) 2 N—CO—O—;
R 10 is hydrogen or alkyl;
R 11 is hydrogen or alkyl;
R 12 is hydrogen or phenyl;
R 13 is hydrogen or methyl;
R 14 is hydrogen, methyl, phenyl, or acetyl;
R a is hydrogen, methoxycarbonyl, t-butyloxycarbonyl, or fluorophenyl; and
R b is hydrogen, methoxy, phenyl, phenylalkyl, fluorophenylalkyl, fluorophenyl, pyridinyl, fluoropyridinyl, pyrimidinyl, methoxycarbonyl, t-butyloxycarbonyl, dimethylaminocarbonyl or dimethylaminothiocarbonyl.
In another preferred embodiment,
is selected from the group consisting of:
In another preferred embodiment,
In another preferred embodiment,
In another preferred embodiment, R 1 is aryl optionally substituted with halo, alkyl, alkoxy, cyano, amino, alkylamino or dialkylamino. More preferably, R 1 is phenyl.
In another preferred embodiment, R 1 is cycloalkyl optionally substituted with one or two substituents independently selected from the group consisting of alkyl, halo, oxo, hydroxy alkoxy, amino, alkylamino and dialkylamino. More preferably, R 1 is cyclopentyl.
In another preferred embodiment, R 1 is heterocyclyl selected from the group consisting of:
More preferably, R 1 is tetrahydropyran-4-yl.
In another preferred embodiment, R 3 is heterocyclylalkyl selected from the group consisting of:
More preferably, R 3 is
In another preferred embodiment, R 3 is heterocyclyl selected from the group consisting of:
More preferably, R 3 is
In another preferred embodiment, R 3 is cycloalkylalkyl selected from the group consisting of:
More preferably, R 3 is
In another preferred embodiment, R 3 is alkyl optionally substituted with one or two substituents independently selected from the group consisting of hydroxy, alkoxy, halogen, amino, alkylamino, and dialkylamino. More preferably, R 3 is
In another preferred embodiment, R 3 is arylalkyl selected from the group consisting of:
More preferably, R 3 is
In another preferred embodiment, R 3 is heteroarylalkyl selected from the group consisting of:
More preferably, R 3 is
In another preferred embodiment, the present invention provides for a compound of formula I
wherein:
is a 6,5-bicyclic ring selected from the group consisting of:
R 1 is selected from the group consisting of:
(a) hydrogen, (b) alkylcarbonyl optionally substituted with heterocyclyl, (c) heterocyclylcarbonyl optionally substituted with alkyl or acetyl, (d) alkyl or haloalkyl, (e) cycloalkyl optionally substituted with one or two substituents independently selected from the group consisting of alkyl, halo, oxo, hydroxy, alkoxy, amino, alkylamino and dialkylamino, (f) heterocyclyl selected from the group consisting of:
(g) aryl optionally substituted with halo, alkyl, alkoxy, cyano, amino, alkylamino or dialkylamino, and
(h) heteroaryl selected from the group consisting of:
R 2 is hydrogen, alkyl, heterocyclyl or, together with R 1 and the carbon to which they are attached, forms a saturated ring substituent selected from the group consisting of:
(a) cycloalkyl, and (b) heterocyclyl selected from the group consisting of: tetrahydrofuranyl, tetrahydropyranyl and piperidinyl optionally N-substituted with alkyl, acetyl or aryl,
X is —NR 13 R 3 or
R 3 is selected from the group consisting of:
(a) hydrogen, (b) alkyl optionally substituted with one or two substituents independently selected from the group consisting of hydroxy, alkoxy, halogen, amino, alkylamino and dialkylamino, (c) cycloalkyl optionally substituted with one or two substituents independently selected from the group consisting of hydroxy, alkoxy, halo, amino, alkylamino and dialkylamino, (d) heterocyclyl selected from the group consisting of:
(e) cycloalkylalkyl selected from the group consisting of:
(f) heterocyclylalkyl selected from the group consisting of:
(g) arylalkyl selected from the group consisting of
(h) heteroarylalkyl selected from the group consisting of:
is a heterocyclic ring selected from the group consisting of:
R 4 is hydrogen, phenyl, halophenyl, acyl or alkoxycarbonyl;
R 5 is hydrogen, hydroxy or alkoxy;
each of R 6 and R 7 is independently selected from hydrogen, halo, cyano, alkyl, alkoxy, haloalkyl, haloalkoxy, amino, alkylamino, dialkylamino, alkoxycarbonyl, dialkylaminocarbonyl, aryl and aryloxy;
R 8 is hydrogen, hydroxyalkyl, acyl, oxo, aryl, pyridinyl, alkyl-SO 2 —O—, R b —NH—CH 2 —, arylalkyl, or R c 2 N—CO—O—;
R 9 is hydrogen, hydroxy, hydroxyalkyl, acyl, halo, dihalo, oxo, aryl, haloaryl-CH 2 —, pyridinyl, alkyl-SO 2 —O—, R a —NH—, R b —NH—CH 2 —, arylalkyl,
R 10 is hydrogen, alkyl, alkoxycarbonyl, aryl or haloaryl;
R 11 is hydrogen, alkyl or aryl;
R 12 is hydrogen or aryl;
R 13 is hydrogen or alkyl;
R 14 is hydrogen, alkyl, aryl or acyl;
R a is hydrogen, alkoxycarbonyl or halophenyl;
R b is hydrogen, alkoxy, phenyl, halophenyl, halophenylalkyl, halopyridinyl, pyrimidinyl, alkoxycarbonyl, dialkylaminocarbonyl, or dialkylaminothiocarbonyl; and
R c is hydrogen or alkyl;
and all optical and geometric isomers, and crystalline forms thereof and with the proviso that the compound of formula (I) is other than [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-(4-phenyl-piperazin-1-yl)-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-morpholin-4-yl-methanone, and [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone.
In another aspect, the present invention provides pharmaceutical compositions comprising a compound of Formula I in an amount effective to antagonize CB-1 receptor stimulation, and a pharmaceutically acceptable carrier, diluent or excipient.
In another aspect, the present invention provides pharmaceutical compositions comprising a compound of Formula I, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-(4-phenyl-piperazin-1-yl)-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-morpholin-4-yl-methanone, or [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone in an amount effective to antagonize CB-1 receptor stimulation, and a pharmaceutically acceptable carrier, diluent or excipient.
In another aspect, the present invention provides pharmaceutical compositions comprising a compound of Formula I, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-(4-phenyl-piperazin-1-yl)-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-morpholin-4-yl-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone, or [4-(3-Fluoro-phenyl)-piperidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone in an amount effective to reduce endocannabinoid neurotransmission through CB-1 receptors, and a pharmaceutically acceptable carrier, diluent or excipient.
In another aspect, the present invention provides pharmaceutical compositions comprising a compound of Formula I, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-(4-phenyl-piperazin-1-yl)-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-morpholin-4-yl-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone, or [4-(3-Fluoro-phenyl)-piperidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone and a pharmaceutically acceptable carrier, diluent or excipient.
In another aspect, the present invention provides a method for treating a condition which is treatable by reducing CB-1 receptor stimulation, comprising administering to a mammal in need thereof a compound of Formula I or a pharmaceutical composition comprising a compound of Formula I in an amount effective to antagonize CB-1 receptor stimulation, or to reduce endocannabinoid neurotransmission and a pharmaceutically acceptable carrier, diluent or excipient.
In another aspect, the present invention provides a method for treating a condition which is treatable by reducing CB-1 receptor stimulation, comprising administering to a mammal in need thereof a compound selected from the group consisting of a compound of Formula I, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-(4-phenyl-piperazin-1-yl)-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-morpholin-4-yl-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone, and [4-(3-Fluoro-phenyl)-piperidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
In another aspect, the present invention provides a method for treating a condition which is treatable by reducing CB-1 receptor stimulation, comprising administering to a mammal in need thereof a pharmaceutical composition comprising a compound selected from the group consisting of a compound of Formula I, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-(4-phenyl-piperazin-1-yl)-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-morpholin-4-yl-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone, and [4-(3-Fluoro-phenyl)-piperidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone in an amount effective to antagonize CB-1 receptor stimulation, or to reduce endocannabinoid neurotransmission and a pharmaceutically acceptable carrier, diluent or excipient.
In another aspect, the present invention provides for a compound of Formula I, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-(4-phenyl-piperazin-1-yl)-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-morpholin-4-yl-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone, or [4-(3-Fluoro-phenyl)-piperidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone for use in therapy.
In another aspect, the present invention provides use of a compound of Formula I for the manufacture of a medicament for treating a condition which is treatable by reducing CB-1 receptor stimulation.
In another aspect, the present invention provides use of a compound of Formula I, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-(4-phenyl-piperazin-1-yl)-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-morpholin-4-yl-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone, or [4-(3-Fluoro-phenyl)-piperidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone for the manufacture of a medicament for treating a condition which is treatable by reducing CB-1 receptor stimulation.
In another aspect, the present invention provides a method for treating a condition selected from the group consisting of psychosis, memory deficit, cognitive disorder, migraine, neuropathy, neuroinflammatory disorder, cerebral vascular accident, head trauma, anxiety disorder, stress, depression, epilepsy, Parkinson's disease, schizophrenia, substance abuse disorder, obesity, and an eating disorder associated with excessive food intake comprising administering to the mammal in need thereof a compound of Formula I, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-(4-phenyl-piperazin-1-yl)-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-morpholin-4-yl-methanone, [4-(2,3-dihydro-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone, or [4-(3-Fluoro-phenyl)-piperidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone. More preferably, the condition is obesity.
In a preferred embodiment, the condition which is treatable by reducing CB-1 receptor stimulation is psychosis, memory deficit, cognitive disorder, migraine, neuropathy, neuroinflammatory disorder, cerebral vascular accident, head trauma, anxiety disorder, stress, depression, epilepsy, Parkinson's disease, schizophrenia, substance abuse disorder, obesity, or eating disorder associated with excessive food intake. More preferably, the condition is obesity.
In another preferred embodiment, the mammal being treated is a human. In another aspect, the invention provides for compounds of formula (IIa)
wherein:
Y is halogen, cyclopent-1-enyl, or cyclopentyl and R 17 is alkyl.
It will be appreciated the all combinations of the aspects and embodiments discussed above and the examples discussed below are contemplated as being encompassed by the present invention. In addition, all examples described herein are for illustrative purposes, and are not intended to narrow the scope of the invention in any way.
DETAILED DESCRIPTION
As used above, and throughout the description of the invention, the following terms, unless otherwise indicated, shall be understood to have the following meanings:
“Acyl” means an alkylcarbonyl (i.e., alkyl-CO—, wherein the alkyl group is as herein described) or heterocyclylcarbonyl (i.e., heterocycyl-CO—, wherein heterocyclyl is as herein described). Preferred acyls contain a lower alkyl (e.g., acetyl).
“Alkoxy” means an alkyl-O— group, wherein the alkyl group is as herein described. Exemplary alkoxy groups include methoxy, ethoxy, n-propoxy, 1-propoxy, and n-butoxy.
“Alkoxycarbonyl” means an alkyl-O—CO— group, wherein the alkyl group is as herein defined. Exemplary alkoxycarbonyl groups include methoxycarbonyl, ethoxycarbonyl, or t-butyloxycarbonyl.
“Alkyl” means a saturated aliphatic hydrocarbon group, which may be straight or branched, having 1 to 6 carbon atoms in the chain. Preferred alkyl groups have 1 to 4 carbon atoms in the chain. For example, methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, and tert-butyl.
“Alkylamino” means an alkyl-NH— group wherein the alkyl group is as herein described.
“Alkylcarbonyl” means alkyl-CO— group wherein the alkyl group is as herein described.
“Alkylthio” means an alkyl-S— group wherein the alkyl group is as herein described. Exemplary alkylthio groups include methylthio, ethylthio, I-propylthio and n-butylthiothio.
“Aryl” means an aromatic mono- or bi-cyclic ring system of 6 to about 10 carbon atoms. Exemplary aryl groups include phenyl and 1- and 2-naphthyl.
“Arylalkyl” means an aryl-alkyl- group wherein the aryl and alkyl groups are as defined herein.
“Aryloxy” means an aryl-O— group wherein the aryl group is as defined herein. Exemplary groups include phenoxy and naphthyloxy.
“Aryloxycarbonyl” means an aryl-O—C(O)— group wherein the aryl group is as defined herein. Exemplary aryloxycarbonyl groups include phenoxycarbonyl and naphthoxycarbonyl.
“Arylthio” means an aryl-S— group wherein the aryl group is as herein described. Exemplary arylthio groups include phenylthio and naphthylthio.
“Carboxy” means a HO(O)C— (i.e., carboxylic acid) group.
“Cycloalkyl” means a fully saturated, mono-carbocyclic ring system of about 3 to about 6 carbon atoms. Exemplary cycloalkyl groups include cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl.
“Cycloalkylalkyl” means cycloalkyl-alkyl- group wherein the cycloalkyl group and the alkyl group are as defined herein.
“Dialkylamino” means an (alkyl) 2 -N— group wherein the alkyl group is as defined herein. It is understood that the two alkyl groups can be the same or different
“Dialkylaminocarbonyl” means a (alkyl) 2 -N—C(O)— group wherein the alkyl group is as defined herein. It is understood that the two alkyl groups can be the same or different.
“Dialkylaminothiocarbonyl” means a dialkylamino-C(S)— group wherein the dialkylamino group is as defined herein. It is understood that the two alkyl groups can be the same or different.
“Effective amount” is means an amount of a compound/composition according to the present invention effective in producing the desired therapeutic effect.
“Halo” means fluoro, chloro, bromo, or iodo. A preferred halo is fluoro.
“Haloalkyl” refers to an alkyl group, as described herein, which is substituted with one to six halo groups, as described herein. Preferred haloalkyls include fluoroalkyls, such as fluoromethyl, difluoromethyl, trifluoromethyl, 2-fluoroethyl, 2,2,2-trifluoroethyl, 1,1,2,2,2-pentafluoroethyl, 3-fluoropropyl, 3,3,3-trifluoropropyl, and 1,1,1,3,3,3-hexafluoroprop-2-yl.
“Haloalkoxy” refers to an alkoxy group, as described herein, which is substituted with one to six halo groups, as described herein. Preferred haloalkoxy groups include fluoroalkoyls, such as fluoromethoxy, difluoromethoxy, trifluoromethoxy.
“Haloaryl” refers to an aryl group, as described herein, which is substituted by halogen, as described herein.
“Haloarylalkyl” refers to an alkyl group, as described herein, which is substituted by a haloaryl group, as described herein.
“Halophenyl” refers to a phenyl group which is substituted by halogen, as described herein.
“Halophenylalkyl” refers to an alkyl group, as described herein, which is substituted by a halophenyl group, as described herein.
“Halopyridinyl” refers to a pyridinyl group which is substituted by a halogen group, as described herein.
“Heteroaroyl” means a heteroaryl-CO— group, wherein the heteroaryl group is as herein described. Exemplary groups include thiophenoyl, nicotinoyl, pyrrol-2-ylcarbonyl, 1- and 2-naphthoyl, and pyridinoyl.
“Heteroaryl” means a monocyclic or bicyclic fully unsaturated ring system of about 5 to 10 ring atoms, in which one or two of the ring atoms is a hetero element(s) other than carbon (e.g., nitrogen, oxygen or sulfur) and the remainder of the ring atoms are carbon. Preferred ring sizes include 5 to 6 ring atoms. Exemplary heteroaryl groups include pyrrolyl, furanyl, thienyl, pyrazolyl, imidazolyl, thiazolyl, pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, quinolinyl, and isoquinolinyl.
“Heteroarylalkyl” means heteroaryl-alkyl- wherein the heteroaryl group is as described herein.
“Heterocyclyl” means a monocyclic, fully-saturated ring system of about 3 to about 7 ring atoms, in which one or two of the ring atoms is a hetero element(s) other than carbon (e.g., nitrogen, oxygen or sulfur) and the remainder of the ring atoms are carbon. Heterocyclyl groups may be optionally substituted, for example with alkyl, hydroxy, alkoxy, aryl, acyl, in particular, methyl, phenyl, halophenyl, alkoxycarbonyl. Exemplary heterocyclyl rings, for example include pyrrolidinyl, tetrahydrofuranyl, tetrahydrothiophenyl, piperidyl, tetrahydropyranyl, tetrahydrothiopyranyl, piperazinyl, morpholinyl, and thiomorpholinyl.
“Heterocyclyalkyl” means heterocycly-alkyl- wherein the heterocyclyl group is as herein described.
“Hydrate” means a solvate, as defined herein, wherein the solvent molecule(s) is/are H 2 O.
“Hydroxyalkyl” means HO-alkyl- group, wherein the alkyl group is as herein described.
“Obesity” refers to a condition whereby a mammal has a Body Mass Index (BMI), which is calculated as weight per height squared (kg/m 2 ), of at least 25.9. Conventionally, those persons with normal weight have a BMI of 19.9 to less than 25.9.
“Phenylalkyl” refers to an alkyl group, as described herein, which is substituted by a phenyl group.
The term “salt(s)” refers to pharmaceutically acceptable salts, as defined herein.
“Pharmaceutically acceptable salts” refers to the relatively non-toxic, inorganic and organic acid addition salts, and base addition salts, of compounds of the present invention. These salts can be prepared in situ during the final isolation and purification of the compounds. In particular, acid addition salts can be prepared by separately reacting the purified compound in its free base form with a suitable organic or inorganic acid and isolating the salt thus formed. Exemplary acid addition salts include the hydrobromide, hydrochloride, sulfate, bisulfate, phosphate, nitrate, acetate, oxalate, valerate, oleate, palmitate, stearate, laurate, borate, benzoate, lactate, phosphate, tosylate, citrate, maleate, fumarate, succinate, tartrate, naphthylate, mesylate, glucoheptonate, lactiobionate, sulphamates, malonates, salicylates, propionates, methylene-bis-O-hydroxynaphthoates, gentisates, isethionates, di-p-toluoyltartrates, methanesulphonates, ethanesulphonates, benzenesulphonates, p-toluenesulphonates, cyclohexylsulphamates and quinateslaurylsulphonate salts, and the like. See, for example S. M. Berge, et al., “Pharmaceutical Salts,” J. Pharm. Sci., 66, 1-19 (1977) which is incorporated herein by reference. Base addition salts can also be prepared by separately reacting the purified compound in its acid form with a suitable organic or inorganic base and isolating the salt thus formed. Base addition salts include pharmaceutically acceptable metal and amine salts. Suitable metal salts include the sodium, potassium, calcium, barium, zinc, magnesium, and aluminum salts. The sodium and potassium salts are preferred. Suitable inorganic base addition salts are prepared from metal bases which include sodium hydride, sodium hydroxide, potassium hydroxide, calcium hydroxide, aluminum hydroxide, lithium hydroxide, magnesium hydroxide, zinc hydroxide. Suitable amine base addition salts are prepared from amines which have sufficient basicity to form a stable salt, and preferably include those amines which are frequently used in medicinal chemistry because of their low toxicity and acceptability for medical use for example, ammonia, ethylenediamine, N-methyl-glucamine, lysine, arginine, ornithine, choline, N,N′-dibenzylethylenediamine, chloroprocaine, diethanolamine, procaine, N-benzylphenethylamine, diethylamine, piperazine, tris(hydroxymethyl)-aminomethane, tetramethylammonium hydroxide, triethylamine, dibenzylamine, ephenamine, dehydroabietylamine, N-ethylpiperidine, benzylamine, tetramethylammonium, tetraethylammonium, methylamine, dimethylamine, trimethylamine, ethylamine, basic amino acids, e.g., lysine and arginine, and dicyclohexylamine, and the like.
“Prevention” (of obesity) refers to preventing obesity from occurring if the treatment is administered prior to the onset of the obese condition. Moreover, if treatment is commenced in already obese subjects, such treatment is expected to prevent, or to prevent the progression of, the medical sequelae of obesity, such as, e.g., arteriosclerosis, Type II diabetes, polycystic ovarian disease, cardiovascular diseases, osteoarthritis, dermatological disorders, hypertension, insulin resistance, hypercholesterolemia, hypertriglyceridemia, and cholelithiasis.
“Solvate” means a physical association of a compound of this invention with one or more solvent molecules. This physical association includes hydrogen bonding. In certain instances the solvate will be capable of isolation, for example when one or more solvent molecules are incorporated in the crystal lattice of the crystalline solid. “Solvate” encompasses both solution-phase and isolable solvates. Exemplary solvates include hydrates, ethanolates, methanolates, and the like.
“Substance abuse disorders” includes substance dependence or abuse with or without physiological dependence. The substances associated with these disorders are: alcohol, amphetamines (or amphetamine-like substances), caffeine, cannabis, cocaine, hallucinogens, inhalants, nicotine, opioids, phencyclidine (or phencyclidine-like compounds), sedative-hypnotics or benzodiazepines, and other (or unknown) substances and combinations of all of the above. In particular, the term “substance abuse disorders” includes drug withdrawal disorders such as alcohol withdrawal with or without perceptual disturbances; alcohol withdrawal delirium; amphetamine withdrawal; cocaine withdrawal; nicotine withdrawal; opioid withdrawal; sedative, hypnotic or anxiolytic withdrawal with or without perceptual disturbances; sedative, hypnotic or anxiolytic withdrawal delirium; and withdrawal symptoms due to other substances. It will be appreciated that reference to treatment of nicotine withdrawal includes the treatment of symptoms associated with smoking cessation. Other “substance abuse disorders” include substance-induced anxiety disorder with onset during withdrawal; substance-induced mood disorder with onset during withdrawal; and substance-induced sleep disorder with onset during withdrawal.
“Therapeutically effective amount” means the amount the compound of structural formula I that will elicit the biological or medical response of a tissue, system, animal or human that is being sought by the researcher, veterinarian, medical doctor or other clinician.
“Treatment” or “treating” (of obesity) refers to reducing the BMI of the mammal and in certain cases where it is desirable for weight loss. The treatment or treating suitably results in a reduction in food or calorie intake by the mammal.
The symbol
in a molecular structure indicates the position of attachment for that particular substituent.
When any variable (e.g., R 1 , R d , etc.) occurs more than one time in any constituent or in formula I, its definition on each occurrence is independent of its definition at every other occurrence. Also, combinations of substituents and/or variables are permissible only if such combinations result in stable compounds. In choosing compounds of the present invention, one of ordinary skill in the art will recognize that the various substituents, i.e. R 1 , R 2 , etc., are to be chosen in conformity with well-known principles of chemical structure connectivity.
Under standard nonmenclature used throughout this disclosure, the terminal portion of the designated side chain is described first, followed by the adjacent functionality toward the point of attachment. For example, an arylcarbonylaminoalkyl substituent is equivalent to aryl-C(O)—NH-alkyl-.
Compounds of Formula I may contain one or more asymmetric centers and can thus occur as racemates and racemic mixtures, single enantiomers, diastereomeric mixtures and individual diastereomers. The present invention is meant to comprehend all such isomeric forms of the compounds of Formula I.
Some of the compounds described herein may exist with different points of attachment of hydrogen, referred to as tautomers. Such an example may be a ketone and its enol form known as keto-enol tautomers. The individual tautomers as well as mixture thereof are encompassed with compounds of Formula I.
Compounds of the Formula I may be separated into diastereoisomeric pairs of enantiomers by, for example, fractional crystallization from a suitable solvent, for example MeOH or ethyl acetate or a mixture thereof. The pair of enantiomers thus obtained may be separated into individual stereoisomers by conventional means, for example by the use of an optically active amine as a resolving agent or on a chiral HPLC column.
Alternatively, any enantiomer of a compound of the general Formula I may be obtained by stereospecific synthesis using optically pure starting materials or reagents of known configuration.
It is generally preferable to administer compounds of the present invention as enantiomerically pure formulations. Racemic mixtures can be separated into their individual enantiomers by any of a number of conventional methods. These include chiral chromatography, derivatization with a chiral auxiliary followed by separation by chromatography or crystallization, and fractional crystallization of diastereomeric salts.
The present invention also provides novel crystalline forms of the compounds of formula (I). Novel crystalline forms may be prepared by crystallization under controlled conditions. Crystallization from a solution and slurrying techniques are contemplated to be within the scope of the present process. In practice, a number of factors can influence the form obtained, including temperature, solvent composition and also optional seeding. Seed crystals can be obtained from previous synthesis of the compound in which crystals were isolated.
A number of methods are available to characterize crystalline forms of organic compounds. For example, methods include differential scanning calorimetry, solid state NMR spectrometry, infra-red spectroscopy, and X-ray powder diffraction. Among these X-ray powder diffraction and solid state NMR spectroscopy are very useful for identifying and distinguishing between crystalline forms.
It will be understood that, as used herein, references to the compounds of Formula I are meant to also include the pharmaceutically acceptable salts.
Compounds of this invention are modulators of the CB1 receptor and as such are useful for the prevention and treatment of disorders or diseases associated with the CB1 receptor. Accordingly, another aspect of the present invention provides a method for the treatment (including prevention, alleviation, amelioration or suppression) of diseases or disorders or symptoms mediated by CB1 receptor binding and subsequent cell activation, which comprises administering to a mammal an effective amount of a compound of Formula I. Such diseases, disorders, conditions or symptoms are, for example, but not limited to, psychosis, memory deficits, cognitive disorders, migraine, neuropathy, anxiety disorders, depression, stress, epilepsy, Parkinson's disease, schizophrenia, substance use disorders, particularly to opiates, alcohol, and nicotine, obesity, and eating disorders associated with excessive food intake. See DSM-IV-TR, Diagnostic and Statistical Manual of Mental Disorders. Revised, 4 th Ed., Text Revision (2000). See also DSM-IV, Diagnostic and Statistical Manual of Mental Disorders 4 th Ed., (1994). The DSM-IV and DSM-IV-TR were prepared by the Task Force on Nomenclature and Statistics of the American Psychiatric Association, and provides descriptions of diagnostic categories. The skilled artisan will recognize that there are alternative nomenclatures, nosologies, and classification systems for pathologic psychological conditions and that these systems evolve with medical scientific progress.
The obesity herein may be due to any cause, whether genetic or environmental. Examples of disorders that may result in obesity or be the cause of obesity include overeating and bulimia, polycystic ovarian disease, craniopharyngioma, the Prader-Willi Syndrome, Frohlich's syndrome, Type II diabetes, GH-deficient subjects, normal variant short stature, Turner's syndrome, and other pathological conditions showing reduced metabolic activity or a decrease in resting energy expenditure as a percentage of total fat-free mass, e.g, children with acute lymphoblastic leukemia. In addition, the compound of formula (I) can be used to ameliorate weight gain, whether or not the associated weight gain can be classified as clinically obese.
The method of treatment of this invention comprises a method of modulating the CB1 receptor and treating CB1 receptor mediated diseases by administering to a patient in need of such treatment a non-toxic therapeutically effective amount of a compound of this invention that selectively antagonizes the CB1 receptor in preference to the other CB or G-protein coupled receptors.
“Neutral antagonists” are ligands without intrinsic activity, i.e. they do not influence the receptor's own activity (constitutive receptor activity) and prevent competitively the binding of an agonist (often endogenous) to the receptor.
“Inverse agonists” are ligands with negative intrinsic activity, they inhibit the receptor's own activity (constitutive receptor activity) shifting the equilibrium of the receptor conformation to its inactive state.
There is evidence suggesting that CB1 receptor ligands act as either neutral antagonists or inverse agonists; these ligands will reduce endocannabinoid neurotransmission through CB1 receptors either by competitive receptor antagonism or by receptor inactivation, respectively.
Compounds of formula Ia (i.e., compounds of Formula I wherein
can be prepared according to the processes illustrated in Scheme 1.
In Scheme 1, Step a involves the introduction of R 1 -substitution at the 3-position on the indole moiety of compound (1), (IIa) or (IIc) (wherein Y is I, Br, B(OH) 2 ,
or SnMe 3 ) under standard conditions employed for palladium mediated cross-coupling reactions. For example, a 3-haloindole of formula (1), (IIa), or (IIc) is reacted with a suitable aryl boronic acid (Suzuki-type) or with a suitable aryl stannane (Stille-type), as generally described in Handbook of Palladium Catalyzed Organic Reactions, Malleron, J.-L.; Fiaud, J.-C.; Legros, J.-Y.; Academic Press, USA, 1997, p. 23-47. It is understood by one of ordinary skill in the art that, in general, an aryl boronic ester can be used in place of the aryl boronic acid in the palladium cross-coupling reactions described herein. By way of illustration, the aryl boronic acids include, but are not limited to, the following:
More specifically, compound (1), (IIa) or (IIc) (Y is I or Br) and the suitable aryl boronic acid or the suitable aryl boronic ester, along with a base (e.g., aqueous sodium carbonate) and a catalyst (e.g., [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium(II) complex) are dissolved in a suitable solvent such as dichloromethane, and the mixture is heated. Aqueous work-up and chromatographic purification affords the desired compound (2), (IIb) or (Ia). More specifically, in the Stille-type reaction, a 3-iodoindole compound (1), (IIa) or (IIc) is combined with an aryl stannane (e.g., 2-tributylstannyl pyrazine, 3-tributylstannylpyridine, 2-tributylstannylpyridine) and a catalyst (e.g., tetrakis(triphenylphosphine)Pd(0)) in an appropriate solvent (e.g., DMF) and heated. After an aqueous work-up, compound (2), (Ia) or (IIb) is isolated by chromatographic purification.
Alternatively, a 3-haloindole compound (1), (IIa) or (IIc) is subjected to a palladium-mediated coupling with an olefin (e.g., cyclopentene) or an α,β-unsaturated ketone or ester (Heck-type), then the resulting intermediate is hydrogenated to provide the desired compound (2), (IIb) or (Ia). (see generally Handbook of Palladium Catalyzed Organic Reactions, Malleron, J.-L.; Fiaud, J.-C.; Legros, J.-Y.; Academic Press, USA 1997 p. 61-71.) More specifically, a 3-iodoindole compound (1), (IIa) or (IIc) is combined with an olefin and a catalyst (e.g., palladium (II) acetate) along with tetrabutylammonium chloride and a base (e.g., potassium acetate) and the resulting mixture heated. After an aqueous work-up, the intermediate product is isolated by chromatographic purification, then subjected to hydrogenation to remove the resulting olefin, thereby providing the desired compound (2), (IIa), or (IIb).
Alternatively, a 3-haloindole compound (1), (IIa) or (IIc) is subjected to a metal halogen exchange with a reagent such as cyclopentyl magnesium bromide and then treated with a ketone such as tetrahydro-4H-pyran-4-one. The resulting alcohol is isolated and treated with a reducing agent (e.g., triethylsilane and TFA) to provide the desired compound (2), (Ia) or (IIb).
Alternatively, a compound (1), (IIa), or (IIc) when Y is B(OH) 2 ,
or SnMe 3 is reacted via a palladium-mediated coupling employing a suitable aryl halide in a manner analogous procedure set forth above. By way of illustration, suitable aryl halides include, but are not limited to, 5-bromo-2-methoxy pyridine, 5-bromo-2-fluoro-pyridine, 2-bromo-5-chloro-thiophene, 4-bromo-isoquinoline, 2-bromo-5-chloro-thiophene, 3-bromo-toluene, 4-bromo-toluene, 1-bromo-3-methoxy-phenyl, 6-bromo-quinoline, 1-bromo-4-dimethylamino-phenyl, 1-bromo-3-fluoro-pyridine, 2-bromo-pyrimidine and 5-bromo-pyrimidine.
In scheme 1 step b, a sulfonamide of formula (Ia), (IIa), (IIb) or (IIc) is prepared via treatment of the appropriate indole of formula (1) or (2) with the requisite sulfonyl chloride of formula (3) or (4) in the presence of a base under standard conditions. More specifically, the indole of formula (1) or (2) and the sulfonyl chloride of formula (3) or (4) are combined with a base (e.g., diisopropylethylamine, potassium tertbutoxide or sodium hydride) in an appropriate solvent (e.g., N,N-dimethylformamide, dioxane or tetrahydrofuran). Alternatively, the indole of formula (1) or (2) and sulfonyl chloride of formula (3) or (4) are combined with a catalyst (e.g., DMAP or 4-pyrrolidin-1-yl-pyridine) with or without a base in an appropriate solvent (e.g., N,N-dimethylformamide, dioxane or acetonitrile). An aqueous work-up and chromatographic purification affords compound (Ia), (IIa), (IIb) or (IIc).
In Scheme 1, step c, the conversion of an ester of formula (IIb) to an amide of formula (Ia) is achieved under standard conditions via the carboxylic acid or acid chloride, as referenced in Comprehensive Organic Transformations, R. C. Larock VCH Publishers Inc, New York, N.Y. 1989. p. 972-976. More Specifically, the ester of formula (IIb) is hydrolyzed to the acid in the presence of a base (e.g., sodium hydroxide), converted to the acid chloride with reagents such as oxalyl chloride, and then treated with the requisite amine in the presence of a base (e.g., triethylamine) to form the compound (Ia). Alternatively the acid is coupled with the amine using a coupling reagent (e.g., EDC, BOP or PyBOP) with or without a catalyst (e.g., NHS). After an aqueous work-up, the products are isolated by chromatographic purification to yield the compound (Ia).
Compounds of formula (Ia) can also be prepared according to the processes illustrated in Scheme 2.
In Scheme 2, step a, direct alkylation of a compound (5), (IId) or (IIe) is achieved via heating with a ketone (e.g., cyclohexanone or 2-methoxycyclohexanone) and a base (e.g., potassium hydroxide). The resulting olefin is hydrogenated to form a compound of formula (2), (IIb), or (Ia) (see, e.g., J. Med. Chem . (1997), 40, 250). Alternatively, direct alkylation of a compound of formula (5), (IId), (IIe) is achieved under protic or lewis acid conditions with an alcohol (e.g., tert-butyl alcohol) or alkyl bromide (e.g., as described in J. Org. Chem. (2002), 67, 2705). Alternatively, conjugate addition to an α,β-unsaturated ketone is achieved in the presence of indium tribromide and isopropylamine in solvents such as dichloromethane, as described in J. Org. Chem (2002), 67, 3700 to form compound (2), (IIb), or (Ia). Steps b and c in Scheme 2 are carried out as described in steps b and c of Scheme 1, respectively.
It should be noted that when R 1 is
step a of Schemes 1 and 2 must be modified as shown in Scheme 3.
In Scheme 3, step a1, a 3-amino □eaction□ed indole compound (2a) is prepared via a palladium-mediated coupling of an amine with a 3-haloindole of formula (6) bearing a protecting group on nitrogen (as described for example in Organic Lett . (2002), 4, 2885) followed by removal of the N-protecting group. More specifically, 3-bromoindole N-protected with a triisopropylsilanyl group is combined with an amine (e.g., piperidine, morphline, or 1-methyl piperazine), a catalyst (e.g., tris(dibenzylideneacetone)dipalladium(0) chloroform adduct and 2-dicyclohexylphosphino-2′-(N,N-dimethylamino)biphenyl), and a base (e.g., lithium bis(trimethylsilyl)amide), and the mixture heated in an appropriate solvent (e.g., THF). The resulting intermediate is deprotected with tetrabutyl ammonium fluoride, after which an aqueous work-up and chromatographic purification yields isolated compound (2a).
Compounds of formula Ib (i.e. where
is
can be synthesized by methods known in the art, as illustrated in Scheme 4.
In Scheme 4, step a involves reduction of the indole compound (2) to the corresponding indoline compound (7) utilizing standard conditions such as sodium borohydride or sodium cyanoborohydride, and as described in Yamamoto, Y et al. Bull Chem. Soc. Jpn 44, 1971, 541-545. Step b involves reaction of the indoline compound (7) with the appropriate sulfonyl chloride compound (4) or (3) under standard conditions described above in Scheme 1 or 2. Alternatively, the indole compound (2) is coupled to the sulfonyl chloride according to Schemes 1, 2, or 3, followed by reduction according to step a to give (Ib). Alternatively, compound (Ia) can be prepared by one of the general methods found in Schemes 1, 2 or 3. In general, when R 1 is aryl, step a is accomplished as the first step. When R 1 is alkyl or cycloalkyl, step b is accomplished as the first step. Compounds, wherein R 1 and R 2 are taken together to form a ring as synthesized by methods known in the art.
The examples set forth herein represent typical syntheses of the compounds of the present invention. The reagents and starting materials are readily available to one of ordinary skill in the art.
Preparation 1
3-(6-Methoxy-cyclohex-1-enyl)-1H-indole
Add 5 ml dry MeOH to a flask under N 2 containing indole (1 g, 8.5 mmol, 8.5 eq) and potassium hydroxide (202 mg, 3.59 mmol, 1 eq). Add to this solution 2-Methoxy-cyclohexanone (834 mg, 6.5 mmol, 6.5 eq). Heat reaction to 63° C. for 18 hours. Cool reaction and purify crude material by silica gel chromatography to give 442 mg (30% yield) of 3-(6-Methoxy-cyclohex-1-enyl)-1H-indole as a waxy yellow solid. Mass Spectrum (m/e): 228.02 (MH+).
Preparation 2
3-(2-Methoxy-cyclohexyl)-1H-indole
Treat 3-(6-methoxy-cyclohex-1-enyl)-1H-indole (200 mg, 0.879 mmol) with 10% Pd/C (40 mg) in EtOAc under atmospheric hydrogenation conditions for 1.5 hours. Filter resulting solution over Celite to remove catalyst. Concentrate crude on rotovap and purify on silica gel chromatography to give 3-(2-Methoxy-cyclohexyl)-1H-indole (127 mg, 63% yield). Mass Spectrum (m/e): 230.03 (MH+), 228.14 (M−).
Preparation 3
3-(1H-Indol-3-yl)-cyclopentanone
Conduct reaction according to literature procedure (JOC, vol 67, 2002, pg 3700-3704) to give final 3-(1H-Indol-3-yl)-cyclopentanone (1.38 g, 81% yield) as a light pink solid. Mass Spectrum (m/e): 199.99 (MH+).
Preparation 10
N-[2-Phenyl-eth-(Z)-ylidene]-N′-pyridin-4-yl-hydrazine
React 4-hydrazinopyridine HCl with phenylacetaldehyde under literature conditions (J Chem Soc, 1959, pg 3830). Instead of NH 3 , neutralize with 1N NaOH and extract with CHCl 3 . Dry organics over MgSO 4 and concentrate on rotovap to give N-[2-Phenyl-eth-(Z)-ylidene]-N′-pyridin-4-yl-hydrazine (7.3 g, approx quantitative) as a crude thick oil that can be used without further purification. Mass Spectrum (m/e): 212.02 (MH+).
Preparation 11
3-Phenyl-1H-pyrrolo[3,2-c]pyridine
React crude N-[2-Phenyl-eth-(Z)-ylidene]-N′-pyridin-4-yl-hydrazine (7.25 g, 34.22 mmol) under literature conditions (Can J Chem, vol 44, 1966, pg 2455) to give 3-Phenyl-1H-pyrrolo[3,2-c]pyridine (2.28 g, 34% yield) after silica gel chromatography: Mass Spectrum (m/e): 194.96 (MH+).
Preparation 12
4-(4-Fluoro-benzylcarbamoyl)-benzenesulfonyl chloride
Add 4-chlorosulfonyl-benzoyl chloride (103 g (0.433 mol) and anhydrous THF (1.2 L) to a 5-L 3-neck round bottom equipped with overhead stirrer, dropping funnel, N 2 line, and temperature probe and cool to −78° C. Add to the stirring solution dropwise over 4 h a solution of 4-fluorobenzylamine (52 g, 0.416 mol), triethylamine (42 g, 0.415 mol), and 4-DMAP (5.3 g, 0.043 mol) in dry THF (1.2 L). Slowly bring to room temperature the resulting mixture and stir overnight. Filter the solids, back-wash with THF, and concentrate the filtrate to a solid. Partition the solid between 1N HCl (1 L) and ethyl acetate (2×1 L). Combine the organics, dry over magnesium sulfate, filter, and concentrate to a solid. Suspend the solid in methyl t-butyl ether (1 L), stir at room temperature for 2 h, filter, and back-wash with ethyl ether (500 mL). Dry the resulting white powder (20 mm Hg, 40° C.) to give 4-(4-fluoro-benzylcarbamoyl)-benzenesulfonyl chloride as a white solid (108.5 g, 80%): 1 HNMR(DMSO-d 6 ) δ 9.07 (t, J=5.9 Hz, 1H), 7.82 (d, J=8.3 Hz, 2H), 7.65 (d, J=7.8 Hz, 2H), 7.35 (m, 2H), 7.14 (t, J=8.8 Hz, 2H), 4.44 (d, J=5.9 Hz, 2H); MS(ESI) m/z 326 (m−H); HPLC, 93.6%.
Preparation 14
3-(3,3-Difluoro-cyclopentyl)-1H-indole
Following a literature procedure (Tet, Vol 46, No 13-14, pg 4925, 1990) previously reported to convert 3-(1H-Indol-3-yl)-cyclopentanone to 3-(3,3-difluoro-cyclopentyl)-1H-indole (246 mg, 22% yield): Mass Spectrum (m/e): 220.11 (MH−).
Preparation 15
3-Morpholin-4-yl-1-triisopropylsilanyl-1H-indole
Combine 3-bromo-1-triisopropylsilanyl-1H-indole (0.33 g, 0.94 mmol), morpholine (0.10 mL, 1.15 mmol), 2-dicyclohexylphosphino-2′-(N,N-dimethylamino)biphenyl (0.012 g, 0.03 mmol), and tris(dibenzylideneacetone)dipalladium(0) chloroform adduct (0.012 g, 0.01 mmol) in a pressure tube. Add 1N solution of lithium bis(trimethylsilyl)amide in THF (2.00 mL, 2.00 mmol), flush tube with nitrogen gas, and close the tube. Stir at 65° C. for 18 h, cool to room temperature, dilute with water, and extract with EtOAc. Wash EtOAc layer with water, brine, dry (Na 2 SO 4 ), and concentrate under vacuum. Purify the residue by flash chromatography using 0 to 50% of EtOAc in hexanes to give the title compound (0.20 g 60%): MS (ES) 359.1 (M+1)+.
Preparation 16
3-(4-Methyl-piperazin-1-yl)-1-triisopropylsilanyl-1H-indole
Following a method similar to 3-morpholin-4-yl-1-triisopropylsilanyl-1H-indole using 3-bromo-1-triisopropylsilanyl-1H-indole (0.70 g, 1.99 mmol), 1-methyl-piperazine (0.30 g, 3.00 mmol), 2-dicyclohexylphosphino-2′-(N,N-dimethylamino)biphenyl (0.02 g, 0.05 mmol), tris(dibenzylideneacetone)dipalladium(0) chloroform adduct (0.05 g, 0.05 mmol) and 1N solution of lithium bis(trimethylsilyl)amide in THF (2.40 mL). Purify by flash chromatography using 0 to 12% of MeOH in dichloromethane to give the title compound (0.23 g, 32%). MS (ES) 372.1 (M+1) + .
Preparation 17
3-Piperidin-1-yl-1-triisopropylsilanyl-1H-indole
Following a method similar to 3-morpholin-4-yl-1-triisopropylsilanyl-1H-indole using 3-bromo-1-triisopropylsilanyl-1H-indole (0.70 g, 1.99 mmol), piperidine (0.26 g, 3.04 mmol), 2-dicyclohexylphosphino-2′-(N,N-dimethylamino)biphenyl (0.02 g, 0.05 mmol), tris(dibenzylideneacetone)dipalladium(0) chloroform adduct (0.05 g, 0.05 mmol) and 1N solution of lithium bis(trimethylsilyl)amide in THF (2.40 mL) to prepare the title compound. Purify by flash chromatography using 0 to 40% of EtOAc in hexanes to give the title compound (0.20 g, 29%): MS (ES) 357.1 (M+1) + .
Preparation 18
3-Morpholin-4-yl-1H-indole
Add 1N solution of tetrabutylammonium fluoride (0.70 mL, 0.70 mmol) to a solution of 3-Morpholin-4-yl-1-triisopropylsilanyl-1H-indole (0.20 g, 0.56 mmol) in THF (2.0 mL). Stir at room temperature for 2 h, dilute with water, and extract with EtOAc. Wash EtOAc with saturated NaHCO 3 , water, dry (Na 2 SO 4 ), and concentrate under vacuum. Purify the residue by flash chromatography using 20 to 80% of EtOAc in hexanes to give the title compound (0.10 g 89%). MS (ES) 203.1 (M+1)+.
Preparation 19
3-(4-Methyl-piperazin-1-yl)-1H-indole
Following a method similar to 3-morpholin-4-yl-1H-indole using 3-(4-Methyl-piperazin-1-yl)-1-triisopropylsilanyl-1H-indole (0.35 g, 0.94 mmol) and 1N solution of tetrabutylammonium fluoride (1.40 mL) to prepare the title compound. Purify by flash chromatography using 2 to 12% methanol in dichloromethane to give the title compound (0.12 g 60%). MS (ES) 216.1 (M+1)+.
Preparation 20
3-Piperidin-1-yl-1H-indole
Following a method similar to 3-morpholin-4-yl-1H-indole using 3-Piperidin-1-yl-1-triisopropylsilanyl-1H-indole (0.30 g, 0.84 mmol) and 1N solution of tetrabutylammonium fluoride (1.30 mL). Purify by flash chromatography using 20 to 50% of EtOAc in hexanes to give the title compound (0.12 g 71%). MS (ES) 201.1 (M+1)+.
Preparation 21
1-(2-Fluoro-phenyl)-cyclobutanecarbonitrile
Slowly add NaH (922 mg, 23.0 mmol) to a solution of (2-fluorophenyl)-acetonitrile (1.27 mL, 9.95 mmol) in DMSO (40.0 mL). Stir the mixture at RT for 30 mins then add via cannula a solution of 1,3-dichloropropane (0.95 mL, 10.0 mmol) in DMSO (20 mL). After addition is complete stir at 75° C. for 5 h. Pour mixture over ice (60 g) and extract with Et 2 O (3×50 mL). Combine the organic solutions and wash with brine (50 mL), dry filter and concentrate. Purify the material by flash chromatography (using a linear gradient of 100% hexanes to 35% EtOAc/hexanes) to give the title compound (1.4 g, 80%) as a yellow oil. 1 H NMR (400 MHz, CDCl 3 ): δ 7.32 (m, 1H), 7.25 (dt, 1H, J=1.9, 8.0), 7.16 (dt, 1H, J=0.9, 7.5), 7.09 (ddd, 1H, J=1.2, 8.1, 10.7), 2.86 (m, 2H), 2.69 (m, 2H), 2.50 (m, 1H), 2.05 (m, 1H).
Preparation 22
4-(2-Fluoro-phenyl)-tetrahydro-pyran-4-carbonitrile
Slowly add NaH (920 mg, 23.0 mmol) to a solution of (2-fluorophenyl)-acetonitrile (1.27 mL, 9.95 mmol) in DMSO (40.0 mL). Stir the mixture at RT for 30 mins then add via cannula a solution of 1,3-dichloropropane (1.0 mL, 8.53 mmol) in DMSO (20 mL). After addition is complete stir at 75° C. for 5 h. Pour mixture over ice (60 g) and extract with Et 2 O (3×50 mL). Combine the organic solutions and wash with brine (50 mL), then dry filter and concentrate. Purify the material by flash chromatography (using a linear gradient of 100% hexanes to 35% EtOAc/hexanes) to give the title compound (1.4 g, 80%) as a yellow oil. 1 H NMR (400 MHz, CDCl 3 ): δ 7.43 (dt, 1H, J=1.7, 7.9), 7.36 (m, 1H), 7.19 (dt, 1H, J=1.4, 7.7), 7.13 (ddd, 1H, J=1.4, 6.6, 14.5), 4.08 (m, 2H), 3.94 (dt, 2H, J=1.7, 7.9), 2.26 (dt, 2H, J=4.4, 13.7), 2.19 (m, 2H).
Preparation 23
Spiro[indoline-3,4′-tetrahydro-pyran]
Add LiAlH 4 (398 mg, 10.5 mmol) to a solution of 4-(2-fluoro-phenyl)-tetrahydro-pyran-4-carbonitrile (1.39 g, 6.77 mmol) in dimethoxyethane (25 mL). Stir the solution at reflux overnight then add aq. Satd Rochelle's salt solution (30 mL) and stir for an additional 1 h at RT. Extract the mixture with CH 2 Cl 2 (3×30 mL). Combine the organic extracts and wash with additional aq satd Rochelle's salt solution (30 mL) and brine (30 mL). Dry, filter and concentrate the organic solution then purify the crude material by flash chromatography, using a linear gradient of 100% hexanes and 50% EtOAc/hexanes, to give the title compound (581 mg, 45%) as a white solid. 1 H NMR (400 MHz, CDCl 3 ): δ 7.09 (d, 1H, J=7.3), 7.06 (t, 1H, J=7.6), 6.77 (m, 1H), 6.67 (m, 1H), 3.97 (m, 2H), 3.94 (dt, 2H, J=1.7, 7.9), 3.56 (dt, 2H, J=2.1, 11.8), 3.55 (s, 2H), 1.99 (m, 2H), 1.67 (m, 2H).
Preparation 24
C-[1-(2-Fluoro-phenyl)-cyclobutyl]-methylamine
Add LiAlH 4 (461 mg, 12.1 mmol) to a solution of 1-(2-fluoro-phenyl)-cyclobutanecarbonitrile (1.38 g, 7.88 mmol) in dimethoxyethane (30 mL). Stir the solution at reflux overnight then add aq. Satd Rochelle's salt solution (30 mL) and stir for an additional 1 h at RT. Extract the mixture with CH 2 Cl 2 (3×30 mL). Combine the organic extracts and wash with additional aq satd Rochelle's salt solution (30 mL) and brine (30 mL). Dry, filter and concentrate the organic solution then purify the crude material by flash chromatography, using 20% MeOH/CH 2 Cl 2 , to give the title compound (1 g, 71%) as a white solid. MS (ES) 180.1 (M+1)+.
Preparation 25
Spiro[cyclobutane-1,3′-indoline]
Add LiAlH 4 (266 mg, 7.01 mmol) to a solution of 4-(2-fluoro-phenyl)-tetrahydro-pyran-4-carbonitrile (488 mg, 2.72 mmol) in dimethoxyethane (30 mL). Stir the solution at reflux for 4d, then add aq. Satd Rochelle's salt solution (30 mL) and stir for an additional 1 h at RT. Extract the mixture with Et 2 O (3×30 mL). Combine the organic extracts and wash with brine (30 mL). Dry, filter and concentrate the organic solution then purify the crude material by flash chromatography, using a linear gradient of 100% hexanes to 30% EtOAc/hexanes, to give the title compound (44 mg, 10%) as a white solid. 1 H NMR (400 MHz, CDCl 3 ): δ 7.31 (m, 1H), 7.03 (dt, 1H, J=1.4, 7.5), 6.79 (dt, 1H, J=0.9, 7.5), 6.64 (d, 1H, J=7.9), 2.36 (m, 2H), 2.21 (m, 2H), 2.02 (m, 2H).
Preparation 26
3-Cyclopropyl-1-triisopropylsilanyl-1H-indole
Dissolve 3-bromo-1-triisopropylsilanyl-1H-indole (1.02 g, 2.89 mmol), cyclopropylboronic acid (259 mg, 3.01 mmol) and K 3 PO 4 (1.8 g, 8.5 mmol) in a mixture of toluene (20 mL) and water (0.8 mL). Add tricyclohexyl-phosphane (86 mg, 0.31 mmol) and palladium(II) acetate (50 mg, 0.22 mmol) and stir the mixture at 70° C. for 3 h. Filter the mixture through celite and wash the solids with EtOAc (30 mL). Collect and concentrate the filtrate and purify the residue by flash chromatography, using a linear gradient of 100% hexanes to 10% EtOAc/hexanes, to give the title compound as a clear oil 765 mg (84%): MS (ES) 314.1 (M+1)+.
Preparation 27
3-tert-Butyl-1H-indole
Add trifluoroacetic acid (TFA; 1.0 mL, 1.5 g, 13 mmol, 1.6 equiv) to a solution of indole (1.00 g, 8.54 mmol, 1 equiv) and tert-butyl alcohol (1.0 mL, 0.78 g, 10 mmol, 1.2 equiv) in anhydr 1,2-dichloroethane (40 mL). The colorless solution slowly turns to brown while heating to reflux. After 1 h reflux, add more TFA (2 mL) and tert-butyl alcohol (2 mL). After 16 h reflux, rotary evaporate the reaction solution (80° C.) giving a dark-brown solid. Transfer this material to a column of silica gel (235 mm×35 mm dia.) and elute (0-10% EtOAc/hex) the desired 3-tert-butyl-1H-indole which co-elutes with a trifluoroacetate derivative of itself (3:1) yielding 284 mg of a brown oil. Elute this material with (10% EtOAc/hex) again through a column of silica gel (125 mm×25 mm dia.) yielding 124 mg (8.4%) of pure 3-tert-butyl-1H-indole as a light-orange crystalline solid. MS (m/z): 173.
Preparation 28
1-Bromo-1-methyl-cyclopentane
Stir 1-methylcyclopentanol (1.12 g, 11.2 mmol, 1 equiv) vigorously with aq HBr (48%; 5.0 mL, 7.4 g [0.48]=3.6 g HBr, 44 mmol, 4.0 equiv) for 30 min. Separate the organic layer and extract the aqueous layer with hexanes (5 mL). Combine the organic layers, dry (anhydr MgSO 4 ) and rotary evaporate (35° C.; some of the product distills) yielding 657 mg (36.0%) of 1-bromo-1-methyl-cyclopentane as a light-green liquid.
Preparation 29
3-(1-Methyl-cyclopentyl)-1H-indole
Add N,N-Diisopropylethylamine (890 μL, 660 mg, 5.1 mmol, 2.2 equiv) to a mixture of indole (410 mg, 3.5 mmol, 2.0 equiv), tetrabutylammonium iodide (860 mg, 2.3 mmol, 1.0 equiv), and zinc triflate (1000 mg, 2.8 mmol, 1.2 equiv) in anhydrous toluene (10 mL). After stirring 15 min, add 1-bromo-1-methyl-cyclopentane (380 mg, 2.3 mmol, 1 equiv). After 15 h, quench the reaction mixture with satd aq NH 4 Cl (10 mL). Separate the organic layer and extract the aqueous layer with Et 2 O (10 mL). Dry the combined organic layers (anhydr MgSO 4 ) and rotary evaporate (40° C.) to give 440 mg of material as a light-yellow oil. Transfer this material to a column of silica gel (125 mm×25 mm dia.) and elute (5-20% CH 2 Cl 2 /hex). Much desired product co-elutes with starting material indole. Transfer this material to a column of silica gel (80 mm×20 mm dia.) and elute (0-15% CH 2 Cl 2 /hex) to yield 99 mg (21%) of pure 3-(1-methyl-cyclopentyl)-1H-indole as a colorless oil. MS (m/z): 199.
Preparation 30
1-[(Toluene-4-sulfonyl-1H-indol-3-yl]-ethanone
Add 1.0 M t-BuOK (3.0 mL, 0.003 mol) to a stirring solution of 3-acetyl indole (0.478 g, 0.0030 mol) in dry DMF (20 mL) under N 2 at ambient temperature and stir for 30 min. Add toluenesulfonyl chloride to this solution and stir the resulting mixture overnight. Pour the reaction into EtOAc—H 2 O, separate the organic layer and extract several times with H 2 O, wash with brine, dry (MgSO 4 ), filter, and evaporate on the rotary evaporator. Chromatograph on the ISCO eluting with a gradient hexane-EtOAc (0-100%) over 30 minutes to give 0.73 g (78%) of the title compound as a solid: 1 H (CDCl 3 ).δ 7.8 (d, 1H), 8.2(s, 1H), 7.9(d,1H), 7.7 (d,2H), 7.4 (m, 2H), 7.3(d,2H), 2.6 (s, 3H), 2.4(s, 3H).
Preparation 31
2-[1-(Toluene-4-sulfonyl)-1H-indol-3-yl]-propan-2ol
Add methyl magnesium bromide 3.0M (0.40 mL) to a stirring solution of 1-[(toluenesulfonyl)-1H-indol-3-yl]-ethanone 0.31 g, 0.0010 mol) in dry THF under N 2 at −30. A solid precipitates immediately. Allow the reaction mixture to warm to 0-10° C. and stir for 1 h. Cool the mixture in an ice bath and quench with a saturated solution of NH 4 Cl. Dilute with Et 2 O, and separate the organic layer, wash with brine, dry (MgSO 4 ) filter. Concentrate to give an oil (0.36 g). Chromatograph using a gradient hexane-EtOAc (0-100 over 30 minutes) to give 0.20 g (62%) of the desired as an off white solid: 1 H NMR (CDCl 3 ) δ 8.0 (d, 1H) 7.8 (m,3H), 7.45 (s, 1H), 7.4-7.2(m,4H), 2.4(s, 3H), 1.7 (s, 6H).
Preparation 32
3-Isopropyl-1-(toluene-4-sulfonyl)-1H-indole
Add TFA (1.35 mL, 0.0174 mol) to a stirring solution of 2-[1-(Toluene-4-sulfonyindol-3-yl]-propan-2ol (0.358 g, 0.001 mol) in CH 2 Cl 2 (20 mL) at 0° C. Stir the resulting mixture at 0-5° C. for 1 h and allow to warn to ambient temperature and stir for 1½ h. Pour the solution into a mixture of saturated NaHCO 3 —CH 2 Cl 2 . Separate the organic layer, filter, and evaporate on the rotary evaporator to give 0.103 g of the desired compound: 1 H NMR (CDCl 3 ) δ 8.0 (d, 2H), 7.8 (d, 2H), 7.55 (d, 1H), 7.3-7.2 (m, 5H), 3.1 (m, 1H), 2.38 (3H), 1.28 (d, 6H).
Preparation 33
3-Isopropyl indole
Add five molar NaOH (3.0 mL), 0.015 mol) to a suspension of 3-isopropyl-1-(toluenesulfonyl)-1H-indole 0.100 g, 0.032 mmol) in EtOH (6.0 mL) at ambient temperature and heat the resulting mixture and stir at 90° C. overnight. Dilute the mixture with H 2 O (5.0 mL) and concentrate on the rotary evaporatory. Extract the resulting suspension with Et 2 O. Separate the organic layer, dry (MgSO 4 ) and filter. Evaporate to give the title compound 0.0387 (77%) as a yellow oil: 1 H NMR(CDCl 3 ) δ 7.88-7.82(bs, 1H), 7.7 (d,1H), 7.4 (d, 1H), 7.25 (t, 1H), 7.2(t, 1H), 7.0 (d,1H), 3.3 (m, 1H), 1.43(d, 6H).
Preparation 34
4-(3-Phenyl-indole-1-sulfonyl)-benzoic acid
Add to a 2 L 3-neck flask equipped with reflux condenser, thermometer and nitrogen inlet, 4-(3-iodo-indole-1-sulfonyl)-benzoic acid methyl ester (0.1 mol, 44.1 g), phenylboronic acid (0.12 mol, 22.35 g), 1,1-bis(diphenylphosphino)ferrocene dichloropalladium (0.0025 mol, 2.04 g), 2M sodium carbonate (140 ml) and 0.5 L THF. Heat the mixture to reflux under nitrogen for 2 hours. Remove THF under vacuum, and add MTBE (500 ml) and DI water (200 ml) to the residue. Filter the solution through a pad of Celite, and wash with MTBE (500 ml). Separate the organic layer and concentrate under vacuum to give a brown solid. Dissolve the solid in THF (250 ml). Add to this solution 5N NaOH (35 ml) dropwise over a 30 minute period. Stir the reaction at ambient temperature for 3 hours, and quench with DI water (250 ml) and MTBE (250 ml). Separate the water layer and back extract the organic layer with DI water (250 ml). Combine the aqueous layers and wash with MTBE (500 ml). Stir the aqueous layer at ambient temperature and adjust the pH is to 1 with concentrated HCl. Stir the slurry at ambient temperature for 2 hours, filter and wash with DI water (500 ml). Dry the off-white, gray solid in vacuum oven at 65° C. for 16 hours to obtain 25.44 g. 1 H NMR (DMSO) 8.2(d, 2H), 8.1(m, 3H), 7.9(d, 1H), 7.7(d, 2H), 7.4(m, 5H). MS (ES−)=376.2 (M−1). Anal. Calcd. For C 21 H 15 NO 4 S: C, 66.8308; H, 4.0060; N, 3.7112. found C, 66.54; H, 4.07; N, 3.20.
Preparation 35
4-(3-Isopropyl-indole-1-sulfonyl)-benzoic acid methyl ester
Add potassium tert butoxide 1.0 M (1.6 mL, 0.0016 mol) dropwise to a stirring solution of 3-isopropyl indole (0.217 g, 0.00136 mol) in dry DMF (20 mL) under N 2 at ambient temperature. Stir the reaction mixture for 30 minutes and add portionwise 4-chlorosulfonyl benzoic acid methyl ester (0.328 g, 0.0014 mol). The light brown reaction mixture decolorizes immediately. Stir the resulting yellow solution overnight. Pour into a EtOAc—H 2 O mixture (100 to 300 mL). Separate the EtOAc and sequentially extract with H 2 O (3×250 mL), wash with brine, dry (MgSO 4 ), filter and evaporate giving 0.38 g. Chromatograph on the ISCO using a gradient hexane-EtOAc (0-50%, 30 30 minutes) to give 0.249 g (51%) of the title compound as a waxy solid. Mass spectrum (m/e) (M+H) 358.1113. found (M+H) 358.1129.
Preparation 36
4-(3-Isopropyl-indole-1-sulfonyl)-benzoic acid
Add five molar NaOH (1.5 mL 0.0075 mol) to a stirring solution of 4-(3-isopropyl-indole-1-sulfonyl)-benzoic acid methyl ester (0.230 g, 0.00061 mol) in THF (10.0 mL) at ambient temperature under N 2 . Stir the resulting mixture overnight Dilute with 5% NaHCO 3 (75 mL) and extract with Et 2 O. Separate the aqueous layer and acidify with 37% HCl. Extract the resulting precipitate into EtOAc, wash with brine, dry (MgSO 4 ), filter and evaporate giving 0.187 g of the title compound as an off white solid: Mass spectrum (m/e) (M−H) 342.0800; Found (M−H) 342.0802.
Preparation 37
4-[3-(2-Fluoro-pyridin-3-yl)-indole-1-sulfonyl]-benzoic acid
Reflux a mixture of 4-(3-iodo-indole-1-sulfonyl)-benzoic acid methyl ester (1.33 g, 3.01 mmol, 1 equiv), 2-fluoropyridine-3-boronic acid (Frontier Scientific®; 0.47 g, 3.3 mmol, 1.1 equiv), sodium carbonate (2M in H 2 O; 3.0 mL, 6.0 mmol, 2.0 equiv), and [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium(II) complex with dichloromethane (62 mg, 0.080 mmol, 0.025 equiv) in THF (15 mL) under N 2 for 2 h (reaction mixture turned very dark when heated). Rotary evaporate the reaction mixture. Dissolve the resultant residue in Et 2 O (15 mL) and wash with H 2 O (5 mL). Back-extract the aqueous layer is with Et 2 O (5 mL). Dry the combined organic layers with (anhydr Na 2 SO 4 ), and rotary evaporate (40° C.) giving the crude 4-[3-(2-fluoro-pyridin-3-yl)-indole-1-sulfonyl]-benzoic acid methyl ester as a brown foam. Dissolve this material in THF (10 mL) and add 5M aq NaOH (2 mL). After 18 h, add H 2 O (25 mL) and Et 2 O (25 mL). Separate the aqueous layer and extract the organic layer with H 2 O (25 mL). Combine the aqueous layers and wash with Et 2 O (25 mL). Acidify this aqueous layer with 1M aq HCl (8 mL) to pH 5 causing much precipitation. Extract this mixture with CHCl 3 (1×50 mL, 2×25 mL). Dry the combined organic layers (anhydr Na 2 SO 4 ) and rotary evaporate (40° C.) yielding 673 mg (56.3%) of 4-[3-(2-fluoro-pyridin-3-yl)-indole-1-sulfonyl]-benzoic acid as a brown powder. MS (m/e): 396.94 (M+1); 394.99 (M−1).
Preparation 38
4-[3-(6-Fluoro-pyridin-3-yl)-indole-1-sulfonyl]-benzoic acid
Prepare the title compound by a similar method described for 4-[3-(2-fluoro-pyridin-3-yl)-indole-1-sulfonyl]-benzoic acid using 4-(3-iodo-indole-1-sulfonyl)-benzoic acid methyl ester (1.33 g, 3.01 mmol, 1 equiv), 2-fluoropyridine-5-boronic acid (Frontier Scientific®; 0.47 g, 3.3 mmol, 1.1 equiv) to give 965 mg (80.8%) of brown powder. MS (m/e): 396.94 (M+1); 394.98 (M−1).
Preparation 39
4-(3-Cyclopropyl-indole-1-sulfonyl)-benzoic acid methyl ester
Add a solution of tetrabutylammoium fluoride (3.0 mL, 3.0 mmol; 1.0M in THF) to a solution of 3-cyclopropyl-1-triisopropylsilanyl-1H-indole (0.76 g, 2.4 mmol) in THF (15.0 mL). Stir at RT for 15 min, concentrate to a viscous oil, and re-dissolve in Et 2 O (50 mL). Wash the organic solution with water (30 mL) and satd NaHCO 3 (30 mL). Dry, filter and concentrate the organic solution and purify the residue by flash chromatography, using a linear gradient of 100% hexanes to 30% EtOAc/hexanes, to give the title compound as a light yellow oil still containing triisopropylflouride as an impurity. Use the material directly in the next reaction without further purification.
Add potassium tert-butoxide (280 mg, 2.49 mmol) to a solution of the above 3-cyclopropyl-1H-indole in DMF (10.0 mL). Treat the solution with 4-chlorosulfonyl-benzoic acid methyl ester (590 mg, 2.51 mmol) and stir at RT for 2 h. Dilute the solution with EtOAc (30 mL) and wash with water (20 mL) and satd NaHCO 3 (20 mL). Dry, filter and concentrate the organic solution and purify the residue by flash chromatography, using a linear gradient of 100% hexanes to 20% EtOAc/hexanes, to give the title compound as a light yellow oil (505 mg, 59%, 2 steps). MS (ES) 355.9 (M+1)+.
Preparation 40
4-(3-Cyclopropyl-indole-1-sulfonyl)-benzoic acid
Add lithium hydroxidemonohydrate (181 mg, 4.31 mmol) to a solution of 4-(3-cyclopropyl-indole-1-sulfonyl)-benzoic acid methyl ester (505 mg, 1.42 mmol) in 3:1 dioxane:water (6.0 mL). Stir the mixture at RT for 4 h, dilute with water (80 mL) and add 1N HCl until mixture reaches pH 2. Collect the white solid by filtration and dry overnight under vacuum to give the title compound (450 mg, 93%). MS (ES) 341.9 (M+1)+, 340.1 (M−1)−.
Preparation 41
4-[3-(4-Hydroxy-tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzoic acid methyl ester
[Note: Dry all glassware in an oven at 120° C. and assemble warm prior to reaction.] Equip a 5-L 3-neck roundbottom flask with an overhead stirrer, temperature probe, N 2 line, and septa and charge with 4-(3-iodo-indole-1-sulfonyl)-benzoic acid methyl ester (159.0 g, 0.360 mol). Introduce THF (1 L) via cannula and stir the solution and cool to −75° C. under N 2 . Dry a dropping funnel as above and assemble on the flask and add 2 M cyclopentylmagnesium bromide in diethyl ether (200 mL, 0.400 mol) to the dropping funnel via cannula Add dropwise the solution over 0.5 h and stir the resulting mixture for 0.5 h. Warm the mixture to 0° C., stir an additional 0.5 h, cool back down to −10° C., and treat with a solution of tetrahydro-4H-pyran-4-one (43.0 g, 0.429 mol) in THF (100 mL) add via cannula to a new previously dried dropping funnel. Add the ketone over 0.5 h as to maintain the internal temperature below −10° C. Warm the solution to room temperature and stir for 1.5 h in the process. Quench the mixture under N 2 by the addition of aqueous saturated ammonium chloride (1 L), separate layers, and dry the organic layer over sodium sulfate. Concentrate to provide a dark oil and dissolve in MTBE (1 L). Addition of 0.5 L of hexanes provides a solid and allows the solid to stand overnight at room temperature. Filter the solid, back-wash with 2:1 MTBE/hexanes (150 mL) to give a tan solid. Reslurry the solid in ethyl acetate (1 L), stir at room temperature for 2 h, filter, dry (20 mm Hg, 50° C.) and found to be highly title compound (49.2 g, 33%); 1 H NMR(DMSO-d 6 ) δ 8.15 (m, 4H), 7.94 (d, J=8.2 Hz, 1H), 7.88 (d, J=7.7 Hz, 1H), 7.60 (s, 1H), 7.36 (t, J=7.7 Hz, 1H), 7.27 (t, J=7.7 Hz, 1H), 5.27 (s, 1H), 3.85 (s, 3H), 3.81 (m, 2H), 3.69 (m, 2H), 2.06 (m, 2H), 1.78 (m, 2H); MS(ESI) m/z 398 (m+H, m−H 2 O). [Note: Concentrate the filtrate from the ethyl acetate reslurry and filter the resulting solid from methylene chloride/hexanes/ethyl ether to provide a second crop of alcohol of good quality, 32 g. Thus, the overall yield is 81.2 g, 54%. Concentrate the initial filtrate from the MTBE/hexanes crystallization to an oil and addition of methylene chloride/hexanes/ethyl ether to provide a solid consisting majorly of the corresponding 3-protioindole analog, 28 g.
Preparation 42
4-[3-(Tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzoic acid methyl ester
Add to a solution of 4-[3-(4-hydroxy-tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzoic acid methyl ester (20.0 g, 48.19 mmol) in anhydrous methylene chloride (500 mL) at room temperature, triethylsilane (20.0 mL, 125.19 mmol) and trifluoroacetic acid (61.5 mL, 798.2 mmol). Stir the resulting solution for 1 h, concentrate, and obtain the oil and partition between ethyl acetate (500 mL) and saturated sodium bicarbonate (500 mL). Dry the organic layer over sodium sulfate, filter through a silica gel pad, and back-wash with ethyl acetate (400 mL). Concentrate the filtrate to low volume, add hexanes, and a separate the solid. Filter the solid and hold aside, 14 g. Concentrate the filtrate to low volume and add MTBE to provide a second crop of crystals, filter and found identical by TLC (3:2 hexanes/ethyl acetate) to the original lot, 2.8 g. Combine the two lots and dry (20 mmg Hg, 40° C.) to provide one lot of highly pure title compound for subsequent hydrolysis (16.8 g, 87%); 1 H NMR (DMSO-d 6 ) δ 8.10 (m, 4H), 7.93 (d, J=8.2 Hz, 1H), 7.68 (d, J=7.7 Hz, 1H), 7.57 (s, 1H), 7.37 (t, J=7.7 Hz, 1H), 7.28 (t, J=7.1 Hz, 1H), 3.94 (m, 2H), 3.85 (s, 3H), 3.50 (t, J=11.5 Hz, 2H), 3.03 (m, 1H), 1.86 (m, 2H), 1.70 (m, 2H); MS(ESI) m/z 400 (m+H).
Preparation 43
4-[3-(Tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzoic acid
Add to a suspension of 4-[3-(tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzoic acid methyl ester (16.7 g, 41.83 mmol) in methanol (200 mL) with stirring THF (600 mL). Treat the solution with 5N NaOH (23.5 ml, 2.8 eq.) and stir for 2 h at room temperature. Concentrate the solution to near dryness and treat with 1N HCl (125 mL), a solid separates. Dilute to 500 mL total volume with water, filter, back-wash with water, and dry (20 mm Hg, 60° C.) to give a resulting solid found to be pure title compound (15.8 g, 98%); 1 H NMR(DMSO-d 6 ) 13.57 (s, 1H), 8.08 (m, 4H), 7.93 (d, J=8.2 Hz, 1H), 7.68 (d, J=8.2 Hz, 1H), 7.57 (s, 1H), 7.37 (t, J=8.2 Hz, 1H), 7.27 (t, J=7.1 Hz, 1H), 3.95 (m, 2H), 3.47 (t, J=12.0 Hz, 2H), 3.03 (m, 1H), 1.85 (m, 2H), 1.70 (m, 2H); MS(ESI) m/z 384 (m−H).
Preparation 44
4-(3-Cyclopent-1-enyl-indole-1-sulfonyl)-benzoic acid methyl ester
Add to a 2-L 3-neck round bottom flask equipped with overhead stirrer, N 2 line, and temperature probe 4-(3-Iodo-indole-1-sulfonyl)-benzoic acid methyl ester (69.0 g, 0.156 mol) and anhydrous DMF (700 mL). Add to the stirring solution at room temperature cyclopentene (138.0 mL, 1.57 mol), palladium II acetate (1.8 g, 8.0 mmol), tetrabutylammonium chloride (43.5 g, 0.156 mol), and potassium acetate (46.0 g, 0.469 mol). Warm the resulting dark mixture at 60-65° C. for 16 h. Cool the reaction mixture filter through celite, and back-wash with ethyl acetate (1 L). Partition the solution with 2×1 L of brine, dry the organic layer over sodium sulfate, and chromatograph over flash silica gel (10% ethyl acetate in hexanes gradually increasing to 20% ethyl acetate in hexanes) to provide pure title compound (48.3 g, 81%); MS(ESI) m/z 382 (m+H); 1 H NMR (DMSO-d 6 ) reveals the material to actually be a mixture of olefinic 3-substituted cyclopentene indoles (approx. 1:1, with olefinic H's at 5.8, 5.9, and 6.0 ppm integrating to 1H each), suitable as such for subsequent hydrogenation.
Preparation 45
4-(3-Cyclopentyl-indole-1-sulfonyl)-benzoic acid methyl ester
Dissolve 4-(3-cyclopent-1-enyl-indole-1-sulfonyl)-benzoic acid methyl ester (2.2 g, 5.77 mmol) in ethanol (25 mL) and ethyl acetate (25 mL) and hydrogenate with 10% palladium on carbon (300 mg) at 33 psi for 16 h. Filter the catalyst over celite and back-wash with 1:1 ethanol/ethyl acetate (50 mL). Concentrate to give a dark solid and dissolve in 1:1 ethyl acetate/hexanes (50 mL) and pass through a silica gel plug. Back-wash the plug with 1:1 ethyl acetate/hexanes (100 mL) and concentrate the filtrate to an oil, which solidifies upon standing and found to be pure title compound (2.0 g, 90%); 1 H NMR DMSO-d 6 ) δ8.10 (m, 4H), 7.93 (d, J=8.2 Hz, 1H), 7.55 (d, J=7.7 Hz, 1H), 7.53 (s, 1H), 7.36 (t, J=7.1 Hz, 1H), 7.28 (t, J=7.7 Hz, 1H), 3.84 (s, 3H), 3.16 (m, 1H), 2.08 (m, 2H), 1.62 (m, 6H); MS(ESI) m/z 384 (m+H).
Preparation 46
C-(5-Fluoro-pyridin-3-yl)-methylamine
Add to a Parr Bottle 2,6 dichloro-3-cyano-5-fluoropyridine (5 g, 26.18 mmol), ethanol (50 ml), concentrated hydrochloric acid (4.3 ml) and 10% Pd—C (0.5 g). Place on a Parr Shaker Apparatus under 36 psig hydrogen for 6 hours at ambient temperature. Add potassium acetate (10.28 g, 104.72 mmol) and continue under 48 psig hydrogen overnight at ambient temperature. Filter the reaction over Celite and concentrate the filtrate under vacuum to a residue. Add to the residue THF (100 ml). Filter the solid, and concentrate the filtrate under vacuum to give (5-Fluoro-pyridin-3-yl)-methylamine as a clear oil (6 g). 1 H NMR (DMSO): 8.6 (d, 2H), 8.0 (d, 1H), 4.2 (s, 2H). MS (ES+)=127.5.
Preparation 47
C-(2-Fluoro-pyridin-3-yl)-methylamine hydrochloride
Add concentrated HCl (0.46 mL) to a suspension 2-fluoro-nicotinonitrile (0.34 g, 2.8 mmol) and 5% Pd/C (0.5 g) in methanol (10 mL) at RT. Stir suspension under an atmosphere of hydrogen at 1 atm. For 6 hours. Filter reaction mixture and concentrate the filtrate. Add ether to the residue, bubble HCl gas through the suspension, filter precipitate, and dry to give the title compound (0.37 g, 82%). MS (ES) 127.1 (M+1) + . 1 H NMR (400 MHz, DMSO) δ: 8.65 (brs, 3H), 8.24 (m, 1H), 8.16 (m, 1H), 7.41 (m, 1H), 4.06 (m, 2H).
Preparation 48
C-(2-Fluoro-pyridin-4-yl)-methylamine hydrochloride
Following a method similar to C-(2-Fluoro-pyridin-3-yl)-methylamine hydrochloride, using 2-fluoro-isonicotinonitrile (0.65 g, 5.3 mmol), concentrated HCl (1.2 mL), and 5% Pd/C (1.2 g) to give the title compound (0.43 g, 50%). MS (ES) 127.1 (M+1) + .
Preparation 49
C-(4-Trifluoromethyl-pyridin-3-yl)-methylamine
Add Raney nickel (0.5 g) to a solution of 4-trifluoromethyl-nicotinonitrile (1.0 g, 5.8 mmol) in ethanol saturated with ammonia (20.0 mL) and shake under hydrogen at 500 psi for 1 hour. Filter reaction, concentrate the filtrate, and dry the solid obtained to give the title compound (1.0 g, 98%). MS (ES) 177.0 (M+1) + .
Preparation 50
2-Fluoro-isonicotinonitrile
Treat a solution of 2-chloro-4-cyanopyridine (6.0 g, 43.5 mmol) and potassium fluoride (7.56 g, 130.3 mmol) in 1-methyl-2-pyrrolidinone (20 mL) with tetrabutylphosphonium bromide (14.8 g, 43.7 mmol) and heat to 100° C. for 18 hours. Dilute with water and extract with EtOAc. Wash EtOAc with water, brine, dry with Na 2 SO 4 , and concentrate to give the title compound (2.3 g, 43%). MS (ES) 123.1 (M+1) + . 1 H NMR (400 MHz, CHCl 3 ) δ 8.43 (d, 1H, J=5.2 Hz), 7.45 (m, 1H), 7.22 (m, 1H).
Preparation 51
2-Fluoro-nicotinonitrile
Add resin bound triphenylphosphine (4.0 g, 12.0 mmol) to a solution of 2-fluoro-nicotinamide (0.6 g, 4.3 mmol) in dichloroethane (20.0 mL) and carbon tetrachloride (20.0 mL). Reflux for 18 hours, cool to RT, filter, and concentrate the filtrate under vacuum. Purify by flash column on silica gel eluting with 10-60% EtOAc in hexanes to give the title compound (0.34 g, 64%). MS (ES) 123.1 (M+1) + . 1 H NMR (400 MHz, CHCl 3 ) δ 8.46 (m, 1H), 8.09 (m, 1H), 7.37 (m, 1H).
Preparation 52
2-Fluoro-nicotinamide
Add thionyl chloride (40 mL) to 2-fluoro-nicotinic acid (2.0 g, 14.3 mmol), reflux for 18 hours, cool to RT, and concentrate under vacuum. Add benzene (100 mL) to the residue and bubble ammonia gas into suspension for 3 hours. Stopper flask, stir for another 18 hours, and concentrate. Add water to residue and extract with EtOAc. Wash EtOAc with water, brine, then dry with Na 2 SO 4 , and concentrate under vacuum to give the title compound (0.6 g, 30%). MS (ES) 141.1 (M+1) + . 1 H NMR (400 MHz, CHCl 3 ) δ 8.32 (d, 1H, J=4.5), 8.17 (m, 1H), 7.92 (brs, 1H), 7.79 (brs, 1H), 7.44(m, 1H).
Preparation 53
C-Pyrazin-2-yl-methylamine
In a Parr bottle, charge pyrazine-2-carbonitrile (1 g) in absolute ethanol (10 ml). Add 10% Pd—C (w/w, 0.4 g) and place on a Parr Hydrogenation Apparatus under 50 psig hydrogen at ambient temperature for sixteen hours. Filter the mixture through a pad of Celite. Purify material on SCX column. Use crude basic material in next step without further purification.
Preparation 54
C-Pyridazin-3-yl-methylamine
Hydrogenate pyridazine-3-carbonitrile using H 2 , NH 3 , MeOH, Raney Nickel at 40° C. and 60 psi. Filter crude material to remove catalyst. Dissolve in MeOH and purify on an SCX column to give basic material. Use material crude in the amide coupling without further purification.
Preparation 55
2-Methoxy-cyclohexylamine
Shake a mixture of o-anisidine (5.0 g, 41 mmol) and rhodium on carbon (5% Rh; 5.0 g) in AcOH (65 mL) under H 2 (60 psig) at 60° C. for 6 h. Filter the reaction mixture and rotary evaporate the filtrate (75° C.). Dissolve this material in CHCl 3 (100 mL) and basify with satd aq NaHCO 3 (50 mL). Dry the organic layer (Na 2 SO 4 ) and rotary evaporate (40° C.) to yield 1.20 g of 2-methoxy-cyclohexylamine as a yellow oil.
Preparation 56
1-(4-Fluoro-phenyl)-piperidin-4-ylamine
Stir 4-Bromo-fluorobenzene (0.300 g, 1.714 mmole), 4-Boc-amino-piperidine (0.411 g, 2.057 mmoles), sodium tert-butoxide (0.230 g, 2.4 mmole), Tris(Dibenzylideneaceton)Dipalladium (0.249 g, 0.257 mmole), 2-(Di-t-butylphosphineol-biphenol (0.1278 g, 0.4285 mmole) in toluene until reaction is complete. Dilute solution with EtOAc and filter. Concentrate the residue and purify via column chromatography with a mixture of EtOAc and hexane. Stir the isolated material in TFA and remove solvent. Dilute the residue with methanol in the presence of hydroxy resin until pH is basic. Decant solvent and concentrate to yield 0.115 g of product (yield=34.5%). Mass Spectrum (m/e) 195.03(M + ).
Preparation 57
(R)-1-(4-Fluoro-phenyl)-pyrrolidin-3-ylamine
Prepare the title compound by a similar method described for 1-(4-Fluoro-phenyl)-piperidin-4-ylamine above using (R)-2-ditertbutylphosphinobiphenyl (0.108 g, 0.362 mmole) to isolate 0.136 g of solid material (Yield=52%) Mass Spectrum (m/e): 181.0(M − ).
Preparation 58
(S)-1-(4-Fluoro-phenyl)-pyrrolidin-3-ylamine
Prepared the title compound by a similar method described for 1-(4-Fluoro-phenyl)-piperidin-4-ylamine above using (S)-2-ditertbutylphosphinobiphenyl (0.108 g, 0.362 mmole) to isolate 0.090 g of solid material (Yield=34%) Mass Spectrum (m/e): 180.99 (M + ).
Preparation 59
1-(4-Fluoro-phenyl)-azetidin-3-yl-amine
Prepare the title compound by a similar method described for 1-(4-Fluoro-phenyl)-piperidin-4-ylamine above using Azetidin-3-yl-carbamic acid tert-butyl ester (0.270 g, 0.186 mmole) to isolate 0.115 g of solid material (Yield=47%) Mass Spectrum (m/e): 168(M + ).
Preparation 60
C-(1-Phenyl-piperidin-4-yl)-methylamine
Prepare as in methods described in J. of Med. Chem. 1999 vol. 42 (no 17) p3342-3355.
Preparation 61
[1-(4-Fluoro-phenyl)-azetidin-3-ylmethyl]-carbamic acid tert-butyl ester
Prepare the title compound by a similar method described for [3-[(4-Fluoro-phenylamino)-methyl]-azetidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone using azetidin-3-ylmethyl-carbamic acid tert-butyl ester (215 mg, 1.15 mmol) to isolate 137 mg (42.3%) of light-yellow foam. MS (m/e): 225.00 (M+1-C 4 H 8 ).
Preparation 62
3-(tert-Butoxycarbonylamino-methyl)-azetidine-1-carboxylic acid methyl ester
Prepare the title compound by a similar method described for 3-[4-(3-phenyl-indole-1-sulfonyl)-benzoylamino]-azetidine-1-carboxylic acid methyl ester using azetidin-3-ylmethyl-carbamic acid tert-butyl ester (Beta Pharma; 559 mg, 3.00 mmol, 1 equiv) to isolate 686 mg (93.6%) of colorless oil.
Preparation 63
3-Aminomethyl-azetidine-1-carboxylic acid methyl ester
Prepare the title compound by a similar method described for (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone using 3-(tert-butoxycarbonylamino-methyl)-azetidine-1-carboxylic acid methyl ester (675 mg, 2.76 mmol) to isolate 399 mg (100%) of light-yellow oil. MS (m/e): 144.98 (M+1).
Preparation 64
[1-(4-Fluoro-phenyl)-pyrrolidin-3-yl]-carbamic acid tert-butyl ester
Prepare the title compound by a similar method described for N-[1-(4-fluoro-phenyl)-azetidin-3-yl]-4-(3-phenyl-indole-1-sulfonyl)-benzamide using 3-(tert-butoxycarbonylamino)pyrrolidine to isolate 341 mg (60.7%) of light-yellow crystalline solid. MS (m/e): 281.00 (M+1).
Preparation 65
1-(4-Fluoro-phenyl)-pyrrolidin-3-ylamine
Prepare the title compound by a similar method described for (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone using [1-(4-fluoro-phenyl)-pyrrolidin-3-yl]-carbamic acid tert-butyl ester (330 mg, 1.18 mmol) to isolate 204 mg (95.1%) of yellow oil. MS (m/e): 181.04 (M+1).
Preparation 66
5-Cyano-nicotinic acid methyl ester
Reflux a solution of methyl 5-bromonicotinate (2.16 g, 10.0 mmol, 1 equiv) and copper(I) cyanide (1.79 g, 20.0 mmol, 2.0 equiv) in anhydr DMF (10 mL) for 15 h. After allowing to cool, filter the reaction mixture through Celite®, rinse with EtOAc (100 mL). A black precipitate forms in the filtrate. Wash the filtrate with salted H 2 O (3×100 mL). Dry the organic layer (anhydr Na 2 SO 4 ) and rotary evaporate (40° C.) giving 546 mg (33.7%) of product as a light-yellow solid. Transfer this material to a column of silica gel (80 mm×20 mm dia.) and elute (20-35% EtOAc/hex) to yield 501 mg (30.9%) of 5-cyano-nicotinic acid methyl ester as an off-white solid. MS (m/e): 163.07 (M+1).
Preparation 67
5-Hydroxymethyl-nicotinonitrile
Add lithium aluminum hydride (1.0M in THF; 1.5 mL, 1.5 mmol, 0.5 equiv) over a period of 3 min to a solution of 5-cyano-nicotinic acid methyl ester (479 mg, 2.95 mmol, 1 equiv) in anhydr THF (15 mL) and cool to −78° C. After 1 h while still at −78° C., quench the reaction with H 2 O (60 μL), 5M aq NaOH (60 L), and more H 2 O (180 μL). Filter the reaction mixture through paper. Rotary evaporate the filtrate (40° C.) to give 369 mg of material as a yellow solid. Transfer this material to a column of silica gel (130 mm×25 mmdia.) and elute (2% MeOH/CH 2 Cl 2 ) to yield 180 mg of a mixture of ester, hemiacetal, and aldehyde as a yellow solid and 45 mg (11%) of 5-hydroxymethyl-nicotinonitrile as a yellow solid. MS (m/e): 163.07 (M+1).
Preparation 68
5-Chloromethyl-nicotinonitrile
Add thionyl chloride (1 mL) to a solution of 5-hydroxymethyl-nicotinonitrile (45 mg, 0.34 mmol, 1 equiv) in anhydr CH 2 Cl 2 (1 mL). After 20 min, basify the reaction with satd aq NaHCO 3 (12 mL). Extract this mixture with Et 2 O (2×5 mL). Dry the combined organic layers (anhydr MgSO 4 ) and rotary evaporate (40° C.) to yield 4.9 mg (9.6%) of 5-chloromethyl-nicotinonitrile as a yellow film. MS (m/z): 152.
Preparation 69
5-Aminomethyl-nicotinonitrile
Dissolve 5-chloromethyl-nicotinonitrile (4.9 mg, 0.032 mmol) in 2.0M N 3 in MeOH (1 mL). Transfer this solution to a pressure tube. Heat the reaction solution at 80° C. for 2 h. Rotary evaporate the reaction solution (40° C.) to yield 5.1 mg of crude 5-aminomethyl-nicotinonitrile as a yellow oil. MS (m/e): 134.00 (M+1).
Preparation 70
Methanesulfonic acid tetrahydro-furan-3-ylmethyl ester
Add triethylamine (6.0 mL, 4.4 g, 43 mmol, 2.1 equiv) to a solution of tetrahydro-3-furanmethanol (2.0 mL, 2.1 g, 21 mmol, 1 equiv) and methanesulfonic anhydride (3.7 g, 21 mmol, 1.0 equiv) in anhydr CH 2 Cl 2 (100 mL). After stirring 20 h, wash the reaction solution with 1 M aq HCl (100 mL). Dry the organic layer (anhydr MgSO 4 ) and rotary evaporate (40° C.) to yield 2.77 g (74.0%) of methanesulfonic acid tetrahydro-furan-3-ylmethyl ester as a light-yellow liquid.
Preparation 71
3-Azidomethyl-tetrahydro-furan
Add sodium azide (1.5 g, 23 mmol, 1.5 equiv) to a solution of methanesulfonic acid tetrahydro-furan-3-ylmethyl ester (2.76 g, 15.3 mmol, 1 equiv) in anhydr DMF (10 mL). Heat the reaction mixture at 50° C. for 16 h. Dilute the reaction mixture with H 2 O (100 mL) and extract with Et 2 O (2×50 mL). Wash the combined organic layers with H 2 O (2×50 mL), dry (anhydr Na 2 SO 4 ), and rotary evaporate (40° C.) to yield 1.20 g (61.6%) of 3-azidomethyl-tetrahydro-furan as a nearly-colorless liquid.
Preparation 72
(Tetrahydro-furan-3-yl)-methylamine
Stir a mixture of 3-azidomethyl-tetrahydro-furan (1.19 g, 9.36 mmol, 1 equiv) and palladium on carbon (10% Pd; 120 mg) in EtOH (20 mL) under H 2 (1 atm) for 18 h. Filter the reaction mixture through Celite® and rotary evaporate the filtrate (40° C.) to yield 777 mg (82.1%) of crude (tetrahydro-furan-3-yl)-methylamine as a nearly-colorless liquid.
Preparation 73
4-Aminomethyl-benzonitrile
Stir 4-bromomethyl-benzonitrile (2.0 g, 0.010 mmoles) in sealed vessel in a solution of 2N ammonia in methanol at 80° C. until completion. Reduce solvent in volume. Dissolve residue in ethyl acetate and wash with 1N HCl. Basify aqueous layer with 5N NaOH. Extract aqueous layer into dichloromethane. Dry organic layer over MgSO 4 and reduce in volume to isolate 0.223 g. Yield=16.8%. Mass Spectrum (m/e): (M − ).
Preparation 74
C-(Tetrahydro-pyran-2-yl)-methylamine
Heat 2-(bromomethyl)tetrahydropyran (2.0 g, 11.16 mmoles), sodium azide (1.088 g, 65.01 mmoles), and DMF to 50° C. with stirring and until reaction is complete. Dilute the reaction mixture with Et 2 O and wash with water once. Extract water layer with ether. Combine organic portions and dry over MgSO 4 and reduce in volume. Dilute residue ethanol and introduce to 10% Palladium (0.500 g) on carbon in the presence of hydrogen until reaction is complete. Remove palladium on carbon via filtration and concentrated to isolate 0.723 g. Yield=56%.
Preparation 75
3-Amino-pyrrolidine-1-carboxylic acid methyl ester
Add methyl chloroformate (460 μL, 560 mg, 6.0 mmol, 3.0 equiv) to a solution of 3-(tert-butoxycarbonylamino)pyrrolidine (TCI; 373 mg, 2.00 mmol, 1 equiv) and triethylamine (1.1 mL, 800 mg, 7.9 mmol, 3.9 equiv) in anhydr CH 2 Cl 2 (4 mL). Vigorous gas evolution, a slight exotherm, and precipitation can occur. After stirring 30 min, rotary evaporate the reaction mixture (60° C.). Dissolve the resultant material in MeOH to quench any residual chloroformate and rotary evaporate the solution (60° C.). Add trifluoroacetic acid (5 mL) to this material causing gas evolution. Rotary evaporate the reaction solution (40° C.; azeotroping 2× with MeOH). Resulting in a yellow oil then dissolve in MeOH (30 mL) and add hydroxide resin (Bio-Rad AG® 1-X8, 20-50 mesh; 9.3 g) to free-base the amine. Filter the mixture and evaporate the filtrate by rotary (40° C.; azeotroped 2× with CH 2 Cl 2 ) to yield 914 mg (300%) of crude product as a light-brown oil. Mass spec indicates desired product is present. Absorb this oil to an SCX column (20 g) activated with 10% AcOH/MeOH. Push MeOH through the column to elute any non-amine material. Elute the product with 2.0 M N 3 in MeOH to yield 269 mg (93.2%) of 3-amino-pyrrolidine-1-carboxylic acid methyl ester as a yellow oil.
Preparation 77
N-(4-Fluoro-benzyl)-4-(3-iodo-indole-1-sulfonyl)-benzamide
Dissolve indole (2.93 g 0.025 mole) in 10 ml DMF. Cool the solution in an ice-water bath. Add potassium-t-butoxide (3.08 g, 0.0275 mole) and 10 ml DMF. Stir in an ice-bath for 22 minutes. Add iodine (7.61 g, 0.03 mole) and stir in an ice-bath for 32 minutes. Add the second shot of potassium-t-butoxide (3.08 g, 0.0275 mole) and 10 ml DMF. Add the appropriate sulfonyl chloride, 4-(4-fluoro-benzylcarbamoyl)-benzenesulfonyl chloride, (9.01 g, 0.0275 mole) and 10 ml DMF. Stir at ambient temperature for 16 hours. Quench the reaction with 100 ml water, and extract with ethyl acetate (3×150 ml). Wash the organics with sodium metabisulfate (10 g in 100 ml water), water (3×200 ml) and saturated brine (1×200 ml). Concentrate the organics and purify over silica gel using 20% ethyl acetate in heptane to obtain 6.96 g (yield=52.2%) of the desired product as an off-white solid: 1 H NMR (DMSO): 9.2(t, 1H), 8.1(m, 3H), 8.0(m, 3H), 7.4(m, 5H), 7.1(m, 2H), 4.4(d, 4H). MS (ES−)=532.91 (M−1).
Preparation 78
N-(4-Fluoro-benzyl)-4-[3-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-indole-1-sulfonyl]-benzamide
Combine N-(4-fluoro-benzyl)-4-(3-iodo-indole-1-sulfonyl)-benzamide (19 g, 35.65 mmol), bis pinnacolborane (10.86 g, 42.78 mmol), potassium acetate (10.49 g, 106.95 mmol), PdCl 2 (dppf) 2 (2.92 g, 3.57 mmol) in DMF (125 ml). Heat the mixture to 100° C. under nitrogen for 5 hours. Cool the mixture to ambient temperature and quench with ethyl acetate (200 ml) and water (200 ml). Filter the mixture through Celite. Separate the layers and wash the organics with water (3×200 ml) and a saturated brine solution (200 ml). Dry the organics over magnesium sulfate, filter and concentrate to an oil which was crystallized with ether (200 ml). Filter the white solid and dry in a vacuum oven at 50° C. overnight to provide (5.6 g) as a white solid. Mp 158-160° C.; 1 H NMR (DMSO): 9.2(t, 1H), 8.1(m, 3H), 8.0(m, 3H), 7.4(m, 5H), 7.1(m, 2H), 4.4(d, 4H), 1.3(s, 12H). MS (ES)=533.4 (M−1).
Preparation 79
4-(3-Cyclopentyl-indole-1-sulfonyl)-benzoic acid
Add to a stirring solution of 4-(3-Cyclopentyl-indole-1-sulfonyl)-benzoic acid methyl ester (2.0 g, 5.22 mmol) in THF (50 mL) and MeOH (25 mL), 5N NaOH (3 mL, 2.9 eq.). Stir the solution for 2 h at room temperature and the remove solvents to give a paste. Treat the paste with 1N HCl (25 mL) and a solid results. Dilute further with water (50 mL). Filter the solid, back-wash with water, and dry (20 mm Hg, 60° C.) to provide the pure title compound (1.63 g, 84%); 1 H NMR (DMSO-d 6 ) δ 8.06 (m, 4H), 7.93 (d, J=8.2 Hz, 1H), 7.63 (d, J=7.7 Hz, 1H), 7.53 (s, 1H), 7.37 (t, J=7.7 Hz, 1H), 7.28 (t, J=7.7 Hz, 1H), 3.17 (m, 1H), 2.08 (m, 2H), 1.69 (m, 6H); MS(ESI) m/z 368 (m−H).
Preparation 80
4-(3-Chloro-indazole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide
Dissolve 3-chloro-1H-indazole (120 mg, 0.79 mmol) and 4-(4-fluoro-benzylcarbamoyl)-benzenesulfonyl chloride (114 mg, 0.35 mmol) in CH 2 Cl 2 (2.0 mL) and treat with Et 3 N (50 L, 0.36 mmol). Stir the solution for 1 h at RT, then dilute with additional CH 2 Cl 2 (20.0 mL) and wash with satd aq. NaHCO 3 (15 mL). Dry, filter, and concentrate the organic phase and purify the crude material by flash chromatography (100% hexanes to 50% EtOAc/hexanes linear gradient) to give the title compound (129 mg, 83%) as a white foam. MS (ES + ) 443.9 (M+1) + , (ES − ) 442.0 (M−1) − . 1 H NMR (400 MHz, CDCl 3 ): δ 8.17 (d, 1H, J=8.3), 8.03 (d, 2H, J=8.2), 7.83 (d, 2H, J=8.9), 7.64 (m, 2H), 7.41 (t, 1H, J=7.4), 7.27 (m, 2H), 7.01 (t, 2H, J=8.9), 6.31 (br s, 1H), 4.57 (d, 2H, J=5.9).
Preparation 81
2-Phenyl-azetidine
Dissolve 4-phenyl-azetidin-2-one (1.0 g, 4.28 mmol) in anhydrous THF (20 mL) and treat with 1.0 M solution of lithium aluminum hydride (8.57 mL, 2.0 equiv.) at room temperature. Stir for 15 h, cool to 0° C. in an ice bath and quench with 8.5 mL 1.0 M NaOH then 8.5 mL H 2 O. Filter resulting solution through celite with additional EtOAc, dry with MgSO 4 , filter and evaporate to yield a milky white oil that solidifies upon standing. Use 2-Phenyl-azetidine without further purification.
Preparation 82
4-(3-Iodo-indole-1-sulfonyl)-benzoic acid methyl ester
Slurry 250 g of 4-sulfobenzoic acid in 750 ml thionyl chloride. Add 0.5 ml DMF, and heat the mixture to reflux for 6 hours. Add 2 L of toluene and azeotropically remove the thionyl chloride. Cool the mixture to ambient temperature and filter. Concentrate the filtrate under vacuum to give an oil which crystallizes upon standing. To obtain 222 g of 4-Chlorosulfonyl-benzoyl chloride as a low melting solid.
In a 22 L RBF, charge 4-Chlorosulfonyl-benzoyl chloride (990 g, 4.159 mole) in 8.3 L THF and cool to −78° C. In an addition funnel charge triethylamine (588 ml, 4.159 mole), methanol (168 ml, 4.159 mole), DMAP (5 g, 0.041 mole) and 4 L THF; add this solution dropwise to the reaction keeping the exotherm <−70° C. over 5 hours. After the addition is complete, stir the reaction in a cold bath overnight. Filter the reaction and rinse with 3×500 ml THF. Concentrate under vacuum the filtrate to give a yellow solid. Dissolve the solid in 7 L EtOAc and 7 L 1N HCl. Separate the organic layer and wash with 5 L brine. Dry the organics over Na 2 SO 4 , filter and concentrate under vacuum to give a white solid, 4-Chlorosulfonyl-benzoic acid methyl ester. Yield=93.1% (906 g).
In a 22 L RBF, charge indole (181 g, 1.545 mole) and 800 ml DMF. Cool to <10° C. in an ice-water bath. Add the first shot of potassium-t-butoxide (190.4 g, 1.70 mole). Exotherm to 18.5° C. Rinse with 400 ml DMF. Stir 30 minutes while cooling back to <10° C. Dissolve Iodine (470.6 g) in 400 ml DMF and charge to the addition funnel. Add this solution dropwise to the reaction over 30 minutes. Keeping the temperature <10° C. Stir at <10° C. for 2.5 hours. Add the second shot of potassium-t-butoxide (190.4 g, 1.70 mole) and rinse with 400 ml DMF. Stir 30 minutes while cooling to 10° C. and add 4-Chlorosulfonyl-benzoic acid methyl ester all at once. Exotherm to 28° C. Rinse with 400 ml DMF. Cool to <10° C. and then stir to ambient temperature overnight. Add 6 L DI water at ambient temperature. Exotherm to 31° C. and reaction is thick with solids. Add 5 L EtOAc and stir 15 min. Filter the solids (which is the product). Obtain 315.1 g white solid as the first crop. Separate the filtrate from the first crop, and extract the aqueous layer 2×3 L EtOAc. Combine all the organics and wash 2×625 g of sodium hydrogensulfite in 4 L DI water and 2×3 L DI water and 1×3 L Brine. Dry organics over Na 2 SO 4 , filter and rinse with EtOAc. Remove the organics under vacuum to give an orange-yellow solid slurry solid in 4 L ether overnight to give a second crop of product 240 g. Total yield=81.4% (555.1 g). MS (EI) m/z 440.9 (M+H).
Preparation 83
5-Chloro-2-cyanopyridine
Add in a 22-L 3-neck round bottom equipped with overhead stirrer, reflux condenser, and thermometer, N,N′-dimethylacetamide (DMAC, 6 L), 2,5-dichloropyridine (347.0 g, 2.34 mol), zinc cyanide (138.0 g, 1.17 mol), bis(diphenylphosphino)dipalladium II CH 2 Cl 2 complex (DPPF, 20.8 g, 0.02 mol), and zinc dust (1.6 g, 0.02 mol). Slowly warm the reaction mixture to 160° C. As the temperature reaches 160° C., an exotherm (controllable) may result and the internal temperature may rise to 180-185° C. Remove the heat from the dark solution and cool the mixture slowly cool to room temperature. Extract the bulk reaction mixture by taking 2 L of the dark solution, diluting with brine (2 L), filtering over celite, and addition of ethyl acetate (4 L). Repeat the process 3 times to extract all material, and dry the combined organics over magnesium sulfate. Cautious concentration at 25-30° C. might give a dark liquid. (Note: Product volatility maybe observed at higher temperatures so the temperature upon concentration is kept low in all steps.) Stir the liquid and add water (5 L), resulting in a solid After 1 h, filter, and back-wash with water (2 L). Dry the filter cake to give 215 g of crude product Extract the aqueous filtrate with ethyl ether (8 L). Dry the organics over magnesium sulfate and concentrate to provide 51 g of crude product. Combine with the 215 g lot and purify by chromatography over silica gel (biotage 150; eluting with 5% ethyl acetate in hexanes increasing to 10% ethyl acetate in hexanes) to provide a white solid of pure title compound (193 g, 59%); 1 H NMR(CDCl 3 ) δ 8.68 (d, J=2.0 Hz, 1H), 7.84(dd, J=2.7, 8.6 Hz, 1H), 7.66(d, J=8.3 Hz, 1H).
Preparation 84
2-Cyano-5-fluoropyridine
Add in a 5-L 3-neck roundbottom equipped with overhead stirrer, reflux condenser, thermometer, and N 2 line, 5-chloro-2-cyanopyridine (193.0 g, 1.39 mol) and 1-methyl-2-pyrrolidinone (NMP, 2 L). Heat the mixture and stir at 210-220° C. for 4 h. Cool the reaction mixture to room temperature, stir overnight, and filter. Wash the filter cake with ethyl ether (1 L). Extract the filtrate with water (6 L) and ethyl ether (3×5 L). Combine the organics and back-extract with water (8 L) and dry over magnesium sulfate. Concentrate at 25-30° C. to give an oily semi-solid, 193 g. Chromatograph over flash silica gel (5% ethyl acetate in hexanes gradually increasing to 10% ethyl acetate in hexanes) to provide the title compound as a white solid. Dissolve the solid in ethyl ether, filter, and add hexanes. Concentrate to low volume to provide a primary crop of pure title compound, 60 g. Repeat the process of crystallization on the filtrate to provide a second crop of highly pure title compound, 24.0 g. (Concentrate the final filtrate to a white solid of product of good quality, and re-chromatograph, conditions as above, to provide an additional 38.6 g of material.) Obtain a total yield of title compound of 122.4 g, 72%; 1 H NMR(CDCl 3 ) δ 8.59 (d, J=3.0 Hz, f), 7.75 (m, 1H), 7.55 (m, 1H).
Preparation 85
2-Aminomethyl-5-fluoropyridine (dihydrochloride
Combine a mixture of 2-cyano-5-fluoropyridine (63.2 g, 0.52 mol), 22.5 g of Raney nickel, and ethanol (1.5 L) saturated with ammonia and hydrogenate at 500 p.s.i. and 70° C. for 16 h. Chromatograph the dark purple liquid over flash silica gel (methylene chloride/methanol/ammonia hydroxide—95:4.5:0.5) to give, after concentration at 25-30° C., a yellow liquid of the pure desired free base, 25.0 g (44%); 1 H NMR (DMSO-d 6 ) δ 8.43 (d, J=2.9 Hz, 1H), 7.66 (m, 1H), 7.50 (m, 1H), 3.77 (s, 2H), 2.10 (br, 2H); MS(ESI) m/z 127(m+H). Add to a solution of the free base (20.0 g, 159.0 mmol) in 150 ml of 1,4-dioxane, 4N HCl in dioxane (150 mL, 3.8 eq.) and a white solid separates immediately. Dilute the solid with ethyl ether (300 mL) and filter. Dry the product at 20 mm Hg, 60° C., to give the pure dihydrochloride title compound, 30.0 g (95%); 1 H NMR(DMSO-d 6 ) δ 8.61 (d, J=2.9 Hz, 1H), 8.50 (brs, 3H), 7.82 (m, 1H), 7.62 (m, 1H), 7.50 (br, 1H), 4.18 (m, 2H); MS(ESI) m/z 127 (m+H, free base).
Preparation 87
N-Pyridin-2-yl-N′-styryl-hydrazine
React Pyridin-2-yl-hydrazine and Phenyl-acetaldehyde under literature conditions (Azaindoles. I. Preparation of 7-azaindoles by thermal indolization of 2-pyridylhydrazones. Canadian Journal of Chemistry (1966), 44(21), 2455-9) to give N-Pyridin-2-yl-N′-styryl-hydrazine (10 g, 100% yield crude material) Mass Spectrum (m/e): 211.96 (MH+).
Preparation 88
3-Phenyl-1H-pyrrolo[2,3-b]pyridine
React N-pyridin-2-yl-N′-styryl-hydrazine according to published literature conditions (Azaindoles. I. Preparation of 7-azaindoles by thermal indolization of 2-pyridylhydrazones. Canadian Journal of Chemistry (1966), 44(21), 2455-9) to give 3-Phenyl-1H-pyrrolo[2,3-b]pyridine (2.5 g, 45% yield) as a dark solid. Mass Spectrum (m/e): 194.96 (MH+).
Preparation 91
4-[3-(1-Hydroxy-cyclohexyl)-indole-1-sulfonyl]-benzoic acid methyl ester
Via addition funnel slowly add over 0.5 hours the 2M EtOEt solution of cyclopropyl magnesium bromide (2.16 g, 6.23 ml, 12.46 mmol, 1.1 eq) to the −78° C. THF solution (30 ml) of 4-(3-Iodo-indole-1-sulfonyl)-benzoic acid methyl ester (5 g, 11.33 mmol, 1.00 eq). Stir for 2 hours and then warm to 0° C. Stir for 0.5 hours. Recool to −10° C. and then slowly add a THF solution (3 ml) of cyclohexanone (1.298 g, 13.03 mmol, 1.15 eq). Stir for 15 min and warm to room temperature. Stir for 1.5 days. Quench reaction with saturated aqueous ammonium chloride, remove organics on rotovap, and add EtOAc to crude mix. Extract product into organics, separate organics, dry over MgSO 4 , and concentrate on rotovap to give crude product as an oil. Purify by silica gel chromatography to give 4-[3-(1-Hydroxy-cyclohexyl)-indole-1-sulfonyl]-benzoic acid methyl ester (948 mg, 20% yield).
Preparation 92
4-(3-Cyclohex-1-indole-1-sulfonyl)-benzoic acid methyl ester
Under N 2 , add triethylsilane (676 mg, 0.929 ml, 5.82 mmol, 2.6 eq) followed by trifluoroacetic acid (4.08 g, 2.7 ml, 35.79 mmol, 16.0 eq) to a CH 2 CL 2 solution (20 ml) of 4-[3-(1-Hydroxy-cyclohexyl)-indole-1-sulfonyl]-benzoic acid methyl ester (925 mg, 2.24 mmol, 1 eq). Stir for 1.5 hours and then remove volatiles on rotovap. Add EtOAc to crude mix and workup with sat aqueous sodium bicarbonate. Extract product into organics, separate organics, dry over MgSO 4 , and concentrate on rotovap to give crude product as a pink oil. Purify by silica gel chromatography to give 4-(3-Cyclohexyl-indole-1-sulfonyl)-benzoic acid methyl ester (775 mg, 87% yield) as a white solid. Mass Spectrum (m/e): 397.99 (MH+).
Preparation 93
4-(3-Cyclohexyl-indole-1-sulfonyl)-benzoic acid
Add 5N sodium hydroxide (1.17 ml, 3 eq) to a solution of 4-(3-Cyclohexyl-indole-1-sulfonyl)-benzoic acid methyl ester (775 mg, 1.95 mmol, 1 eq) dissolve in a mixture of 10 ml THF and 5 ml MeOH. Stir for 1.5 hours. Remove solvent on rotovap and add 1 N HCl. Dissolve the solid that crashes out of solution in EtOAc. Extract product into organics, separate organics, dry over MgSO 4 , and concentrate on rotovap to give 4-(3-Cyclohexyl-indole-1-sulfonyl)-benzoic acid (646 mg, 86% yield) as a white solid.
Preparation 94
4-[3-(3,3-Difluoro-cyclopentyl)-indole-1-sulfonyl]-benzoic acid methyl ester
Add potassium tertbutoxide (368 mg, 3.28 mmol, 1.1 eq) to a 3 ml dioxane solution of 3-(3,3-difluoro-cyclopentyl)-1H-indole (660 mg, 2.98 mmol, 1.0 eq) under N 2 . Stir solution for 5 minutes. Add 4-Chlorosulfonyl-benzoic acid methyl ester 117 mg, 0.497 mmol, 1.1 eq). Stir reaction for 4 hours at room temperature. Strip reaction of solvent and purify by silica gel chromatography to give 4-[3-(3,3-Difluoro-cyclopentyl)-indole-1-sulfonyl]-benzoic acid methyl ester (466 mg, 37% yield).
Preparation 95
4-[3-(3,3-Difluoro-cyclopentyl)-indole-1-sulfonyl]-benzoic acid
Add aqueous sodium hydroxide (5N, 0.72 ml, 3 eq) to a solution of 4-[3-(3,3-Difluoro-cyclopentyl)-indole-1-sulfonyl]-benzoic acid methyl ester (500 mg, 1.20 mml, 1 eq) in 5 ml THF, 2.5 ml MeOH. Stir reaction at room temperature for 2 hours. Remove solvent on rotovap and add 1N HCl and EtOAc. Extract products into organics, separate organics, and then dry organics with MgSO4. Filter off drying agent, and remove organics on rotovap to give 4-[3-(3,3-Difluoro-cyclopentyl)-indole-1-sulfonyl]-benzoic acid (450 mg, 92% yield) which was used without further purification.
Preparation 96
3-Piperidin-1-yl-1-triisopropylsilanyl-1H-indole
Dissolve piperidine (1.28 mL, 12.9 mmol) in THF (10 mL) and treat with lithium bis(trimethylsilyl)-amide (1.0M in THF, 11.2 mL, 11.2 mmol). To the above solution add 3-bromo-1-triisopropylsilanyl-1H-indole (TCI-US, 3.04 g, 8.62 mmol), (2′-dicyclohexyl-phosphanyl-biphenyl-2-yl)-dimethyl-amine (88 mg, 0.22 mmol), and Pd 2 dba 3 .CHCl 3 (225 mg, 0.22 mmol). Heat the red solution to 70° C. for 4 h then cool to RT and concentrate. Purify the crude material by flash chromatography, using a linear gradient of 100% hexanes to 40% EtOAc/hexanes, to give the title compound (837 mg, 27%). MS (ES + ) 357.2 (M+1) + . 1 H NMR (400 MHz, CDCl 3 ): δ 7.61 (d, 1H, J=8.4), 7.41 (d, 1H, J=8.4), 7.07 (m, 2H), 6.68 (s, 1H), 3.03 (m, 4H), 1.79 (m, 4H), 1.65 (septet, 3H, J=7.7), 1.58 (m, 2H), 1.12 (d, 18H, J=7.1).
Preparation 97
3-Piperidin-1-yl-1H-indole
Add nBu 4 NF (1.0M in THF, 3.2 mL, 3.2 mmol) to a solution of 3-piperidin-1-yl-1-triisopropylsilanyl-1H-indole (835 mg, 2.34 mmol) in THF (10 mL). Stir the red solution at RT for 1 h, then dilute with EtOAc (40 mL) and wash with satd NaHCO 3 (20 mL). Dry, filter, and concentrate the organic solution then purify the crude material by flash chromatography, using a linear gradient of 100% hexanes to 40% EtOAc/hexanes. Obtain the title compound (347 mg, 74%) as a grey solid. MS (ES + ) 201.1 (M+1) + . 1 H NMR (400 MHz, CDCl 3 ): δ 7.65 (d, 1H, J=8.1), 7.59 (br s, 1H), 7.29 (d, 1H, J=8.4), 7.16 (t, 1H, J=7.5), 7.06 (t, 1H, J=7.9), 6.70 (s, 1H), 3.03 (m, 4H), 1.80 (m, 4H), 1.59 (m, 2H).
Preparation 98
4-Fluoro-3-methoxy-benzylamine
Add 4-fluoro-3-methoxy-benzonitrile (2 g, 0.01 mol), 10% palladium on carbon (0.400 g) and glacial acetic acid (120 ml) to a pressure vessel. Purge the reaction vessel with nitrogen, purge the reaction vessel with hydrogen, pressurize the reaction mixture with hydrogen (415 Kpa), seal the vessel, and agitate the reaction. After 8 hours stop the agitation, vent the excess hydrogen from the vessel and purge the vessel with nitrogen. Filter the reaction mixture to remove the 5% palladium on carbon and return the filtrate for product isolation. Concentrate the crude solution, re-dissolve in CH 2 Cl 2 (80 mL) and wash with 5N NaOH (35 mL). Separate the organic and aqueous phases and extract the aqueous with additional CH 2 Cl 2 (20 mL). Combine the organic solutions, dry, filter and concentrate to give the crude material 2.08 g (100%). The title compound as the major product (Rf=0.12, 10% MeOH/CH 2 Cl 2 ) is used without further purification. MS (ES + ) 156.1 (M+1) + . 1 H NMR (400 MHz, CDCl 3 ): δ 7.01(dd, 1H, J=8.2, 11.4), 6.95 (dd, 1H, J=2.1, 8.4), 6.80 (m, 1H), 3.89 (s, 3H), 3.82 (s, 2H), 1.54 (br s, 2H).
Preparation 99
4-(4-Fluoro-3-methoxy-benzylcarbamoyl)-benzenesulfonyl chloride
Dissolve 4-chlorosulfonyl-benzoyl chloride (3.18 g, 13.3 mmol) in THF (25 mL) and cool to −78° C. Slowly add a pre-mixed solution of 4-fluoro-3-methoxybenzyl-amine (1.91 g, 12.3 mmol), Et 3 N (1.64 mL, 11.8 mmol), and DMAP (150 mg, 1.23 mmol) in THF (25 mL) to the above cooled solution over 1 h. Stir the resulting mixture at −78° C. for 1 h, then warm to RT and stir for 4 h. Remove all solids by filtration and wash with THF (5 mL). Concentrate the filtrate and re-dissolve the crude material in EtOAc (30 mL) and wash with 1N HCl (30 mL). Separate the organic and aqueous layers and extract the aqueous phase with additional EtOAc (30 mL). Combine the organic solutions dry, filter, and concentrate. Purify the crude material by flash chromatography, using a linear gradient of 100% hexanes to 40% EtOAc/hexanes) to give the title compound as a white solid (1.36 g, 28%). MS (ES − ) 356.1 (M−1) − . 1 H NMR (400 MHz, CDCl 3 ): δ 8.11 (d, 2H, J=8.3), 8.00 (d, 2H, J=8.8), 7.05 (dd, 1H, J=8.2, 11.1), 6.96 (dd, 1H, J=1.9, 8.0), 6.86 (m, 1H), 6.44 (br s, 1H), 4.61 (d, 2H, J=5.7), 3.88 (s, 3H).
Preparation 100
Cyclopentyl-(2-fluoro-phenyl)-methanone
Stir 2-Fluorobenzonitrile (5.0 g, 41.01 mmole) in 80 ml of THF with a 2 molar cyclopentyl magnesium bromide THF solution (20.51 ml, 41.01 mmole) and CuBr (0.100 g, 0.697 mmole) for 15 hrs at 60° C. under argon gas. Add a 15% solution of sulfuric acid to the reaction at 0° C. and stir for 15 hrs. Extract the reaction mixture three times with diethyl ether. Combine organic layers and dry over MgSO 4 and concentrate Purify residue via column chromatography using mixture of Ethyl Acetate and hexanes; to give 3.085 grams. Yield 40% MS (ES)=192.15 (M+1)+.
Preparation 101
3-Cyclopentyl-1H-indazole
Dissolve Cyclopentyl-(2-fluoro-phenyl)-methanone (2.5 g 13.005 mmoles) in hydrazine (20 ml) heat to 130° C. for 72 hrs. Cool mixture to 0° C. Filter the precipitate and wash with cold water to give the title compound: 2.171 g (yield=89%) MS ES+ 187.12:MSES− 185.22.
Preparation 102
4-(3-Cyclopentyl-indazole-1-sulfonyl)-benzoic acid methyl ester
Combine 3-Cyclopentyl-1H-indazole (2.168 g 11.640 mmole) with triethylamine (3.526 g, 34.92 mmoles) in 50 mls of dichloromethane. Dissolve 4-Chlorosulfonyl-benzoic acid methyl ester (4.085 g, 17.460 mmole) in dichloromethane 50 ml and add drop wise to solution at 0° C. Stir the reaction is for 12 hrs. Dilute the reaction and wash with NaHCO 3 . Dry organic layer over MgSO 4 and concentrate. Purify the residue via column chromatography with a mixture of ethyl acetate and hexanes to isolate 2.046 g (Yield=48.5%) of the title compound: MS ES+385.3.
Preparation 103
4-(3-Cyclopentyl-indazole-1-sulfonyl)-benzoic acid
Combine 4-(3-Cyclopentyl-indazole-1-sulfonyl)-benzoic acid methyl ester (2.045 g, 5.325 mmoles) in 50 ml of THF. Add 3 ml of 5 N NaOH and allow to stir for 15 hrs. Make the reaction acidic with HCl and extract into diethyl ether. Dry organic layer over MgSO 4 and concentrate to isolate 1.243 g (Yield=63%) of the title compound: MS ES+ 369.47; MS ES− 369.46.
Preparation 104
(S)-1-(4-Fluoro-phenyl)-pyrrolidin-3-ylamine
Combine (S)-pyrrolidin-3-yl-carbamic acid tert-butyl ester (1.741 mmole) 1-bromo-4-Fluorobenzene (1.45 mmole), Pd 2 dba (0.217 mmole), NaOtBu (2.03 mmole), 2-di-t-butylphospineolbiphenyl (0.362 mmole) in 30 ml of toluene and stir at 80° C. Dilute solution with ethyl acetate and filter. Concentrate the solution. Purify the residue via column chromatography with a mixture of ethyl acetate and hexanes and add a mixture of methanol and Trifluoro acetic acid and stir for 1 hr at 0° C. Concentrate the reaction and dissolve in methanol in presence of hydroxy resin until pH is 10. Filter the solution and concentrate to isolate 0.136 of title compound yield=52 MS ES−=182.0.
Preparation 105
Azetidin-3-yl-(4-fluoro-phenyl)-amine
Using a procedure similar to 1-(4-Fluoro-phenyl)-pyrrolidin-3-ylamine to give 0.053 g (yield=21%) of the title compound. MS ES not observed.
Preparation 106
C-(Tetrahydro-pyran-2-yl)-methylamine
Combine C-(Tetrahydro-pyran-2-yl)-methylamine with Sodium azide and heat to 50° C. for 15 hrs in 30 ml of DMF. Dilute the reaction with dichloromethane and wash with NaHCO 3 . Treat organic layer with MgSO 4 and concentrate. Dissolve the residue in 30 ml of ethanol with Palladium on carbon in the presence of hydrogen gas until reaction is complete. Filter the reaction mixture. Concentrate solvent to produce 1.32 g of the title compound (yield=54.9%) MS ES+ 115.95.
Preparation 107
4-(3-Cyclopent-1-enyl-indole-1-sulfonyl)-benzoic acid methyl ester
In a 12 L RBF, charge 4-(3-iodo-indole-1-sulfonyl)-benzoic acid methyl ester (620 g, 1.406 mol), cyclopentene (958 g, 14.06 mol), potassium acetate (414 g, 4.218 mol), tetrabutylammonium chloride (391 g, 1.406 mol), palladium acetate (15.8 g, 0.0703 mol) and DMF (6.2 L). Heat the mixture to 60° C. for sixteen hours, cool and filter through Hyflo. Wash the filter cake with ethyl acetate (5 L). Add additional ethyl acetate (4 L) and DI water (12 L). Stir for 30 minutes, separate the layers and wash the organic layer with brine (6 L). Dry the organic layer over sodium sulfate, filter and rinse the cake with ethyl acetate (2 L). Remove the solvents under vacuum to give 609 g of a dark oil. Dissolve the oil in methylene chloride (1 L) and filter through silica gel (6 kg). Wash the silica plug with MTBE (20 L) to eluent the product Concentrate the MTBE layer under vacuum to give 535 g of an oil (yield=99.8%) of the title compound.
Preparation 108
4-(3-Cyclopentyl-indole-1-sulfonyl)-benzoic acid methyl ester
In a 3 gallon autoclave, charge 4-(3-Cyclopent-1-enyl-indole-1-sulfonyl)-benzoic acid methyl ester (475 g), ethyl acetate (2.5 L), absolute ethanol (2.5 L) and 10% Pd—C (45 g, w/w) under 35 psi hydrogen at ambient temperature for 5 hours. Filter the crude reaction over Hyflo. Concentrate the filtrate under vacuum to give a light yellow solid (465 g) of the title compound.
Preparation 109
4-(3-Cyclopentyl-indole-1-sulfonyl)-benzoic acid
In a 12 L RBF, charge 4-(3-cyclopentyl-indole-1-sulfonyl)-benzoic acid methyl ester (465 g 1.213 mol) and THF (4.7 L). Add 5N NaOH (485 ml) dropwise at ambient temperature. Stir the solution at room temperature overnight. Bring the pH of the reaction to 1 with c.HCl. Separate the layers and extract the aqueous layer with ethyl acetate (4 L). Dry the combined organic layers over sodium sulfate, filter and rinse with ethyl acetate. Concentrate the organics under vacuum to give an off-white solid (401 g, yield=89.5%) of the title compound.
Preparation 110
Tetrahydro-pyran-4-carboxylic acid amide
In a 5 L flask, charge methyltetrahydropyran-4-carboxylate (500 ml, 3.75 mol) and concentrated ammonium hydroxide (1.3 L) and stir the reaction at room temperature for 48 hours. Filter the reaction and dry the white solid in a vacuum oven at 60° C. overnight to obtained 36.33 g white solid of the title compound.
Preparation 111
C-(Tetrahydro-pyran-4-yl)-methylamine
In a 2 L flask, charge tetrahydro-pyran-4-carboxylic acid amide (51 g, 0.395 mol) and THF (1.3 L) and cool the reaction in an ice-bath. Add LAH (30 g, 0.791) portion-wise. Stir the reaction at 10° C. for 16 hours and quench by the drop-wise addition of DI water (30 ml), 15% NaOH (30 ml), and DI water (90 ml). Stir the reaction at ambient temperature for 16 hours. Filter the salts and concentrate the filtrate under vacuum to give 36.79 g clear oil of the title compound.
Preparation 112
4-{[4-(3-Phenyl-indole-1-sulfonyl)-benzoylamino]-methyl}-benzoic acid
Combine 4-(3-Phenyl-indole-1-sulfonyl)-benzoic acid (1.324 mmole) with N-hydroxy-succinamide (NHS− 1.457 mmoles), and EDC (1.324 mmoles) and stir in 20 ml dichloromethane for 15 hr. Condense the reaction to produce a solid. Isolate 0.613 g (yield=97.6%). React 1.05 mmole of residue with 4-aminomethyl-benzoic acid (1.05 mmole) in 3 ml dichloromethane for 15 hrs. Dilute reaction mixture and wash with 1 N HCl. Treat dichloromethane with MgSO 4 and concentrate. Isolate a mixture of 4-(3-Phenyl-indole-1-sulfonyl)-benzoic acid and the title compound 0.258 g (48%): MS ES+5.10-77 MS ES−509.21.
EXAMPLE 1
N-(4-Fluoro-benzyl)-4-(3-phenyl-pyrrolo[3,2-c]pyridine-1-sulfonyl)-benzamide
Add a 5 ml THF solution of 3-Phenyl-1H-pyrrolo[3,2-c]pyridine (500 mg, 2.57 mmol, 1 eq) to a 4 ml THF solution of KotBu (303 mg, 2.70 mmol, 1.05 eq) under N 2 atmosphere. Stir reaction for 10 minutes and then add a 5 ml THF solution of 4-(4-Fluoro-benzylcarbamoyl)-benzenesulfonyl chloride (844 mg, 2.57 mmol, 1 eq). Stir reaction for 16 hours, remove solvent on rotovap, and purify by silica gel chromatography to give N-(4-Fluoro-benzyl)-4-(3-phenyl-pyrrolo[3,2-c]pyridine-1-sulfonyl)-benzamide (982 mg, 79% yield). Mass Spectrum (m/e): 485.96 (MH+).
EXAMPLE 2
N-(4-Fluoro-benzyl)-4-[3-(3-oxo-cyclopentyl)-indole-1-sulfonyl]-benzamide
Add a 3 ml DMF solution of 3-(1H-Indol-3-yl)-cyclopentanone (500 mg, 2.57 mmol, 1 eq) to a 3 ml DMF solution of NaH (155 mg, 60% by weight, 3.86 mmol, 1.1 eq) under N 2 atmosphere. Stir reaction for 15 minutes and then add a 5 ml DMF solution of 4-(4-Fluoro-benzylcarbamoyl)-benzenesulfonyl chloride (1.27 g, 3.86 mmol, 1.1 eq). Stir reaction for 48 hours, remove solvent on rotovap, and purify by silica gel chromatography to give N-(4-Fluoro-benzyl)-4-[3-(3-oxo-cyclopentyl)-indole-1-sulfonyl]-benzamide (375 mg, 22% yield). Mass Spectrum (m/e): 490.53 (MH+).
EXAMPLE 3
N-(4-Fluoro-benzyl)-4-(3-propyl-indole-1-sulfonyl)-benzamide
Add NaH 60% in mineral oil (0.080 g, 2.0 mmol) to a stirred solution of 3-propyl-indole (0.266 g, 1.67 mmol) in dry THF (25 mL) under N2. Stir the reaction mixture at ambient temperature for 45 min. Add 4-(4-fluoro-benzylcarbamoyl)-benzenesulfonyl chloride (0.547 g, 1.67 mmol) portion wise at ambient temperature. Stir the reaction mixture overnight at ambient temperature. Pour the reaction mixture into a two-phase mixture of EtOAc (150 mL) and saturated solution of NaHCO 3 (50 ml). Separate the organic layer, wash with brine, separate and dry (MgSO 4 ). Filter and evaporate the filtrate. Purify the residue on the chromatron using a 4 mm plate and eluting with a gradient hexane-EtOAC system to give 0.262 g (34%) of N-(4-fluoro-benzyl)-4-([3-propyl-indole-1-sulfonyl]-benzamide. Mass spectrum (m/e) M+1) 451.1.
EXAMPLE 5
N-(4-Fluoro-benzyl)-4-(pyrrolo[2,3-b]pyridine-1-sulfonyl)-benzamide
Add MeCN (2 ml) to a flask under N 2 containing 4-(4-Fluoro-benzylcarbamoyl)-benzenesulfonyl chloride (50 mg, 0.152 mmol), 1H-pyrrolo[2,3-b]pyridine (18 mg, 0.152 mmol), 4-Pyrrolidin-1-yl-pyridine (2 mg, 0.167 mmol), and triethylamine (17 mg, 0.167 mmol). Heat reaction to 80° C. for 16 hours. Cool the solution to room temperature, remove MeCN on rotovap. Purify crude material on silica gel to give 45 mg (73% yield) of N-(4-Fluoro-benzyl)-4-(pyrrolo[2,3-b]pyridine-1-sulfonyl)-benzamide. Mass Spectrum (m/e): 410.1(M+).
Prepare the following sulfonamides in Table 1 using methods similar to the noted reference examples.
TABLE 1
Mass Spec
(M + H)
except
Ex.
where
Reference
No.
Name
Structure
noted
Examples
9
N-(4-Fluoro-benzyl)-4-(indole-1-sulfonyl)-benzamide
409.0
2
10
N-(4-Fluoro-benzyl)-4-[3-spiro N-methylpiperidin-4-yl)(indole-1-sulfonyl]-benzamide
494.0
2
14
N-(4-Fluoro-benzyl)-4-[3-(2-methoxy-cyclohexyl)-indole-1-sulfonyl]-benzamide
521.05
2
22
N-(4-Fluoro-benzyl)-4-[3-(1-methyl-piperidin-4-yl)-indazole-1-sulfonyl]-benzamide
507.02
1
23
N-(4-Fluoro-benzy1)-4-(3-phenyl-indazole-1-sulfonyl)-benzamide
485.96
1
25
4-(2,3-Dihydro-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide
411.1
5
26
N-(4-Fluoro-benzyl)-4-(3-methyl-indole-1-sulfonyl)-benzamide
423.12
3
30
4-(3-Acetyl-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide
451.1
3
33
N-(4-Fluoro-benzyl)-4-(3-trifluoromethyl-indazole-1-sulfonyl)-benzamide
476.07(M − H)
1
34
4-[3-(1-Acetyl-piperidin-4-yl)-indole-1-sulfonyl]-N-4-fluoro-benzyl)-benzamide
534.03
2
35
N-(4-Fluoro-benzyl)-4-[3-(4-methyl-piperazine-1-carbonyl)-indole-1-sulfonyl]-benzamide
534.94
2
36
N-(4-Fluoro-benzyl)-4-[3-(1-methyl-piperidin-2-yl)-indole-1-sulfonyl]-benzamide
505.97
2
37
N-(4-Fluoro-benzyl)-4-[3-2-morpholin-4-yl-acetyl)-indole-1-sulfonyl]benzamide
535.94
2
38
N-(4-Fluoro-benzyl)-4-[3-(2-tetrahydropyran-1-acetyl)-indole-1-sulfonyl]-benzamide
506.9
2
39
N-(4-Fluoro-benzyl)-4-[3-(1-methyl-piperidin-4-yl)-indole-1-sulfonyl]-benzamide
505.98
2
40
N-(4-Fluoro-benzyl)-4-[3-(3,3-difluorocyclopentyl)-indole-1-sulfonyl]-benzamide
512.93
2
41
4-(3-Ethyl-3-methyl-2,3-dihydro-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide
453.2
2dioxane assolventAmine ref:Takayama et al.TetrahedronLett.; 1973,365, 366
42
N-(4-Fluoro-benzyl)-4-(spiro[cyclopentane-1,3′-indoline])-benzamide
464.9
2dioxane assolventJoiner, K. A.;King, F. DEuropeanPatent0287, 196,1988.
43
N-(4-Fluoro-benzyl)-4-(spiro[indoline-3,4′-tetrahydro-pyran])-benzamide
481.4
2dioxane assolvent
44
N-(4-Fluoro-benzyl)-4-(spiro[cyclopropane-1,3′-indoline])-benzamide
436.9
2dioxane assolventJoiner, K. A.;King, F. DEuropeanPatent0287, 196,1988.
45
N-(4-Fluoro-benzyl)-4-(spiro[cyclohexane-1,3′-indoline])-benzamide
478.9
2dioxane assolventJoiner, K. A.;King, F. DEuropeanPatent0287, 196,1988.
46
N-(4-Fluoro-benzyl)-4-(spiro[cyclobutane-1,3′-indoline])-benzamide
450.9
2dioxane assolvent
47
N-(4-Fluoro-benzyl)-4-(3-morpholin-4-yl-indole-1-sulfonyl)-benzamide
494
2dioxane assolvent
48
N-(4-Fluoro-benzyl)-4-[3-(4-methyl-piperazin-1-yl)-indole-1-sulfonyl]-benzamide
507
2dioxane assolvent
49
N-(4-Fluoro-benzyl)-4′-(3-piperidin-1-yl-indole-1-sulfonyl)-benzamide
492
2dioxane assolvent
50
4-(3-tert-Butyl-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide
464.97
1
51
N-(4-Fluoro-benzyl)-4-[3-(1-methyl-cyclopentyl)-indole-1-sulfonyl]-benzamide
490.93
1
EXAMPLE 53
N-(4-Fluoro-benzyl)-4-(3-piperidin-1-yl-indazole-1-sulfonyl)-benzamide
Dissolve 4-(3-chloro-indazole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide (91 mg, 0.20 mmol) in piperidine (1.0 mL) and stir at 90° C. overnight. Dilute the solution with EtOAc (30 mL) and wash with 1N HCl (15 mL) and satd NaHCO 3 (15 mL). Dry, filter and concentrate the organic solution and purify the residue by flash chromatography, using a linear gradient of 100% hexanes to 50% EtOAc/hexanes, to give the title compound as a light yellow foam (7 mg, 7%). MS (ES) 493.0 (M+1)+, 491.2 (M−1)−.
EXAMPLE 54
N-(4-Fluoro-benzyl)-4-(3-morpholin-4-yl-indazole-1-sulfonyl)-benzamide
Dissolve 4-(3-chloro-indazole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide (91 mg, 0.20 mmol) in morpholine (1.0 mL) and stir at 100° C. overnight. Dilute the solution with EtOAc (30 mL) and wash with 1N HCl (11 mL), water (10 mL), and satd NaHCO 3 (10 mL). Dry, filter and concentrate the organic solution and purify the residue by flash chromatography, using a linear gradient of 20% to 80% EtOAc/hexanes, to give the title compound as a white foam (17 mg, 34%). MS (ES) 495.0 (M+1)+, 493.1 (M−1)−.
EXAMPLE 55
N-(4-Fluoro-benzyl)-4-[3-(3-hydroxy-cyclopentyl)-indole-1-sulfonyl]-benzamide
Add sodium borohydride (23 mg, 0.601 mmol) to a 0° C. solution of N-(4-fluoro-benzyl)-4-[3-(3-oxo-cyclopentyl)-indole-1-sulfonyl]-benzamide (295 mg, 0.601 mmol) in MeOH (7 ml) under N 2 . Stir for 30 min and them warm to room temperature. Stir for 18 hours. Add a small amount of water to quench reaction and then remove MeOH on rotovap. Add EtOAc and water and extract the product into organics. Separate, and dry organics over MgSO 4 . Condense organics on rotovap and then purify by silica gel chromatography to give N-(4-fluoro-benzyl)-4-[3-(3-hydroxy-cyclopentyl)-indole-1-sulfonyl]-benzamide (205 mg, 69% yield) as a light orange solid. Mass Spectrum (m/e): 493.01 (MH+).
EXAMPLE 56
4-[3-(2,3-Dihydro-furan-3-yl)-indole-1-sulfonyl]-N-(4-fluoro-benzyl)-benzamide
Add 3,4dihydrofuran (0.70 g, 0.76 mL, 0.01 mol) to N-(fluoro-benzyl)-4-(3-iodo-indole-1-sulfonyl)-benzamide (0.534 g, 0.001 mol) followed sequentially by Pd(Oac) 2 (0.024 g, 0.075 mmol), tetra butyl ammonium chloride (0.283 g, 0013 mol), and DMF (16.0 mL). Add sodium acetate (0.246 g, 003 mol) and stir and heat the resulting mixture at 50° C. for 8 h. Pour the reaction mixture into a DMF-H 2 O mixture Separate the EtOAc layer and extract it several times with H 2 O. Wash with brine, dry, filter and chromatograph on the chromatron eluting with EtOAc-hexane (3:7) to give 0.040 g of the title compound as a viscous gum. Mass spectrum (m/e) (M+1) 477; (M−1) 475.
EXAMPLE 57
N-(4-Fluoro-benzyl)-4-[(3-tetrahydro-furan-3-yl)-indole-1-sulfonyl]-benzamide
Add 4-[3-(2,3-dihydro-furan-3-yl)-indole-1-sulfonyl]-N-(4-fluoro-benzyl)-benzamide (0.095 g, 0.10 mmol) to absolute EtOH (25 mL) and 5% P/C 0.0029 g and hydrogenate in a PARR shaker overnight at 60 lbs per square inch. Filter the catalyst and evaporate the solvent giving 0.071 g of oil. Chromatograph on the ISCO using a gradient EtOAc-hexane system (0-100%) to give a viscous oil which solidifies to a glass 0.050 g. Mass spectrum (m/e) (M+1) 479.1441; Found (M+1) 479.1457.
EXAMPLE 60
N-(4-Fluoro-benzyl)-4-(3-phenyl-2,3-dihydro-indole-1-sulfonyl)-benzamide
Add 3-phenyl-2,3-dihydro-1H-indole (Yamamoto, Y et al. Bull Chem. Soc. Jpn 44, 1971, 541-545) (0.158, 0.81 mmol), 4-(4-fluoro-benzylcarbamoyl)-benzenesulfonyl chloride (0.266 g, 0.81 mmol), Et 3 N (0.161 g, 0.23 mL, 1.5 mmol) and DMAP (0.011 g, 0.09 mmol) to CH 2 Cl 2 (25 mL) and stir at ambient temperature under N 2 overnight. Dilute the reaction to 150 mL with CH 2 Cl 2 and pour into saturated NaHCO 3 (50 mL). Separate the organic layer and extract with 1M HCl (2×75 mL). Wash with brine, separate dry (MgSO 4 ) filter and evaporate the filtrate. Chromatograph the residue on the ISCO using a gradient EtOAc-hexane system (0-100%) to give 0.167 g of the title compound. Mass spectrum (m/e) (M+1) 487.1492; Found: 487.1479.
EXAMPLE 60a
Isomer 1
Separate on a chiracel column OD (0.46×255 cm) at a flow rate of 1.0 mL./min, 255 nM eluting with ⅔EtOH/heptane and 20 μL injection to give 0.060 g of the desired enantiomer.
RT=5.45 min.
EXAMPLE 60b
Isomer 2
Separate on a Chiracel column OD (0.46×255 cm) at a flow rate of 1.0 mL./min, 255 nM, eluting with ⅔EtOH/heptane and 20 μL injection to give 0.061 g of the desired enantiomer. RT=7.20 min.
EXAMPLE 61
N-(4-Fluoro-benzyl)-4-[3-(tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzamide
Add to a 1 L 3-neck roundbottom flask previously dried overnight at 120° C. is assembled warm with an overhead stirrer, N 2 line, temperature probe, and dropping funnel 4-(3-tetrahydro-pyran-4yl)-indole-1-sulfonyl)-benzoic acid (15.0 g, 38.94 mmol) and anhydrous THF (200 mL), stir the solution and cool to 0° C. under N 2 . Add N-methylmorpholine (4.3 mL, 39.09 mmol) at once via syringe, following by 2-chloro-4,6-dimethoxy-1,3,5-triazine (CDMT, 6.8 g, 38.80 mmol) in portions as a solid. Stir the mixture for 1 h at 0° C. and treat with a solution of 4-fluorobenzylamine (4.9 mL, 42.89 mmol) in anhydrous THF (50 mL) via dropping funnel over 10 min. Warm the resulting mixture to room temperature, stir for 3 h, cool back down to 0° C., and quench with 1N HCl (150 mL). Add ethyl acetate (150 mL) and separate the layers (add a small amount of brine to more efficiently separate the layers). Wash the organic layer with brine (150 mL), dry over sodium sulfate, and concentrate to an oil. Dissolve the oil in methylene chloride and add to a flash 65M biotage cartridge. Elute with 3:1 hexanes/ethyl acetate followed by 3:2 hexanes/ethyl acetate to provide isolation of the major product as a foam. Treat the foam with MTBE and re-concentrate to a paste. After standing awhile at room temperature, crystallization of the material occurs. Recrystallize from ethyl acetate/hexanes to provide a solid. Reslurry in MTBE (400 mL) and stir at room temperature for 3 h. longer. Filter the solid, back-wash with MTBE, dry (20 mm Hg, 55° C., to give homogeneous title compound (14.5 g, 76%); 1 H NMR (DMSO-d 6 ) δ 9.24 (t, J=6.0 Hz, 1H), 8.10 (m, 2H), 7.98 (m, 3H), 7.67 (d, J=7.7 Hz, 1H), 7.58 (s, 1H), 7.32 (m, 5H), 7.12 (t, J=8.8 Hz, 1H), 4.42 (d, J=5.5 Hz, 2H), 3.96 (m, 2H), 3.50 (t, J=11.5 Hz, 2H), 3.02 (m, 1H), 1.85 (m, 2H), 1.71 (m, 2H); MS(ESI) m/z 493 (m+H); LC/MS, 100% DAD.
EXAMPLE 63
(3-Aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Add trifluoroacetic acid (5 mL) to [1-[4-(3-phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-ylmethyl]-carbamic acid tert-butyl ester (853 mg, 1.56 mmol) causing much gas evolution. Rotary evaporate the reaction solution (40° C.; azeotroping 2× with MeOH). Dissolve the resultant yellow oil in MeOH (10 mL) and add hydroxide resin (Bio-Rad AG® 1-X8, 20-50 mesh; 5 g) to free-base the amine. Filter the mixture and rotary evaporate the filtrate (40° C.; azeotroped 3× with CH 2 Cl 2 ) to yield 664 mg (95.3%) of (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone as an off-white foam. MS (m/e): 446.02 (M+1).
EXAMPLE 64
N-Azetidin-3-yl-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Prepare the title compound by a similar method described for (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone using 3-[4-(3-phenyl-indole-1-sulfonyl)-benzoylamino]-azetidine-1-carboxylic acid tert-butyl ester (792 mg, 1.49 mmol) to give 568 mg (88.4%) of off-white foam. MS (m/e): 431.92 (M+1); 430.03 (M−1).
EXAMPLE 65
(R)-3-Amino-pyrrolidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Prepare the title compound by a similar method described for (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone using [(R)-1-[4-(3-phenyl-indole-1-sulfonyl)-benzoyl]-pyrrolidin-3-yl]-carbamic acid tert-butyl ester (655 mg, 1.20 mmol) to give 474 mg (88.6%) of white foam. MS (m/e): 445.95 (M+1).
EXAMPLE 66
((S)-3-Amino-pyrrolidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Prepare the title compound by a similar method described for (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone using [(S)-1-[4-(3-phenyl-indole-1-sulfonyl)-benzoyl]-pyrrolidin-3-yl]-carbamic acid tert-butyl ester (903 mg, 1.65 mmol) to give 674 mg (91.4%) of white foam. MS (m/e): 445.95 (M+1).
EXAMPLE 67
(3-Amino-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Prepare the title compound by a similar method described for (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone using [1-[4-(3-phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-yl]-carbamic acid tert-butyl ester (325 mg, 0.611 mmol) to give 239 mg (90.6%) of white foam. MS (m/e): 431.97 (M+1).
EXAMPLE 70
4-(3-Phenyl-indole-1-sulfonyl)-N-pyrazin-2-ylmethyl-benzamide
Add 10 ml dry DMF to a flask under N2 containing 4-(3-Phenyl-indole-1-sulfonyl)-benzoic acid (500 mg, 1.33 mmol, 1.0 eq), 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (279 mg, 1.46 mmol, 1.1 eq), Dimethyl-pyridin-4-yl-amine (16 mg, 0.132 mmol, 0.1 eq), and C-Pyrazin-2-yl-methylamine (217 mg, 1.99 mmol, 1.5 eq). Stir for 18 hours at room temperature. Remove solvent on rotovap and purify by silica gel chromatography to give 4-(3-Phenyl-indole-1-sulfonyl)-N-pyrazin-2-ylmethyl-benzamide (127 mg, 20% yield). Mass Spectrum (m/e): 468.95 (MH+).
EXAMPLE 71
N-(4-Cyano-benzyl-4-[(3-tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzamide
Stir 4-(3-tetrahydro-pyran-4-yl)-indole-1-sulfonyl)-benzoic acid (0.200 g, 0.518 mmole) with EDC [1892-57-5] (0.118 g, 0.662 mmoles) 4-aminomethyl-benzonitrile (0.082 g, 0.662 mmoles) in dichloromethane until completion. Dilute reaction and wash with 1 N HCl. Dry organic layer over MgSO 4 and concentrate. Purify the residue via flash column chromatography with a mixture of methanol and dichloromethane or EtOAc and dichloromethane to isolate 0.102 g of solid material (Yield=41%). Mass Spectrum (m/e): 498.04 (M−).
EXAMPLE 72
(2-Phenyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Combine 4-(3-phenyl-indole-1-sulfonyl)-benzoic acid (125 mg, 0.33 mmol) and 2-phenyl-azetidine (100 mg, 0.75 mmol, excess) in dichloromethane (1.0 mL) and triethylamine (0.300 mL, 2.15 mmol, excess) and add benzotriazol-1-yloxytris(dimethylamino)phosphonium hexfluorophosphate (BOP Reagent) (150 mg, 0.33 mmol) at room temperature. Stir for 30 minutes, load entire reaction directly onto pre-packed silica gel column and purify by flash column chromatography (EtOAc/Hexanes) to yield 149 mg of (2-Phenyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone as a glassy solid (92%). LRMS: MH+ 493.08.
Prepare the following sulfonamides in Table 2 using methods similar to the noted reference examples.
TABLE 2
Mass spec
(M + H)
except
Ex.
where
Reference
No.
Name
Structure
Amine
designated
Examples
73
(3-Phenyl-indole-1-sulfonyl)-N-pyrimidin-2-ylmethyl-benzamide
C-Pyrimidin-2-yl-methylamine
468.9
70
74
[4-(3-Phenyl-indole-1-sulfonyl)-phenyl]-(3,4,5,6-tetrahydro-2H-[4,4′]bipyridinyl-1-yl)-methanone
1,2,3,4,5,6-Hexahydro-[4,4′]bipyridinyl
522.1
70
75
4-(3-Phenyl-indole-1-sulfonyl)-N-pyridin-3-ylmethyl-benzamidehydrochloride*
Pyridin-3-yl-methylamine
467.93
72
76
N-(5-Fluoro-pyridin-3-ylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamideHydrochloride*
5-Fluoro-pyridin-3-yl-methylamine
485.82
72
77
N-(5-Fluoro-pyridin-2-ylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamideHydrochloride*
5-Fluoro-pyridin-2-yl-methylamine
485.95
72
78
Trans-N-(2-Hydroxy-cyclohexylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Trans-2-Aminomethyl-cyclohexanol
489.07
72
79
Cis-N-(2-Hydroxy-cyclohexylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Cis-2-Aminomethyl-cyclohexanol
488.98
72
80
(S)-4-(3-Phenyl-indole-1-sulfonyl)-N-(tetrahydro-furan-2-ylmethyl)-benzamide
(S)-(+)-Tetrahydro-furan-2-yl-methylamine
461.00
72
81
(R)-4-(3-Phenyl-indole-1-sulfonyl)-N-(tetrahydro-furan-2-ylmethyl)-benzamide
(R)-(−)-Tetrahydrofuran-2-yl-methylamine
461.01
72
82
4-(3-Phenyl-indole-1-sulfonyl)-N-pyridin-2-ylmethyl-benzamidehydrochloride *
Pyridin-2-yl-methylamine
467.94
72
83
4-(3-Phenyl-indole-1-sulfonyl)-N-pyridin-4-ylmethyl-benzamidehydrochloride *
Pyridin-4-yl-methylamine
467.99
72
84
Trans-N-(2-Hydroxy-cyclohexyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Trans-2-Amino-cyclohexanol
474.98
72
85
Cis-N-(2-Hydroxy-cyclohexyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Cis-2-Amino-cyclohexanol
474.99
72
86
Azetidin-1-yl-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Azetidine
416.94
72
87
(4-Benzyl-piperidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
4-Benzyl-piperidine
536.05
72
88
(4,4-Difluoro-piperidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
4,4-Difluoro-piperidine
480.97
72
89
[4-(3-Phenyl-indole-1-sulfonyl)-phenyl]-piperidin-1-yl-methanone
Piperidine
444.97
72
90
[4-(3-Phenyl-indole-1-sulfonyl)-phenyl]-pyrrolidin-1-yl-methanone
Pyrrolidine
430.96
72
91
4-(3-Phenyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-4-yl)-benzamide
Tetrahydro-pyran-4-ylamine
461.20
72
92
N,N-Dimethyl-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Dimethylamine
405.10
72
93
1-[4-(3-Phenyl-indole-1-sulfonyl)-benzoyl]-piperidin-4-one
Piperidin-4-one
528.90
72
94
(3-Hydroxy-piperidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
3-Hydroxy-piperidine
460.95
72
95
Morpholin-4-yl-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Morpholine
446.96
72
96
(2-Hydroxymethyl-piperidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Piperidin-2-yl-methanol
474.90
72
97
(3-Hydroxymethyl-piperidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Piperidin-3-yl-methanol
475.00
72
98
Trans-N-(4-Hydroxy-cyclohexyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Trans-4-Aminocyclohexanol
474.99
72
100
4-(3-Phenyl-indole-1-sulfonyl)-N-pyridazin-3-ylmethyl-benzamide
C-Pyridazin-3-yl-methylamine
469.01
70
101
N-[1-(4-Fluoro-phenyl)-piperdin-4yl]-4-(3-phenyl-indole-1-sulfonyl)-benzamide
1-(4-Fluoro-phenyl)-piperidin-4-ylamine
552.38(M − )
70
102
4-(3-Phenyl-indole-1-sulfonyl)-N-(1-phenyl-piperidin-4-ylmethyl)-benzamide
C-(1-Phenyl-piperidin-4-yl)-methylamine
550.06
70
103
(R)-N-[1-(4-Fluoro-phenyl)-pyrrolidin-3-yl]-4-(3-phenyl-indole-1-sulfonyl)-benzamide
(R)-1-(4-Fluoro-phenyl)-pyrrolidin-3-ylamine
539.97
70
104
(S)-N-[1-(4-Fluoro-phenyl)-pyrrolidin-3-yl]-4-(3-phenyl-indole-1-sulfonyl)-benzamide
(S)-1-(4-Fluoro-phenyl)-pyrrolidin-3-ylamine
540.00
70
105
N-[1-(4-Fluoro-phenyl)-azetidin-3-yl]-4-(3-phenyl-indole-1-sulfonyl)-benzamide
1-(4-Fluoro-phenyl)-azetidin-3-ylamine
525.96
72
106
4-(3-Phenyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-4-ylmethyl)-benzamide
4-aminomethyltetrahydropyran
475.0
72
107
N-(2-Methoxy-ethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
2-methoxyethylamine
434.96
72
108
N-(2-Isopropoxy-ethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
2-amimoethyl-propylamine
462.99
72
109
N-(2-Ethoxy-ethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
2-ethoxyethyl-amine
434.96
72
110
4-[[4-(3-Phenyl-indole-1-sulfonyl)-benzoylamino]-methyl]-benzoicacid methyl ester
4-aminomethyl-benzoic acidmethyl ester
525.07
72
111
N-(3-Methoxy-benzyl)-4-(3-phenyl-indole-1-sulfonyl)-ethyl-benzamide
3-methoxybenzylamine
496.93
72
112
N-(4-Dimethylamino-benzyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
4-dimethylaminobenzylamine
510.01
72
113
N-(4-amino-benzyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
4-aminobenzylamine
481.94
72
114
(2-Phenylaminomethyl-pyrrolidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
(4-Fluoro-phenyl)-pyrrolidin-3-ylmethyl-amine
536.03
70
115
2-[1-[4-(3-Phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-ylmethyl]-isoindole-1,3-dione
2-Azetidin-3-ylmethyl-isoindole-1,3-dione
576.02
70
116
3-[4-(3-Phenyl-indole-1-sulfonyl)-benzoylamino]-azetidine-1-carboxylic acidtert-butyl ester
3-Amino-azetidine-1-carboxylic acidtert-butyl ester
531.95
70
117
(R)-1-[4-(3-Phenyl-indole-1-sulfonyl)-benzoyl]-pyrrolidin-3-yl]-carbamic acid tert-butyl ester
(R)-Pyrrolidin-3-yl-carbamic acidtert-butyl ester
546.05
70
118
[(S)-1-[4-(3-Phenyl-indole-1-sulfonyl)-benzoyl]-pyrrolidin-3-yl]-carbamic acid tert-butyl ester
(S)-Pyrrolidin-3-yl-carbamic acidtert-butyl ester
546.01
70
119
[1-[4-(3-Phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-ylmethyl]-carbamic acid tert-butyl ester
Azetidin-3-ylmethyl-carbamic acidtert-butyl ester
546.17
70
120
[1-[4-(3-Phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-yl]-carbamic acidtert-butyl ester
Azetidin-3-yl-carbamic acidtert-butyl ester
532.02
70
121
N-Cyclobutyl-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Cyclobutyl amine
430.98
70
122
3-[[4-(3-Phenyl-indole-1-sulfonyl)-benzoylamino]-methyl]-azetidine-1-carboxylic acidmethyl ester
3-Aminomethyl-azetidine-1-carboxylic acidmethyl ester
503.98
70
123
(3-Hydroxymethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Azetidin-3-yl-methanol
447.2
72
124
N-(Tetrahydro-(R)-furan-2-ylmethyl)-4-[3-(tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzamide
(R)(−)(Tetrahydro-furan-2-yl)-methanol
468.9
72
126
N-(2-Methoxy-cyclohexyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
2-Methoxy-cyclohexylamine
489.05
70
127
N-[1-(4-Fluoro-phenyl)-pyrrolidin-3-yl]4-(3-phenyl-indole-1-sulfonyl)-benzamide
1-(4-Fluoro-phenyl)-pyrrolidin-3-ylamine
540.2
70
128
N-[4-(3-Phenyl-indole-1-sulfonyl)-benzoylamino]-pyrrolidine-1-carboxylic acidmethyl ester
3-Amino-pyrrolidine -1-carboxylic acidmethyl ester
504.02
70
129
[4-(3-Fluoro-phenyl)-piperidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
4-(3-Fluoro-phenyl)piperidine
539.09
70
130
4-[3-(2-Fluoro-pyridin-3-yl)-indole-1-sulfonyl]-N-(tetrahydro-pyran-4-ylmethyl)-benzamide
4-aminomethyltetrahydropyran
494.01
70
131
N-Cyclobutyl-4-[3-(2-fluoro-pyridin-3-yl)-indole-1-sulfonyl]-benzamide
Cyclobutyl amine
449.99
70
132
N-Cyclopropyl-methyl4-[3-(2-fluoro-pyridin-3-yl)-indole-1-sulfonyl]-benzamide
Cyclopropylmethyl amine
449.94
70
133
4-[3-(6-Fluoro-pyridin-3-yl)-indole-1-sulfonyl]-N-(tetrahydro-pyran-4-ylmethyl)-benzamide
4-aminomethyltetrahydropyran
493.90
70
134
N-Cyclopropylmethyl-4-[3-(6-fluoro-pyridin-3-yl)-indole-1-sulfonyl]-benzamide
Cyclopropylmethyl amine
449.94
70
135
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-cyclopropylmethyl-benzamide
Cyclopropylmethyl amine
422.99
70
136
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-cyclopropylmethyl-benzamide
Cyclopropylmethyl amine
423.00
72
137
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-cyclobutyl-benzamide
Cyclopropylamine
423.00
70
138
Azetidin-1-yl-[4-(3-cyclopentyl-indole-1-sulfonyl)-phenyl]-methanone
azetidine
409.02
70
139
N-(5-Cyano-pyridin-3-ylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
5-Aminomethyl-nicotinonitrile
492.91
70
140
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-[(R)-1-(tetrahydro-furan-2-yl)methyl]-benzamide
R-(Tetrahydro-furan-2-yl)-methylamine
452.96
70
141
N-Cyclopropylmethyl-4-[3-(tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzamide
Cyclopropylmethyl amine
438.93
72
142
4-(3-Phenyl-indole-1-sulfonyl)-N-(tetrahydro-furan-3-ylmethyl)-benzamide
C-(Tetrahydro-furan-3-yl)-methylamine
460.96
72
143
N-(4-Cyano-benzyl)-4-[3-(cyclopentyl)-indole-1-sulfonyl]-benzamide
4-Aminomethyl-benzontrile
498.04
72
144
N-(4-Cyano-benzyl)-4-(3-cyclopropyl-indole-1-sulfonyl)-benzamide
4-Aminomethyl-benzontrile
455.92
70
145
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-2-ylmethyl)-benzamide
C-(Tetrahydro-pyran-2-yl)-methylamine
473.11(M + 1)-
72
146
N-(4-Amino-benzyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
4-Aminomethyl-benzonitrile
482.07(M + 1)-
72
147
N-Isobutyl-4-(3-phenyl-indole-1-sulfonyl)-benzamide
isobutylamine
433.1598
70
148
N-Isoamyl-4-(3-phenyl-indole-1-sulfonyl)-benzamide
isoamylamine
447.1752
70
149
N-2-methylbutylamine-4-(3-phenyl-indole-1-sulfonyl)-benzamide
2-methylbutylamine
447.1738
72
150
4-(3-Cyclopropyl-indole-1-sulfonyl)-N-(5-fluoro-pyridin-2-ylmethyl)-benzamide
C-(5-Fluoro-pyridin-2-yl)-methylamine
450
70
151
4-(3-Cyclopropyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-4-ylmethyl)-benzamide
4-aminomethyltetrahydropyran
439.1
70
152
4-(3-Cyclopropyl-indole-1-sulfonyl)-N-(2-isopropoxy-ethyl)-benzamide
2-Isopropoxy-ethylamine
427
70
153
N-(4-Cyano-benzyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
4-Aminomethyl-benzonitrile
491.94
72
154
N-(5-Fluoro-pyridin-2-ylmethyl)-4-[3-(tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzamide
C-(5-Fluoro-pyridin-2-yl)-methylamine
493.89
72
155
4-[3-(Tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-N-(tetrahydro-pyran-4-ylmethyl)-benzamide
4-aminomethyltetrahydropyran
482.93
72
156
N-Cyclobutyl-4-[3-(tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzamide
Cyclobutyl amine
438.98
72
157
N-(5-Fluoro-pyridin-3-ylmethyl)-4-[3-(tetrahydro-pyran-4-yl)-indole-1-sulfonyl]-benzamide
C-(5-Fluoro-pyridin-3-yl)-methylamine
493.95
72
157a
N-Cyclopropylmethyl-4-3-phenyl-indole-1-sulfonyl)-benzamide
cyclopropylmethyl amine
431.2
72
157b
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-pyridin-3-ylmethyl-benzamide
Pyridin-3-yl-methylamine
M-1 458
72
157c
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-piperidin-1-yl-benzamide
N-aminopiperidine
452.1
72
157d
4-(3-Phenyl-indole-1-sulfonyl)-N-piperidin-1-yl-benzamide
N-aminopiperidine
460.1
72
*Dissolve the purified compound in a minimum amount of tetrahydrofuran, cool to 0° C. and treat with 1-2 equivalents of anhydrous HCl in THF and evaporate the solvents to give the final HCl salt.
EXAMPLE 158
Resolution of Cis-N-(2-Hydroxy-cyclohexyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Separate the title compound by chiral chromatography (prep ChiralPak AD, 100% EtOH, 14 mL/min, analytical ChiralPak AD, 100% EtOH, 1.0 mL/min. Isomer 1 retention time (analytical) 8.35 min LRMS: 475.06. Isomer 2 retention time (analytical) 11.85 min LRMS: 475.05.
EXAMPLE 159
Resolution of Trans-N-(2-Hydroxy-cyclohexylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Separate the title compounds by chiral chromatography (prep ChiralPak AD, 100% EtOH, 14 mL/min, analytical ChiralPak AD, 100% EtOH, 1.0 mL/min. Isomer 1 retention time (analytical) 6.75 min LRMS: 489.10. Isomer 2 retention time (analytical) 9.55 min LRMS: 489.11.
EXAMPLE 161
(3-Hydroxy-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl-phenyl]-methanone
Dissolve 1-Benzhydryl-azetidin-3-ol (250 mg, 1.04 mmoL) in methanol (3.0 mL) and add to Pd(OH) 2 (50 mg) under nitrogen. Degas reaction vessel and purge with 60 psi H2 (g). Repeat degass/H 2 purge cycle again. Allow to stir under 60 psi H 2 for 15 h. Release reaction and filter through celite with additional methanol. Evaporate methanol to yield azetidin-3-ol as a liquid which is used without further purification. Combine 4-(3-Phenyl-indole-1-sulfonyl)-benzoic acid (200 mg, 0.53 mmol) and azetidin-3-ol (50 mg, 0.68 mmol, excess) in dichloromethane (1.0 mL) and triethylamine (0.500 mL, 3.58 mmol, excess) and add benzotriazol-1-yloxytris(dimethylamino)phosphonium hexfluorophosphate (BOP Reagent) (300 mg, 0.66 mmol, excess) at room temperature. Stir for 30 minutes, load entire reaction directly onto pre-packed silica gel column and purify by flash column chromatography (EtOAc/Hexanes) to yield 167 mg of (3-Hydroxy-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone as a white foam (73%). LRMS: MH+ 432.97.
EXAMPLE 162
Methanesulfonic acid 1-[4-(3-phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-yl ester
Prepare the title compound utilizing Methanesulfonic acid 1-benzhydryl-azetidin-3-yl ester in the same procedure as above.
EXAMPLE 163
Dimethyl-carbamic acid 1-[4-(3-phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-yl ester
Combine (3-Hydroxy-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (95 mg, 0.219 mmol), triethylamine (0.200 mL, 1.43 mmol, excess) and 4-dimethylaminopyridine (5 mg, 0.04 mmol) in dichloromethane (1.0 mL) and treat with N,N-dimethylcarbamoyl chloride (0.050 mL) at room temperature. Stir for 15 h, load directly onto pre-packed silica gel column and purify by flash column chromatography (EtOAc/Hexanes) to yield 82 mg of Dimethyl-carbamic acid 1-[4-(3-phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-yl ester as a white foam (74%). LRMS: MH+ 503.97.
EXAMPLE 164
N-[1-(4-Fluoro-phenyl)-azetidin-3-ylmethyl]-4-(3-phenyl-indole-1-sulfonyl) 1-benzamide
Add trifluoroacetic acid (2 mL) to [1-(4-fluoro-phenyl)-azetidin-3-ylmethyl]-carbamic acid tert-butyl ester (135 mg, 0.482 mmol) causing much gas evolution. Rotary evaporate the reaction solution (40° C.; azeotroping 3× with CH 2 Cl 2 ). Dissolve this material in anhydr CH 2 Cl 2 (3 mL). Add 4-(3-Phenyl-indole-1-sulfonyl)-benzoic acid (200 mg, 0.53 mmol, 1.1 equiv), 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC; 140 mg, 0.73 mmol, 1.5 equiv), and 4-(dimethylamino)pyridine (DMAP; 270 mg, 2.3 mmol, 4.7 equiv). After stirring 16 h, transfer the reaction solution to a column of silica gel (80 mm×20 mm dia.) and elute (10-45% EtOAc/hex) to yield 31 mg (12%) of N-[1-(4-fluoro-phenyl)-azetidin-3-ylmethyl]-4-(3-phenyl-indole-1-sulfonyl)-benzamide as a light-yellow foam. MS (m/e): 539.99 (M+1); 538.16 (M−1).
EXAMPLE 165
[3-[(4-Fluoro-phenylamino)-methyl]-azetidin-1-yl-]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Add 1-bromo-4-fluorobenzene (220 μL, 350 mg, 2.0 mmol, 2.0 equiv) to a mixture of (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (446 mg, 1.00 mmol, 1 equiv), tris(dibenzylideneacetone)dipalladium(0) (23 mg, 0.025 mmol, 0.025 equiv), 2-(di-tert-butylphosphino)biphenyl (15 mg, 0.057 mmol, 0.050 equiv), and sodium tert-butoxide (120 mg, 1.2 mmol, 1.2 equiv) in anhydr toluene (4 mL) and heat at 100° C. for 19 h. After cooling, transfer the reaction mixture through a 0.45-μm filter disc to a column of silica gel (125 mm×25 mm dia.) and elute (10-100% EtOAc/hex) to yield 98 mg (18%) of [3-[(4-fluoro-phenylamino)-methyl]-azetidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone as a light-yellow foam. 1 H NMR indicated pure desired product. MS (m/e): 540.07 (M+1); 538.19 (M−1).
EXAMPLE 166
[(R)-3-(4-Fluoro-phenylamino)-pyrrolidin-1-yl-]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Prepare the title compound by a similar method described for [3-[(4-Fluoro-phenylamino)-methyl]-azetidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone using ((R)-3-Amino-pyrrolidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (334 mg, 0.750 mmol) to isolate 35 mg (8.7%) of light-yellow foam. MS (m/e): 540.01 (M+1).
EXAMPLE 167
[(S)-3-(4-Fluoro-phenylamino)-pyrrolidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Prepare the title compound by a similar method described for [3-[(4-Fluoro-phenylamino)-methyl]-azetidin-1-yl]-[4-(3-phenyl-indole-1 sulfonyl)-phenyl]-methanone using ((S)-3-Amino-pyrrolidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (334 mg, 0.750 mmol) to isolate 59 mg (15%) of light-yellow foam. MS (m/e): 540.02 (M+1).
EXAMPLE 170
[3-[(6-Fluoro-pyridin-2-ylamino)-methyl]-azetidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Add 2,6-difluoropyridine (55 μL, 70 mg, 0.61 mmol, 2.0 equiv) to a solution of (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (134 mg, 0.301 mmol, 1 equiv) and triethylamine (120 μL, 87 mg, 0.86 mmol, 2.9 equiv) in 1,4-dioxane (3 mL) and heat at 80° C. for 16 h. Mass spec shows no desired product. Add more triethylamine (120 μL) and 2,6-difluoropyridine (110 μL). After 32 h at 80° C., LC/MS shows a small amount of desired product. Add more triethylamine (200 μL) and 2,6-difluoropyridine (110 μL). After 38 h, add more triethylamine (200 μL) and 2,6-difluoropyridine (110 μL). After 100 h, transfer the reaction solution to a column of silica gel (80 mm×20 mm dia.) and elute (50-65% EtOAc/hex) to yield 65 mg (40%) of [3-[(6-fluoro-pyridin-2-ylamino)-methyl]-azetidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone as a white foam. MS (m/e): 541.02 (M+1); 539.17 (M−1).
EXAMPLE 171
[4-(3-Phenyl-indole-1-sulfonyl)-phenyl]-[3-(pyrimidin-2-ylaminomethyl)-azetidin-1-yl]-methanone
Prepared the title compound by a similar method as described for [3-[(6-Fluoro-pyridin-2-ylamino)-methyl]-azetidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone using (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (134 mg, 0.301 mmol) to isolate 56 mg (36%) of off-white foam. MS (m/e): 524.01 (M+1).
EXAMPLE 172
1,1-Dimethyl-3-[1-[4-(3-phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-ylmethyl]-urea
EXAMPLE 173
1,1-Dimethyl-3-[1-[4-(3-phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-ylmethyl]-thiourea
Add dimethylthiocarbamoyl chloride (350 mg, 2.8 mmol, 12 equiv) to a suspension of (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (101 mg, 0.227 mmol, 1 equiv) and triethylamine (130 μL, 94 mg, 0.93 mmol, 4.1 equiv) in anhydr CH 2 Cl 2 (3 mL). After stirring 17 h, transfer the reaction to a column of silica gel (80 mm×20 mm dia.) and elute (20-100% EtOAc/hex; 2% MeOH/CH 2 Cl 2 ) to yield 15 mg (12%) of 1,1-dimethyl-3-[1-[4-(3-phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-ylmethyl]-urea as a white foam. The staring dimethylthiocarbamoyl chloride contains some dimethylcarbamoyl chloride.
Elute the column of silica gel with more polar solvent (20% MeOH/CH 2 Cl 2 ) to give the thiourea along with triethylamine hydrochloride. Dissolve this material in CH 2 Cl 2 and wash with satd aq NaHCO 3 . Dry the organic layer (anhydr MgSO 4 ) and rotary evaporate (40° C.) to yield 30 mg (25%) of 1,1-dimethyl-3-[1-[4-(3-phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-ylmethyl]-thiourea as a tan foam.
EXAMPLE 174
3-[(4-Fluoro-benzylamino)-methyl]-azetidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone
Add 4-fluorobenzaldehyde (26 μL, 31 mg, 0.25 mmol, 1.0 equiv) to a solution of (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (112 mg, 0.251 mmol, 1 equiv) in MeOH (1 mL). After a few minutes, observe white precipitate. After 1 h, add H 2 O and extract the reaction mixture with CHCl 3 (3×). Combine the organic layers, dry and rotary evaporate (40° C.) to give 120 mg of imine as a colorless film. Dissolve the imine anhydr THF (2 mL) and add sodium triacetoxyborohydride (80 mg, 0.38 mmol, 1.5 equiv). After 19 h, quench the reaction mixture with satd aq NaHCO 3 (5 mL) and extract with EtOAc (5 mL). Dry the organic layer (anhydr MgSO 4 ) and rotary evaporate (40° C.). Transfer the resultant colorless oil to a column of silica gel (60 mm×12 mm dia.) and elute (2% MeOH/CH 2 Cl 2 ) to yield 54 mg (39%) of [3-[(4-fluoro-benzylamino)-methyl]-azetidin-1-yl]-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone as a white foam. MS (m/e): 553.96 (M+1).
EXAMPLE 175
N-[1-(4-Fluoro-phenyl)-azetidin-3-yl]-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Add 1-bromo-4-fluorobenzene (110 μL, 180 mg, 1.0 mmol, 2.0 equiv) to a mixture of N-azetidin-3-yl-4-(3-phenyl-indole-1-sulfonyl)-benzamide (216 mg, 0.501 mmol, 1 equiv), tris(dibenzylideneacetone)dipalladium(0) (12 mg, 0.012 mmol, 0.025 equiv), 2-(di-tert-butylphosphino)biphenyl (8 mg, 0.03 mmol, 0.05 equiv), and sodium tert-butoxide (58 mg, 0.60 mmol, 1.2 equiv) in anhydr toluene (2 mL). Heat the reaction mixture at 100° C. for 14 h. After cooling, dilute the reaction mixture with CH 2 Cl 2 and transfer through a 0.45-μm filter disc to a column of silica gel (80 mm×20 mm dia.) and elute (10-35% EtOAc/hex) to yield 63 mg (24%) of N-[1-(4-fluoro-phenyl)-azetidin-3-yl]-4-(3-phenyl-indole-1-sulfonyl)-benzamide as a white solid.
EXAMPLE 176
3-[4-(3-Phenyl-indole-1-sulfonyl)-benzoylamino]-azetidine-1-carboxylic acid methyl ester
Add methyl chloroformate (60 μL, 73 mg, 0.78 mmol, 3.1 equiv) to a suspension of N-azetidin-3-yl-4-(3-phenyl-indole-1-sulfonyl)-benzamide (108 mg, 0.250 mmol, 1 equiv) and triethylamine (140 μL, 100 mg, 1.0 mmol, 4.0 equiv) in anhydr CH 2 Cl 2 (3 mL). Observe a vigorous gas evolution. After stirring 4 h, rotary evaporate the reaction solution. Transfer the resultant material to a column of silica gel (80 mm×20 mm dia.) and elute (20-60% EtOAc/hex) to yield 84 mg (69%) of 3-[4-(3-phenyl-indole-1-sulfonyl)-benzoylamino]-azetidine-1-carboxylic acid methyl ester as an off-white foam. MS (m/e): 489.96 (M+1); 488.09 (M−1).
EXAMPLE 177
[(R)-1-[4-(3-Phenyl-indole-1-sulfonyl)-benzoyl]-pyrrolidin-3-yl]-carbamic acid methyl ester
Prepare the title compound by a similar method described for 3-[4-(3-phenyl-indole-1-sulfonyl)-benzoylamino]-azetidine-1-carboxylic acid methyl ester using ((R)-3-amino-pyrrolidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (111 mg, 0.249 mmol) to isolate 98 mg (78%) of white foam. MS (m/e): 503.98 (M+1); 502.09 (M−1).
EXAMPLE 178
[(S)-1-[4-(3-Phenyl-indole-1-sulfonyl)-benzoyl]-pyrrolidin-3-yl]-carbamic acid methyl ester
Prepare the title compound by a similar method described for 3-[4-(3-phenyl-indole-1-sulfonyl)-benzoylamino]-azetidine-1-carboxylic acid methyl ester using ((S)-3-amino-pyrrolidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (111 mg, 0.249 mmol) to isolate 97 mg (77%) of white foam. MS (m/e): 504.00 (M+1); 502.09 (M−1).
EXAMPLE 179
[1-[4-(3-Phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-yl-methyl]-carbamic acid methyl ester
Prepare the title compound by a similar method described for 3-[4-(3-phenyl-indole-1-sulfonyl)-benzoylamino]-azetidine-1-carboxylic acid methyl ester using (3-aminomethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (111 mg, 0.249 mmol) to isolate 99 mg (79%) of white foam. MS (m/e): 504.02 (M+1); 502.15 (M−1).
EXAMPLE 180
[1-[4-(3-Phenyl-indole-1-sulfonyl)-benzoyl]-azetidin-3-yl]-carbamic acid methyl ester
Prepare the title compound by a similar method described for 3-[4-(3-phenyl-indole-1-sulfonyl)-benzoylamino]-azetidine-1-carboxylic acid methyl ester using (3-amino-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone (111 mg, 0.249 mmol) to isolate 99 mg (79%) of white foam. MS (m/e): 489.99 (M+1); 488.04 (M−1).
EXAMPLE 183
N-(4-Fluoro-benzyl)-4-(3-pyridin-3-yl-indole-1-sulfonyl)-benzamide hydrochloride
Combine N-(4-fluoro-benzyl)-4-(3-iodo-indole-1-sulfonyl)-benzamide 300 mg, 0.56 mmol, 1 equiv), 3-tributylstannylpyridine (Frontier Scientific®; 90%; 230 mg (0.90)=210 mg, 0.56 mmol, 1.0 equiv), and tetrakis(triphenylphosphine)palladium(0) (100 mg, 0.087 mmol, 0.15 equiv) in deoxygenated toluene (3 mL) and heat at 100° C. for 18 h. Transfer the reaction solution to a column of silica gel (125 mm×25 mm dia.) and elute (0-70% EtOAc/hex) to yield 73 mg (27%) of free amine as an orange oil. Dissolve this material in MeOH (5 mL) and add 12 M aq HCl (2 drops). Rotary evaporate this solution (40° C.) to yield 78 mg (27%) of N-(4-fluoro-benzyl)-4-(3-pyridin-3-yl-indole-1-sulfonyl)-benzamide hydrochloride as a brown glass. MS (m/e): 485.95 (M+1); 484.10 (M−1).
EXAMPLE 184
N-(4-Fluoro-benzyl)-4-(3-pyridin-2-yl-indole-1-sulfonyl)-benzamide hydrochloride
Prepare the title compound by a method similar to Example 183 using 2-tributylstannylpyridine (Frontier Scientific®; 85%; 250 mg [0.85]=210 mg, 0.58 mmol, 1.0 equiv) to isolate 109 mg (37%) of yellow glass. MS (m/e): 485.96 (M+1); 484.10 (M−1).
EXAMPLE 185
N-(4-Fluoro-benzyl)-4-[3-(6-methoxy-pyridin-3-yl)-indole-1-sulfonyl]-benzamide
Combine N-(4-Fluoro-benzyl)-4-[3-(4,4,5,5-tetramethyl-[1,3,2]-dioxaboralan-2-yl)-indole-1-sulfonyl]-benzamide (0.534 g, 1.0 mmol), 5-Bromo-2-methoxy pyridine (0.155 mL, 1.2 mmol) and PdCl 2 (dppf).CH 2 Cl 2 (0.088 g, 0.07 mmol) in dry DMF (40 mL). Add 2M Na 2 CO 3 (1.40 mL, 2.8 mmol) and heat under N 2 at 100° C. for 4 h. Stir overnight at ambient temperature. Pour the reaction mixture into EtOAc—H 2 O, separate, extract several times with H 2 O and wash with brine. Dry the EtOAc (MgSO 4 ) and filter through celite®. Evaporate and chromatograph using a hexane-EtOAc gradient 0-100% EtOAc to give 0.347 g (67%) of the desired compound. MS (M+1) 516; (M−1) 514.
EXAMPLE 186
N-(4-Fluoro-benzyl)-4-[3-(6-fluoro-pyridin-3-yl)-indole-1-sulfonyl]-benzamide
Combine N-(4-Fluoro-benzyl)-4-[3-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-indole-1-sulfonyl]-benzamide (150 mg, 0.28 mmol), 5-Bromo-2-fluoro-pyridine (0.05 mL, 0.56 mmol), CsF (212 mg, 1.4 mmol) and Pd(Ph 3 P) 4 (32 mg, 0.028 mmol) in 1.0 mL DMF and 0.100 mL of water. Evacuate the reaction vessel and place under an atmosphere of nitrogen. Heat the resulting reaction at 90 degrees 12 h. Load the reaction directly onto silica gel and purify by flash column chromatography (EtOAc/Hexanes) to yield 98 mg of white foam (70%) LRMS: MH+ 504.02.
EXAMPLE 187
4-[3-(5-Chloro-thiophen-2-yl)-indole-1-sulfonyl]-N-(4-fluoro-benzyl)-benzamide
Combine N-(4-Fluoro-benzyl)-4-[3-(4,4,5,5-tetramethyl-[1,3,2]-dioxaboralan-2-yl)-indole-1-sulfonyl]-benzamide (0.534 g, 1.0 mmol), 2-bromo-5-chloro-thiophene (0.012 mL, 1.1 mmol), PdCl 2 (dppf), CH 2 Cl 2 (0.051 g, 0.069 mmol) and KOAc (0.294 g, 3.0 mmol) in dry DMF (22.0 mL) under N 2 heat and stir at 100° C. for 16 h. Cool to ambient temperature and pour into a mixture of EtOAc—H 2 O. Separate and extract the EtOAc several times with H 2 O, wash with brine and dry (MgSO4). Filter and evaporate to an oily residue. Purify the product by chromatography using a hexane-EtOAc gradient 0-100% EtOAc to give 0.209 g (40%) of a viscous oil. TOF MS (M−1) 523.0332.
EXAMPLE 188
4-(3-Cyclopropyl-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide
Combine N-(4-fluoro-benzyl)-4-(3-iodo-indole-1-sulfonyl)-benzamide (0.50 g, 0.94 mmol), cyclopropylboronic acid (0.24 g, 2.8 mmol), tricyclohexylphosphine (0.05 g, 0.18 mmol), potassium phosphate (0.70 g, 3.30 mmol), and palladium acetate (0.02 g, 0.09 mmol) in a mixture of toluene (15 mL) and water (0.4 mL). Heat to 100° C. under nitrogen for 18 hours, filter through celite, and wash solids with EtOAc. Wash EtOAc with saturated NaHCO 3 (30 mL), then dry with Na 2 SO 4 , and concentrate under vacuum. Purify by flash column on silica gel eluting with 0-50% EtOAc in hexanes to give the title compound (0.25 g, 60%). MS (ES) 449.2 (M+1)+, 447.4 (M−1)−.
EXAMPLE 189
N-(4-Fluoro-benzyl)-4-(3-thiophen-3-yl-indole-1-sulfonyl)-benzamide
Combine N-(Fluoro-benzyl)-4-(3-iodo-indole-1-sulfonyl)-benzamide (0.534 g, 1.1 mmol), thiophene-3-boronic acid (0.154 g, 1.25 mmol), PdCl 2 (dppf).CH 2 Cl 2 (0.10 mmol) and 2 M Na 2 CO 3 (1.32 mL)l, 2.64 mmol) respectively in dry DMF (40 mL) under N 2 . Stir and heat at 81° C. under N 2 for one and a half hours. Cool to ambient temperature and stir overnight. Pour the reaction into EtOAc (150 mL) and extract with H 2 O (3×150 mL). Wash with brine, separate and dry the organic layer (MgSO 4 ). Filter through celite and evaporate the filtrate on the rotary evaporator. Chromatograph using a hexane-EtOAc gradient from 0-100% EtOAc to give 0.352 g (71%) of the desired compound as and off white solid MS(ES+) (M+1) 491.0; (M−1) 490.10.
EXAMPLE 190
4-[3-(2-Chloro-phenyl)-indole-1-sulfonyl]-N-(4-fluoro-benzyl)-benzamide
Add N-(4-Fluoro-benzyl)-4-(3-iodo-indole-1-sulfonyl)-benzamide (268 mg, 0.0.50 mmol), 2-chlorophenylboronic acid (78.2 mg, 0.50 mmol), PdCl 2 (dppf).CH 2 Cl 2 (41 mg, 0.05 mmol) and 2M Na 2 CO 3 (0.55 mL, 1.1 mmol) respectively to DMF (15.0 mL) at ambient temperature under N 2 . Heat the reaction to 100° C. for 16 h. Cool the reaction to ambient temperature and pour into a H 2 O-EtOAc mixture (200 mL/100 mL). Separate the EtOAc, extract several times with H 2 O and wash with brine. Dry (MgSO 4 ), filter and evaporate the filtrate. Purify the crude material on silica gel using a gradient hexane-EtOAc system to give 0.155 g (60% yield) of 4-[3-(2-chloro-phenyl)-indole-1-sulfonyl]-N-(4-fluoro-benzyl)-benzamide: Mass spectrum (m/e) M−1) 517.0787.
EXAMPLE 191
N-(4-Fluoro-benzyl)-4-[3-(2-fluoro-pyridin-3-yl)-indole-1-sulfonyl]-benzamide
Combine N-(4-Fluoro-benzyl)-4-(3-iodo-indole-1-sulfonyl)-benzamide (300 mg, 0.56 mmol), 2-Fluoro-3-boronic acid-pyridine (140 mg, 1.12 mmol), CsF (170 mg, 1.12 mmol) and Dichlorobis(triphenylphosphine)palladium (100 mg, 0.14 mmol) in dioxane (2.0 mL) and water (0.200 mL). Evacuate the reaction and place under a nitrogen atmosphere. Heat the resulting reaction in an 80 degree oil bath for 15 h. Cool the reaction and filter through a short pad of silica gel with additional ethyl acetate. Evaporate and purify by flash column chromatography (EtOAc/Hexanes) to yield 141 mg of an off white foam (50%) LRMS: MH+ 503.92.
Prepare the following sulfonamides in Table 3 using methods similar to the noted reference examples.
TABLE 3
Ex
MS data(m/e)
Reference
No.
Final Structure
Name
(M + H)
Examples
194
N-(4-Fluoro-benzyl)-4-(3-pyridin-4-yl-indole-1-sulfanyl)-benzamide
486.13
189
195
N-(4-Fluoro-benzyl)-4-(3-thiophen-2-yl-indole-1-sulfonyl)-benzamide
512.73
189
196
N-(4-Fluoro-benzyl)-4-[3-(2-fluoro-phenyl)-indole-1-sulfonyl]-beazamide
503.12
189
197
N-(4-Fluoro-benzyl)-4-[3-(3-fluoro-phenyl)-indole-1-sulfonyl]-benzamide
501.2
190
198
N-(4-Fluoro-benzyl)-4-[3-(4-fluoro-phenyl)-indole-1-sulfonyl]-benzamide
503.1
189
199
N-(4-Fluoro-benzyl)-4-(3-furan-3-yl-indole-1-sulfonyl)-benzamide
475.11
189
200
N-(4-Fluoro-benzyl)-4-(3-o-tolyl-indole-1-sulfonyl)-benzamide
499.1
189
201
4-[3-(4-Chloro-phenyl)-indole-1-sulfonyl]-N-(4-fluoro-benzyl)-benzamide
517.08
189
202
4-[3-(3-Chloro-phenyl)-indole-1-sulfonyl]-N-(4-fluoro-benzyl)-benzamide
437.13
189
203
N-(4-Fluoro-benzyl)-4-(3-isoquinolin-4-yl-indole-1-sulfonyl)-benzamide
534.13
185
205
N-(4-Fluoro-benzyl)-4-(3-m-tolyl-indole-1-sulfonyl)-benzamide
499.15
187
206
N-(4-Fluoro-benzyl)-4-[3-(3-methoxy-phenyl)-indole-1-sulfonyl]-benzamide
515.14
187
208
N-(4-Fluoro-benzyl)-4-(3-furan-2-yl-indole-1-sulfonyl)-benzamide
475.11
189
209
N-(4-fluoro-benzyl)-4-[3-(5-methyl-thiophene-2-yl)-indole-1-sulfonyl]-benzamide
505.1
189
210
N-(4-fluorobenzyl)-4-(3-p-tolyl-indole-1-sulfonyl)-benzamide
499.15
185
211
N-(4-Fluoro-benzyl)-4-(3-quinolin-6-yl-indole-1-sulfonyl)-benzamide
536.14
185
212
4-[3-(4-Dimethylamino-phenyl)-indole-1-sulfonyl]-N-(4-fluoro-benzyl)-benzamidehydrachloride*
550
185
213
N-(4-Fluoro-benzyl)-4-[3-(3-fluoro-pyridin-4-yl)-indol-1-sulfonyl]-benzamide
MH+503.96
186
*Dissolve the purified compound in a minimum amount of tetrahydrofuran, cool to 0° C. and treat with 1-2 equivalents of anhydrous HCl in THF, evaporate the solvents to give the final HCl salt
EXAMPLE 214
N-(4-Fluoro-benzyl)-4-(3-pyrimidin-2-yl-indole-1-sulfonyl)-benzamide
Stir a mixture of N-(4-fluoro-benzyl)-4-[3-(4,4,5,5-tetramethyl-[1,3,2]-dioxaboralan-2-yl)-indole-1-sulfonyl]-benzamide (0.200 g, 0.374 mmoles), 2-bromo-pyrimidine (0.282 g, 1.872 mmole), Tetrakis(triphenylphosphine)palladium(0) (0.043 g, 0.0374 mmoles), Cesium Fluoride (0.282 g, 1.872 mmole) in dioxane until reaction goes to completion at 90° C. Concentrate the reaction and purify via column chromatography using a mixture of EtOAc and Hexanes to give 0.049 g of solid material (yield=27%): Mass Spectrum (m/e): 485.09 (M − ).
EXAMPLE 215
N-(4-Fluoro-benzyl)-4-(3-pyrimidin-5-yl-indole-1-sulfonyl)-benzamide
Prepare the title compound by a similar method of N-(4-Fluoro-benzyl)-4-(3-pyrimidin-2-yl-indole-1-sulfonyl)-benzamide using 5-bromo-pyrimidine (0.118 g, 0.748 mmoles) to isolate 0.070 g of solid (yield=95%). Mass Spectrum (m/e): 486.1(M + ).
EXAMPLE 216
N-(4-Fluoro-benzyl)-4-(3-pyrimidin-5-yl-indole-1-sulfonyl)-benzamide: chloride
Stir N-(4-Fluoro-benzyl)-4-(3-pyrimidin-5-yl-indole-1-sulfonyl)-benzamide (0.041 g, 0.084 mmole) in dioxane with 1 N HCl until completion and remove solvent to isolate 0.026 g (Yield=61%).
EXAMPLE 217
N-(4-Fluoro-benzyl)-4-(3-pyrazin-2-yl-indole-1-sulfonyl)-benzamide
Degas DMF with N 2 for 30 minutes. Add 2-tributylstannyl pyrazine (0.214 g, 0.58 mmol), N-(4-fluoro-benzyl)-4-(3-iodo-indole-1-sulfonyl)-benzamide 0.300 g, 0.56 mmol) and tetrakis(triphenylphosphine)Pd(0) (0.100 g, 0.086 mmol) to DMF (5.0 ml). Heat and stir at 100° under N 2 for 16 h. Pour the reaction mixture into H 2 O-EtOAc. Separate the EtOAc layer and extract several times with H 2 O, wash with brine, dry (MgSO 4 ) and filter through celite. Remove the solvent on the rotary evaporator to give an oil. Chromatograph on the chromatron using a 1 mm plate and elute with 1% CH 3 OH—CH 2 Cl 2 to give the title compound. Mass spectrum (m/e) (M+H) 487.1240; found: 487.1220.
EXAMPLE 218
N-(4-Fluoro-benzyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
In a 100 ml RBF combine 4-(3-phenyl-indole-1-sulfonyl)-benzoic acid (2.5 g, 6.62 mmol) and THF (25 ml). Cool the solution in an ice water bath and add 4-methylmorpholine (0.73 ml, 7.29 mmol) follow by the portion wise addition of CDMT (1.16 g, 7.29 mmol). Stir the solution in an ice water bath for one hour. Add dropwise, a solution of 4-fluorobenzylamine (0.83 ml, 7.29 mmol) in THF (8 ml) to the reaction at 0° C. Stir the solution at 0° C. for five hours, and quench with 1N HCl (50 ml). Extract the reaction MTBE (2×50 ml), filter and wash with saturated aqueous sodium chloride (50 ml). Dry the organics over magnesium sulfate, filter and concentrate to give N-(4-fluoro-benzyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide (2.43 g) as a white solid. HPLC=95.5%, MS (ESI) m/z observed 485.1334 calculated 485.1335 (M+H).
Dissolve 4 g of N-(4-fluoro-benzyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide in 15 mL of absolute ethanol. As the sample wetted, sonicate and observe crystallization. Collect a powder diffraction pattern on these crystals. Characterize the crystals as having a melt onset beginning at 140° C.
EXAMPLE 219
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-4-yl)-benzamide
Stir a solution of 4-(3-cyclopentyl-indole-1-sulfonyl)-benzoic acid (19.0 g, 51.43 mmol) in anhydrous THF (250 mL), cool to 5° C., add N-methylmorpholine (5.8 mL, 52.72 mmol) and 2-chloro-4,6-dimethoxy-1,3,5-triazine (CDMT) (9.0 g, 51.34 mmol). Stir the mixture at 0-5° C. for 1 h, add a solution of 4-aminotetrahydro-pyran (5.8 g, 57.36 mmol) in dry THF (75 mL) via dropping funnel. Bring the mixture to room temperature, stir for 3 h, and cool back down to 5° C. Stir the mixture and add 1N HCl (250 mL), add the resulting solution to a separatory funnel, and extract with ethyl acetate (250 mL). Separate the layers, wash the organic layer with brine (250 mL), and combine the aqueous layers and extract with ethyl acetate (250 mL). Combine the organics and wash with saturated aqueous sodium bicarbonate (400 mL) and dry the organic layer over sodium sulfate. Concentrate to give a foam, dissolve in minimum methylene chloride, and add to a biotage flash 65M cartridge. Elute with 3:2 hexanes/ethyl acetate to provide the major product as a foam, and dry (20 mm Hg, 40° C.) to give a white powder of pure product (20.3 g, 87%); MS (ESI) m/z 453 (m+H).
EXAMPLE 220
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-4-ylmethyl)-benzamide
Stir a stir solution of 4-(3-cyclopentyl-indole-1-sulfonyl)-benzoic acid (19.0 g, 51.43 mmol) in anhydrous THF (250 mL) cool to 5° C. under N 2 add N-methylmorpholine (5.8 mL, 52.72 mmol) and 2-chloro-4,6-dimethoxy-1,3,5-triazine (CDMT) (9.0 g, 51.34 mmol). Stir the mixture for 1 h and add a solution of 4-aminomethyltetrahydropyran (6.6 g, 57.34 mmol) in dry THF (75 mL) by dropping funnel. Warm the mixture to room temperature and stir for 3 h. Cool the mixture to 5° C., add 1N HCl (250 mL) and partition the resulting solution with ethyl acetate (250 mL). Extract the organic layer with aqueous saturated sodium bicarbonate (250 mL), brine (250 mL), and dry over sodium sulfate. Concentrate to give a foam, dissolve in minimum methylene chloride and add to a flash 65 M cartridge. Elute with 3:2 hexanes/ethyl acetate to give the major product as a solid, filter from hexanes, and dry (20 mm Hg, 40° C.) to give the homogeneous white solid (20.5 g, 85%); MS(ESI) m/z 467 (m+H).
EXAMPLE 221
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide
Charge a 500 mL 3-neck roundbottom flask equipped with overhead stirrer, temperature probe, dropping funnel, and N 2 line with 4-(3-cyclopentyl-indole-1-sulfonyl)-benzoic acid (7.8 g, 21.1 mmol) in anhydrous THF (100 mL). Cool the solution and stir at 0° C. and add N-methylmorpholine (NMM, 2.4 mL, 21.8 mmol) and 2-chloro-4,6-dimethoxy-1,3,5-triazine (CDMT, 3.7 g, 21.1 mmol). Stir the mixture for 1 h at 0° C. and add a solution of 4-fluorobenzylamine (2.7 mL, 23.6 mmol) in anhydrous THF (30 mL) over 10 minutes via dropping funnel. Bring the resulting suspension to room temperature and stir for 3 h. Cool the mixture to 0° C. and treat with 1N HCl (100 mL). Add ethyl acetate (100 mL) and separate the layers. Dry the organic layer over sodium sulfate and concentrate to a residue which was held aside at this point.
Repeat the reaction exactly as outlined above using 4-(3-cyclopentyl-indole-1-sulfonyl)-benzoic acid (8.8 g, 23.82 mmol), NMM (2.7 mL, 24.5 mmol), CDMT (4.2 g, 23.9 mmol), 4-fluorobenzylamine (3.1 mL, 27.1 mmol) and anhydrous THF (160 mL). Following reaction and workup as previously described, obtain the crude organic residue (similar, albeit less pure) TLC profile (3:2 hexanes/ethyl acetate) to that from the initial reaction. Independently chromatograph the two organic extracts (biotage 65M, 5% ethyl acetate in toluene) to provide in both cases separation of the major component. Pool the appropriate fractions at this point and concentrate to a white foam. Dry the foam (20 mm Hg, 40° C.) to provide a white powder (14.6 g, 68%); MS(ESI) m/z 477 (m+H). Dissolve 20 mg 4-(3-cyclopentyl-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide in isopropyl ether, though a small amount of oil remained at the bottom. Vigorously stir the sample until evaporation occurs and a white powder forms: onset of melting is 113° C.
EXAMPLE 222
N-(5-Fluoro-pyridin-3-ylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Make a 242.7 mg/mL solution of N-(5-fluoro-pyridin-3-ylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide in methanol. Allow the solution to evaporate to dryness: onset of melting at 131° C.
EXAMPLE 223
(N-(5-Fluoro-pyridin-2-ylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Add to a stirring mixture of 4-(3-phenyl-indole-1-sulfonyl)-benzoic acid (5.0 g, 13.25 mmol) and 2-aminomethyl-5-fluoropyridine (dihydrochloride) (2.9 g, 14.57 mmol) in anhydrous methylene chloride (60 mL), EDCI (3.8 g, 19.82 mmol) and 4-DMAP (6.0 g, 49.10 mmol). Stir the resulting solution overnight at room temperature, concentrate to a paste, and partition between ethyl acetate (100 mL), water (100 mL), and brine (100 mL). Dry the organic layer over sodium sulfate and concentrate to an oil. Dissolve the oil in methylene chloride and add to a biotage 65 cartridge. Elute with 1:1 ethyl acetate/hexanes to provide isolation of the pure 3 (N-(5-Fluoro-pyridin-2-ylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide as a solid, 5.7 g (89%): 1 H NMR(DMSO-d 6 ) δ 9.32 (t, J=5.9 Hz, 1H), 8.46 (d, J=2.9 Hz, 1H), 8.20 (d, J=8.3 Hz, 2H), 8.12 (s, 1H), 8.03 (m, 3H), 7.82 (d, J=7.8 Hz, 1H), 7.72 (d, J=6.8 Hz, 2H), 7.62 (dt, J=2.9, 8.8 Hz, 1H), 7.50(t, J=7.3 Hz, 2H), 7.39 (m, 4H), 4.50 (d, J=5.9 Hz, 2H); MS(ESI) m/z 486 (m+H).
EXAMPLE 224
(N-(5-Fluoro-pyridin-3-ylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide
Add to a stirring mixture of 4-(3-phenyl-indole-1-sulfonyl)-benzoic acid (5.0 g, 13.25 mmol), and 2-aminomethyl-4-fluoropyridine (2.9 g, 14.57 mmol) in anhydrous methylene chloride (60 mL) EDCI (3.8 g, 19.82 mmol) and 4-DMAP (6.0 g, 49.10 mmol). Stir the resulting solution overnight at room temperature and concentrate to an oil. Partition the oil between ethyl acetate (100 mL), water (100 mL), and brine (100 mL). Combine the aqueous layers and back-extract with methylene chloride (100 mL) and dry the organics over sodium sulfate. Concentrate to give an oil and dissolve in methylene chloride and add to a biotage 65 cartridge. Elute with 3:2 ethyl acetate/hexanes gradually increasing to 4:1 ethyl acetate/hexanes to give the major product as a foam which is found to be homogeneous 3 (N-(5-Fluoro-pyridin-3-ylmethyl)-4-(3-phenyl-indole-1-sulfonyl)-benzamide 5.6 g (87%); 1 H NMR (DMSO-d 6 ) δ 9.28 (t, J=5.9 Hz, 1H), 8.44 (d, J=2.9 Hz, 1H), 8.39 (s, 1H), 8.19 (d, J=8.8 Hz, 2H), 8.12 (s, 1H), 8.04 (d, J=8.3 Hz, 1H), 8.00 (d, J=8.3 Hz, 2H), 7.82 (d, J=7.8 Hz, 1H), 7.72 (d, J=7.3 Hz, 2H), 7.60 (m, 1H), 7.49 (t, J=7.3 Hz, 2H), 7.39(m, 3H), 4.48 (d, J=5.9 Hz, 2H); MS(ESI) m/z 486 (m+H).
EXAMPLE 226
N-(4-Fluoro-benzyl)-4-(3-phenyl-pyrrolo[2,3-b]pyridine-1-sulfonyl)-benzamide
Slowly add 3-phenyl-1H-pyrrolo[2,3-b]pyridine (178 mg, 0.915 mmol, 1.0 eq) as a 2 ml DMF solution to a flask under N 2 containing potassium tertbutoxide (108 mg, 0.961 mmol, 1.05 eq) in 1 ml DMF solution. Stir solution for 5 minutes. Slowly add 4-(4-Fluoro-benzylcarbamoyl)-benzenesulfonyl chloride (300 mg, 0.915 mmol, 1.0 eq) as a 3 ml DMF solution. Stir reaction for 18 hours at room temperature. Strip reaction of solvent and purify on silica gel chromatography to give N-(4-Fluoro-benzyl)-4-(3-phenyl-pyrrolo[2,3-b]pyridine-1-sulfonyl)-benzamide (82 mg, 18% yield). Mass Spectrum (m/e): 485.94 (MH+).
EXAMPLE 228
N-(4-Fluoro-benzyl)-4-[3-(2-piperidin-1-yl-acetyl)-indole-1-sulfonyl]-benzamide
Slowly add 1-(1H-Indol-3-yl)-2-piperidin-1-yl-ethanone (199 mg, 0.821 mmol, 1.0 eq) as a 2 ml DMF solution to a flask under N 2 containing sodium hydride (36 mg, 60 wt % on oil, 0.903 mmol, 1.1 eq) in 2 ml DMF solution. Stir solution for 5 minutes. Slowly add 4-(4-Fluoro-benzylcarbamoyl)-benzenesulfonyl chloride (296 mg, 0.903 mmol, 1.1 eq) as a 3 ml DMF solution. Stir reaction for 18 hours at room temperature. Strip reaction of solvent and purify on silica gel chromatography to give N-(4-Fluoro-benzyl)-4-[3-(2-piperidin-1-yl-acetyl)-indole-1-sulfonyl]-benzamide (249 mg, 57% yield). Mass Spectrum (m/e): 534 (MH+).
EXAMPLE 229
4-(3-Cyclohexyl-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide
Add 4-Fluoro-benzylamine (72 mg, 0.574 mmol, 1.1 eq) followed by triethylamine (343 mg, 0.472 ml, 3.39 mmol, 6.5 eq) to a CH 2 CL 2 solution (8 ml) of 4-(3-Cyclohexyl-indole-1-sulfonyl)-benzoic acid (200 mg, 0.521 mmol, 1 eq). Add benzotriazol-1-yloxytris(dimethylamino)phosphonium hexafluorophosphate (231 mg, 0.521 mmol, 1 eq) and stir at room temperature for 16 hours. Remove solvent on rotovap and purify crude by silica gel chromatography to give 4-(3-Cyclohexyl-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide (232 mg, 99% yield). Mass Spectrum (m/e): 490.92 (MH+).
EXAMPLE 230
4-(3-Cyclohexyl-indole-1-sulfonyl-N-(tetrahydro-pyran-4-ylmethyl)-benzamide
Using a similar procedure as for 4-(3-Cyclohexyl-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide to give 275 mg (100% yield) of the title compound Mass Spectrum (m/e): 480.97 (MH+).
EXAMPLE 231
4-(3-Cyclohexyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-4-yl)-benzamide
Using a similar procedure as for 4-(3-Cyclohexyl-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide to give 198 mg (71% yield) of the title compound: Mass Spectrum (m/e): 466.94 (MH+).
EXAMPLE 232
4-[3-(3,3-Difluoro-cyclopentyl)-indole-1-sulfonyl]-N-(tetrahydro-pyran-4-yl)-benzamide
Add a 2 ml CH 2 Cl 2 solution of Tetrahydro-pyran-4-ylamine (62 mg, 0.0610 mmol, 1.1 eq) and triethylamine (365 mg, 3.6 mmol, 6.5 eq) to a 2 ml CH 2 Cl 2 solution of 4-[3-(3,3-Difluoro-cyclopentyl)-indole-1-sulfonyl]-benzoic acid. Add benzotriazol-1-yloxytris(dimethylamino)phosphonium hexafluorophosphate (245 mg, 0.555 mmol, 1.0 eq) and stir reaction at room temperature for 18 hours. Remove volatiles on rotovap and purify by silica gel chromatography, followed by SCX ionic chromatography to give 4-[3-(3,3-Difluoro-cyclopentyl)-indole-1-sulfonyl]-N-(tetrahydro-pyran-4-yl)-benzamide (240 mg, 89% yield). Mass Spectrum (m/e): 489.71 (MH+).
EXAMPLE 233
4-[3-(3,3-Difluoro-cyclopentyl)-indole-1-sulfonyl]-N-(tetrahydro-pyran-4-ylmethyl)-benzamide
Using a similar procedure as for 4-[3-(3,3-Difluoro-cyclopentyl)-indole-1-sulfonyl]-N-(tetrahydro-pyran-4-yl)-benzamide using C-(Tetrahydro-pyran-4-yl)-methylamine in place of Tetrahydro-pyran-4-ylamine to give 4-[3-(3,3-Difluoro-cyclopentyl)-indole-1-sulfonyl]-N-(tetrahydro-pyran-4-ylmethyl)-benzamide (280 mg, 100% yield). Mass Spectrum (m/e): 503.98 (MH+).
EXAMPLE 234
N-(4-Fluoro-3-methoxy-benzyl)-4-(3-piperidin-1-yl-indole-1-sulfonyl)-benzamide Hydrochloride
Add KotBu (211 mg, 1.88 mmol) to a solution of 3-piperidin-1-yl-1H-indole (299 mg, 1.49 mmol) in dioxane (15 mL). Stir the yellow solution at RT for 30 min then treat with 4-(4-fluoro-3-methoxy-benzylcarbamoyl)-benzenesulfonyl chloride (560 mg, 1.56 mmol). Stir the solution at RT for an additional 2 h, then dilute with EtOAc (50 mL) and wash with satd NaHCO 3 (25 mL). Remove the organic phase and extract the aqueous layer with additional EtOAc (50 mL). Combine the organic solutions, dry over Na 2 SO 4 , filter, and concentrate. Purify the crude material by flash chromatography (3×) using an oversized silica column and a gradient of 100% hexanes to 40% EtOAc/hexanes. Concentrate fractions containing pure material then redissolve in CH 2 Cl 2 (10 mL) and treat with 4M HCl/dioxane (0.5 mL). Filter the off-white precipitate and dry under vacuum to give the title compound as a white powder (417 mg). MS (ES + ) 522.1 (M+1) + , (ES − ) 520.2 (M−1) − . 1 H NMR (400 MHz, DMSO-d 6 ): δ 9.19 (m, 1H), 8.03 (d, 2H, J=8.4), 7.97 (m, 1H), 7.95 (d, 2H, J=8.4), 7.61 (d, 1H, J=7.5), 7.37 (t, 1H, J=7.6), 7.26 (t, 2H, J=7.5), 7.06-7.13 (m, 2H), 6.81 (m, 1H), 6.12 (br s, 1H), 4.39 (d, 2H, J=5.7), 3.78 (s, 3H), 3.06 (s, 4H), 1.72 (s, 4H), 1.56 (s, 2H).
EXAMPLE 240
4-{[4-(3-Phenyl-indole-1-sulfonyl)-benzoylamino]-methyl}-N,N,-dimethyl-benzamide
Combine 4-{[4-(3-Phenyl-indole-1-sulfonyl)-benzoylamino]-methyl}-benzoic acid (0.489 mmole) with dimethylamine (0.587 mmole), and EDC (0.733 mmole) in 5 ml of dichloromethane and stir for 15 hrs. Dilute □eaction and wash with 1 N HCl. Dry organic layer over MgSO 4 and concentrate. Purify the residue via column chromatography with a mixture of ethyl acetate and dichloromethane to isolate 0.040 g (15.2%) of the title compound: MSES+ 537.95; MSES− 536.08.
GENERAL EXAMPLE 241
EDC Coupling
Combine the amine (0.809 mmole), benzoic acid, for example, 4-(3-Cyclopentyl-indazole-1-sulfonyl)-benzoic acid (0.539 mmole), EDC (0.809 mmole) in 5 ml of dichloromethane and stir for 15 hrs. Dilute the reaction mixture and wash with 1 N HCl. Dry organic material over MgSO 4 and concentrate. Purify the residue via column chromatography using a mixture of ethyl acetate and dichloromethane.
Prepare the following compounds by essentially following General Example 241.
Ex
Structure and name
Name of the amine
MS ES+/
%
No
of final cmpd
starting material
MS ES−
yield
242
4-Fluoro-benzylamine
478.30/476.50
60
4-(3-Cyclopentyl-indazole-1-sulfonyl)-N-
(4-fluoro-benzyl)-benzamide
243
Tetrahydro-pyran-4-ylamine
454.00452.20
46
4-(3-Cyclopentyl-indazole-1-sulfonyl)-N-
tetrahydro-pyran-4-yl)-benzamide
244
C-(Tetrahydro-pyran-4-yl)-methylamine
468.00466.20
38
4-(3-Cyclopentyl-indazole-1-sulfonyl)-N-
(tetrahydro-pyran-4-ylmethyl)-
245
Isobutylamine
426.00/424.20
47
4-(3-Cyclopentyl-indazole-1-sulfonyl)-N-
isobutyl-benzamide
246
C-Cyclopropyl-methylamine
424.00/422.20
47
4-(3-Cyclopentyl-indazole-1-sulfonyl)-N-
cyclopropylmethyl-benzamide
247
Dimethylamine
537.95/536.08
15.2
4-{[4-(3-Phenyl-indole-1-sulfonyl)
benzoylamino]-methyl}-N,N,-
dimethyl-benzamide
GENERAL EXAMPLE 248
Bop Couplings
Combine the amine (0.525 mmole), BOP (0.421 mmole), Triethylamine (1.05 mmole), and the appropriate benzoic acid (0.350 mmole) and stir in 5 ml of dichloromethane for 4 hrs. Concentrate the reaction and purify vial column chromatography using a mixture of ethyl acetate and dichloromethane.
Prepare the following compounds by essentially following General Example 248.
Ex
Structure and name
Name of the amine
MS ES+/
%
No
of final cmpd
starting material
MS ES−
yield
249
(R)-C-(Tetrahydro-furan-2-yl)-methylamine
454.00/452.20
80
(R)-4-(3-Cyclopentyl-indazole-1-sulfonyl)-
N-(tetrahydro-furan-2-ylmethyl)-benzamide
250
(S)-C-(Tetrahydro-furan-2-yl)-methylamine
454.00/452.10
75
(S)-4-(3-Cyclopentyl-indazole-1-sulfonyl)-
N-(tetrahydro-furan-2-ylmethyl)-benzamide
252
C-(Tetrahydro-pyran-2-yl)-methylamine
483.00/481.10
10.9
4-[3-(Tetrahydro-pyran-4-yl)-indole-1-
sulfonyl]-N-(tetrahydro-pyran-2-ylmethyl)-
benzamide
GENERAL EXAMPLE 253
EDC-DMAP
Combine the amine (0.300 mmole), the appropriate benzoic acid (0.300 mmole), DMAP (0.300 mmole), and EDC (0.450 mmole) in 5 ml of dichloromethane and stir until reaction is complete. Dilute the reaction and wash with 1 N HCl. Dry organic layer over MgSO 4 and concentrate. Purify the residue via column chromatography with a mixture of ethyl acetate and dichloromethane.
Prepare the following compounds by essentially following General Example 253.
Ex
Structure and name
Name of the amine
MS ES+/
%
No
of final cmpd
starting material
MS ES−
yield
254
(R)-1-(4-Fluoro-phenyl)-pyrrolidin-3-ylamine
539.97/538.23
52
(R)-N-[1-(4-Fluoro-phenyl)-pyrrolidin-3-yl]-4-
(3-phenyl-indole-1-sulfonyl)-benzamide
254a
(S)-1-(4-Fluoro-phenyl)-pyrrolidin-3-ylamine
52
(S)-N-[1-(4-Fluoro-phenyl)-pyrrolidin-3-yl]-4-
(3-phenyl-indole-1-sulfonyl)-benzamide
255
Azetidin-3-yl-(4-fluoro-phenyl)-amine
525.96
12.4
[3-(4-Fluoro-phenylamino)-azetidin-1-yl]-[4-(3-
phenyl-indole-1-sulfonyl)-phenyl]-methanone
256
C-(Tetrahydro-pyran-2-yl)-methylamine
474.99
19
4-(3-Phenyl-indole-1-sulfonyl)-N-(tetrahydro-
pyran-2-ylmethyl)-benzamide
257
C-(Tetrahydro-pyran-2-yl)-methylamine
466.94/465.10
81.2
4-(3-Cyctopentyl-indole-1-sulfonyl)-N-
(tetrahydro-pyran-2-ylmethyl)-benzamide
EXAMPLE 257a
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-2-ylmethyl)-benzamide Isomer 1
Separate the racemate of 4-(3-Cyclopentyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-2-ylmethyl)-benzamide on a 8×29 cm Chiralpak AD column with 100% 3A (anhydrous ethanol) using as the mobile phase, 300 ml/min flow rate, and UV detection at 220 nm. Analyze on a 4.6×150 mm Chiralpak AD-H column with 100% 3A as the mobile phase, 0.6 ml/min flow rate, and UV detection at 219 nm to give the isolation of isomer 1 which elutes at 12.6 min MS ES+ 466.98 MS ES− 465.07.
EXAMPLE 257b
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-2-ylmethyl)-benzamide Isomer 2
Separate the racemate of 4-(3-Cyclopentyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-2-ylmethyl)-benzamide on a 8×29 cm Chiralpak AD column with 100% 3A (anhydrous ethanol) as the mobile phase, 300 ml/min flow rate, and UV detection at 220 nm. Analyze on a 4.6×150 mm Chiralpak AD-H column with 100% 3A as the mobile phase, 0.6 ml/min flow rate, and UV detection at 219 nm to give the isolation of isomer 2 MS ES+ 467.0 MS ES− 465.1 elutes at 18.8 min.
EXAMPLE 259
4-(3-Cyclopentyl-indole-1-sulfonyl-N-pyridin-3ylmethyl-benzamide
Add to a stirring mixture of 4-(3-cyclopentyl-indole-1-sulfonyl)-benzoic acid (0.188 g, 0.50 m mol), PyBOP (0.0.288 g, 0.50 m mol), and 3-amino-pyridine (0.063 g, 0.59 mmol) in dry CH 2 Cl 2 (10 mL) under N 2 , Hunigs base (0.148 g, 0.200 mL, 1.11 m mol.). Stir the reaction is overnight at ambient temperature and evaporate on the rotary evaporator. Chromatograph the residue on the ISCO system using a 40 g column and a hexane-EtOAc gradient system (0-100%) to give 0.048 g of the title compound as white foam: Mass spectrum (m/e) (M+H) 460.1697; found 460.1681.
EXAMPLE 260
4-(3-Cyclopentylindole-1-sulfonyl)-N—[(R)-1-(tetrahydrofuran-2-yl)methyl]benzamide
Add 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC; 98 mg, 0.51 mmol, 1.5 equiv) and 4-(dimethylamino)pyridine (DMAP; 70 mg, 0.57 mmol, 1.7 equiv) to a solution of 4-(3-cyclopentylindole-1-sulfonyl)benzoic acid (126 mg, 0.341 mmol, 1 equiv) and (R)-(−)-tetrahydrofurfurylamine (Aldrich; 140 μL, 140 mg, 1.4 mmol, 4.0 equiv) in anhydr CH 2 Cl 2 (1 mL). After stirring 16 h, transfer the reaction solution to a column of silica gel (80 mm×20 mm dia.) and elute (10-45% EtOAc/hex) to give 24 mg (16%) of 4-(3-cyclopentylindole-1-sulfonyl)-N—[(R)-1-(tetrahydrofuran-2-yl)methyl]benzamide as a white foam. MS (m/e): 452.96 (M+1); 451.14 (M−1).
EXAMPLE 261
4-(3-Phenylindole-1-sulfonyl)-N-(tetrahydrofuran-3-ylmethyl)benzamide
Add benzotriazol-1-yloxytris(dimethylamino)phosphonium hexafluorophosphate (2.2 g, 5.0 mmol, 1.5 equiv) to a solution of 4-(3-phenyl-indole-1-sulfonyl)-benzoic acid (1.23 g, 3.26 mmol, 1 equiv), (tetrahydro-furan-3-yl)-methylamine (331 mg, 3.27 mmol, 1.0 equiv), and triethylamine (2.3 mL, 1.7 g, 17 mmol, 5.0 equiv) in anhydr CH 2 Cl 2 (12 mL). After 1 h, rotary evaporate the reaction solution and transfer the resultant residue to a column of silica gel (235 mm×35 mm dia.) and elute (50-90% EtOAc/hex). This yields 486 mg (32.4%) of rac-4-(3-phenyl-indole-1-sulfonyl)-N-(tetrahydro-furan-3-ylmethyl)-benzamide as a yellow foam. MS (m/e): 460.96 (M+1); 459.04 (M−1).
EXAMPLE 261a
4-(3-Phenylindole-1-sulfonyl)-N-(tetrahydrofuran-3-ylmethyl)benzamide isomer 1
Separate the enantiomers of rac-4-(3-phenyl-indole-1-sulfonyl)-N-(tetrahydro-furan-3-ylmethyl)-benzamide (470 mg) using a Chiralpak AD-H column (4.6×150 mm) with 95% EtOH/MeOH at 0.6 mL/min. Collect peak at 9.8 min followed by rotary evaporation to give 154 mg (32.8%) of 4-(3-phenylindole-1-sulfonyl)-N-(tetrahydrofuran-3-ylmethyl)benzamide isomer 1. MS (m/e): 460.96 (M+1); 459.03 (M−1).
EXAMPLE 261b
4-(3-Phenylindole-1-sulfonyl)-N-(tetrahydrofuran-3-ylmethyl)benzamide isomer 2
Separate the enantiomers of rac-4-(3-phenyl-indole-1-sulfonyl)-N-(tetrahydro-furan-3-ylmethyl)-benzamide (470 mg) using a Chiralpak AD-H column (4.6×150 mm) with 95% EtOH/MeOH at 0.6 mL/min. Collect peak at 12.6 min followed by rotary evaporation to give 156 mg (33.2%) of 4-(3-phenylindole-1-sulfonyl)-N-(tetrahydrofuran-3-ylmethyl)benzamide isomer 2. MS (m/e): 460.96 (M+1); 459.04 (M−1).
EXAMPLE 265
(3-Hydroxymethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]methanone
Dissolve azetidine-1,3-dicarboxylic acid mono-tert-butyl ester (300 mg, 1.50 mmoL) in THF (5.0 mL) and treat with lithium aluminum hydride (1.0M in ether, 3.0 mL, 3.0 mmol). Stir for 18 hours, quench with 3.0 mL of 1.0M NaOH, dilute with ether, filter through celite and evaporate. Treat the resulting 3-hydroxymethyl-azetidine-1-carboxylic acid tert-butyl ester with 10 mL of trifluoroacetic acid for 20 minutes an evaporate. Use this material without further purification. Combine 4-(3-Phenyl-indole-1-sulfonyl)-benzoic acid (100 mg, 0.26 mmol) and the resulting azetidin-3-yl-methanol in dichloromethane (1.0 mL) and triethylamine (0.100 mL, 0.717 mmol, excess) and add benzotriazol-1-yloxytris(dimethylamino)phosphonium hexfluorophosphate (BOP Reagent) (150 mg, 0.33 mmol, excess) at room temperature. Stir for 30 minutes, evaporate and load entire reaction directly onto pre-packed silica gel column and purify by flash column chromatography (EtOAc/Hexanes) to give 41 mg of (3-Hydroxymethyl-azetidin-1-yl)-[4-(3-phenyl-indole-1-sulfonyl)-phenyl]-methanone as a white solid (35%). LRMS: MH+ 447.2.
EXAMPLE 266
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-(tetrahydro-pyran-4-ylmethyl)-benzamide
In a 12 L RBF, charge 4-(3-Cyclopentyl-indole-1-sulfonyl)-benzoic acid (400 g, 1.084 mol) and THF (3.6 L) and cool the solution to 5° C., and add 4-methylmorpholine (121 g, 1.192 mol). Add CDMT (209 g, 1.192 mol) over a 5 minute period and stir for 1 hour at 5° C. Add a solution of 4-aminomethyltetrahydropyran (150 g, 1.300 mol) and THF (500 ml) drop-wise over a 1 hour period at 5° C. Remove the cooling bath and stir the reaction for 75 minutes. Cool the solution to 10° C. and quench with 1N HCl (4 L). Add ethyl acetate (2.5 L), DI water (2 L) and back extract the aqueous layer with ethyl acetate (2 L). Wash the organic layers with saturated sodium bicarbonate (3 L), brine (3 L), dry over sodium sulfate, filter and concentrate under vacuum to give 575 g of an oil/foam. Purify the crude material by silica plug filtration and slurry in methanol (2 L) for 2 hours. Cool the slurry to 5° C., stir for 2 hours, filter, rinse with methanol (0.5 L) and dry at 45° C. in a vacuum oven to provide 485 g of a white solid (yield=96%) of the title compound demonstrating two melts one at 136-138° C. and a second at 153-155° C.
EXAMPLE 267
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide
In a 22 L RBF, charge 4-(3-Cyclopentyl-indole-1-sulfonyl)-benzoic acid (435 g, 1.177 mol) and THF (4 L). and cool the solution to 5° C., and add 4-methylmorpholine (131 g, 1.295 mol). Add CDMT (227 g, 1.295 mol) in one portion and stir for 1 hour at 5° C. Add a solution of 4-fluorobenzylamine (162 g, 1.295 mol) and THF (500 ml) drop-wise over a 1 hour period at 5° C. Remove the cooling bath and stir the reaction wa for 120 minutes. Cool the solution to 10° C. and quench with 1N HCl (4 L). Add ethyl acetate (3 L), DI water (3 L) and back extract the aqueous layer with ethyl acetate (3 L). Wash the organic layers with saturated sodium bicarbonate (3 L), brine (3 L), dry over sodium sulfate, filter and concentrate under vacuum to give 575 g of an amber oil/foam. Purify the crude material by silica plug filtration and slurry in methanol (2 L) for 17 hours. Cool the slurry to 5° C., stir for 1 hour, filter, rinse with methanol (0.75 L) and dry at 45° C. in a vacuum oven to provide 450 g of a white solid (yield=80.2%) of the title compound having a single melt ranging from 118° C. to 121° C.; 1 H NMR (DMSO) d 9.2 (t, 1H), 8.1 (m, 2H), 7.95(m, 2H), 7.9 (d, 1H), 7.6 (d, 1H), 7.5 (s, 1H), 7.3 (m, 4H), 7.1 (t, 2H), 4.4 (dd, 2H), 3.1 (t, 1H), 2.05 (m, 2H), 1.7 (m, 6H). % Theory C, 68.0484; H, 5.2876; N, 5.8781; % Found C, 68.0; H, 5.13; N, 5.88.
EXAMPLE 268
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-pyridin-3yl-methyl-benzamide
Stir a mixture of 4-(3-Cyclopentyl-indole-1-sulfonyl)-benzoic acid (0.188 g, 0.50 mmol), PyBOP (0.0.288 g, 0.50 m mol), and 3-amino-pyridine (0.063 g, 0.59 mmol) in dry CH 2 Cl 2 (10 mL) under N 2 add Hunigs base (0.148 g, 0.200 mL, 1.11 mmol). Stir overnight the reaction at ambient temperature and evaporate on the rotary evaporator. Chromatograph the residue on the ISCO using a 40 g column and a hexane-EtOAc gradient system (0-100%) to give 0.048 g of the title compound as a white foam. Mass spectrum (m/e) (M+H) 460.1697; found 460.1681.
EXAMPLE 269
4-(3-Cyclopentyl-indole-1-sulfonyl)-n-isobutyl-benzamide
Stir to a mixture of 4-(3-Cyclopentyl-indole-1-sulfonyl)-benzoic acid (0.163 g, 0.44 m mol), PyBOP (0.226 g, 0.51 mmol), and isobutylamine (0.038 g, 0.52 mmol) in dry CH 2 Cl 2 (10 mL) under N 2 add Hunigs base (0.148 g, 0.11 mmol). Stir the reaction overnight at ambient temperature and evaporate on the rotary evaporator. Chromatograph the residue on the ISCO using a 40 g column and a hexane-EtOAc gradient system (0-100%) to give 0.110 g of the title compound as a white foam. Mass spectrum (m/e) (M+H) 425.1899; found 460.1925.
EXAMPLE 270
N-(4-Fluoro-benzyl)-4-(3-isopropyl-indole-1-sulfonyl)-benzamide
Stir a mixture of 3-isopropyl indole in dry DMF (20 ml) under N 2 add potassium t-butoxide 1.0 M (1.2 ml, 1.2 mmol) dropwise. Stir the resulting solution for 30 minutes at ambient temperature. Add 4-(4-Fluoro-benzylcarbamoyl)-benzenesulfonyl chloride (0.360 g, 0.1.1 mmol) portionwise and stir the resulting mixture overnight. Pour the reaction mixture into a mixture of EtOAc—H 2 O. Separate the EtOAc layer, extract with H 2 O wash with brine and dry (MgSO 4 ) Filter and evaporate to give the crude product. Chromatograph on the ISCO eluting with hexane-EtOAc to give a white solid (0.150 g). Mass spectrum (m/e) (M+H) 451.1492; found 451.1488.
EXAMPLE 271
N-Cyclopropylmethyl-4-(3-isopropyl-indole-1-sulfonyl)-benzamide
Stir mixture of 4-(3-isopropyl-indole-1-sulfonyl)-benzoic acid (0.181 g, 0.53 mmol), PyBOP (0.243 g, 0.55 mmol) and cyclopropylmethyl amine (0.064 g, 0.59 mmol) in CH 2 Cl 2 (20 mL) add Hunigs base (0.28 mL, 1.62 mmol) under N 2 . Stir the resulting mixture overnight at ambient temperature. Extract the reaction with H 2 O, wash with brine dry (MgSO 4 ), filter, evaporate and chromatograph using hexane-EtOAc (0-100%) to give 0.183 g of the title compound as an off white solid: Mass spectrum (m/e) (M+H) 397.1593; found 397.1586.
EXAMPLE 272
4-(3-Cyclopentyl-2,3-dihydro-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide
Add 4-(3-cyclopentyl-indole-1-sulfonyl)-N-(4-fluoro-benzyl)-benzamide (0.152 g, 0.319 mmol) portionwise to a stirring mixture of NaCNBH 3 (0.096 g, 1.52 mmol) in TFA at 0 to 5° C. under N 2 . Stir the mixture for 15 minutes at 0-5° C., allow to warm to ambient temperature and add an additional 0.096 g NaCNBH 3 . Stir the resulting yellow solution for 2 h at ambient temperature, dilute with H 2 O (13.0 mL) and stir overnight. Pour the reaction mixture is into EtOAc (100 mL). Separate the EtOAc, extract with H 2 O, 5% NaHCO 3 and wash with brine. Separate the EtOAc, dry (MgSO 4 ), filter and evaporate giving a glass. Chromatograph on the chromatotron eluting with EtOAc-hexane 3:7 to give 0.060 g of the title compound: Mass spectrum (m/e) (M+H) 479.1805; found 479.1788.
EXAMPLE 273
N-(4-Fluoro-benzyl)-4-(3-methyl-2,3-dihydro-indole-1-sulfonyl)-benzamide
Add N-(4-Fluoro-benzyl)-4-(3-methyl-indole-1-sulfonyl)-benzamide (0.106 g, 0.25 mmol) portionwise to a stirring mixture of NaCNBH 3 (0.074 g, 1.2 mmol) in TFA (5.0 mL) at 0 to 5° C. under N 2 . Stir the mixture for 15 minutes at 0-5° C., allow to war to ambient temperature and stir for 1 h. add NaCNBH 3 (0.074 g, 1.2 mmol) and stir the reaction is for 2 h dilute with H 2 O (13.0 mL) and work up as described in the above example. Chromatograph and elute with EtOAc-hexane (0-50%) to give 0.075 g of the title compound: Mass spectrum (m/e) (M+H) 425.1335; found 425.1341.
EXAMPLE 274
N-(4-Fluoro-benzyl)-4-(3-phenyl-2,3-dihydro-indole-1-sulfonyl)-benzamide
Stir 3-phenyl-2,3-dihydro-1H indole (0.233 g, 1.19 mmol), 4-(4-fluoro-benzylcarbamoyl)-benzenesulfonyl chloride (1 equiv.), Et 3 N (0.50 mL, 0.36 g, 3.57 mmol), DMAP (0.015 g, 0.123 mmol) in CH 2 Cl 2 (45 mL) overnight under N 2 . Dilute the CH 2 Cl 2 to 150 mL and pour into a saturated solution of NaHCO 3 (50 mL) and stir for 15 minutes. Separate the organic layer and wash with H 2 O (100 mL), extract with 1N HCl (2×75 mL), wash with brine, separate and dry (MgSO 4 ). Filter and evaporate followed by chromatography on the ISCO using a 40 g silica gel column and elute with EtOAc-hexane 90-100%) to give 0.33 g of the racemic compound.
EXAMPLE 274a
N-(4-Fluoro-benzyl)-4-(3-phenyl-2,3-dihydro-indole-1-sulfonyl)-benzamide Isomer 1
Separate N-(4-Fluoro-benzyl)-4-(3-phenyl-2,3-dihydro-indole-1-sulfonyl)-benzamide via chromatograph separation on chiracel OD (column 90.46×25 cm) (EtOAc-hexane 90-100%) 1.0 mL/min to give (isomer 1) (0.60 g) retention time 5.45 min
EXAMPLE 274b
N-(4-Fluoro-benzyl)-4-(3-phenyl-2,3-dihydro-indole-1-sulfonyl)-benzamide Isomer 2
Continue to separate Example 274a via chromatograph separation on chiracel OD (column 90.46×25 cm) (EtOAc-hexane 90-100%) 1.0 mL/min to give (isomer 2) (0.61 g) retention time 7.21 min.
EXAMPLE 275
4-[3-(3-Cyano-phenyl)-indole-1-sulfonyl]-N-(4-fluoro-benzyl)-benzamide
Stir N-(4-Fluoro-benzyl)-4-{3-(4,4,5,5-tetramethyl-[1,3,2]dioxaboralan-2yl)-indole-1-sulfonyl}-benzamide (0.267 g, 0.50 mmol), 3-bromobenzonitrile (0.160 g, 0.55 mmol), PdCl 2 (dppf).CH 2 Cl 2 (0.032 g, 0.039 mmol) and 2M Na 2 CO 3 (0.50 mL, 1.0 mmol) and heat in dioxane (20 mL) at 81° C. under N 2 for 6 h. Concentrate the reaction and chromatograph the residue on the ISCO using a 12 g silica gel column and eluting with hexane-EtOAc (0-100%) to give the title compound as a light tan foam 0.100 g Mass spectrum (m/e) (M+H) 510.1288; found 510.1283.
EXAMPLE 276
N-(4-Fluoro-benzyl)-4-(3-thiazol-2-yl-indole-1-sulfonyl)-benzamide
Stir N-(4-Fluoro-benzyl) 4 -{3-(4,4,5,5-tetramethyl-[1,3,2]dioxaboralan-2yl)-indole-1-sulfonyl}-benzamide (0.267 g, 0.50 mmol), 2-bromothiazole (0.090 g, 0.55 mmol), PdCl 2 (dppf).CH 2 Cl 2 (0.032 g, 0.039 mmol) and 2M Na 2 CO 3 (0.25 mL, 0.50 mmol) and heat in dioxane (20 mL) at 99° C. under N 2 for 14 h. Concentrate the reaction mixture to dryness and chromatograph the residue on the ISCO, using a 12 g silica gel column and eluting with hexane-EtOAc (5-100%) to give the title compound as a white solid. Mass spectrum (m/e) (M+H) 492.0852; found 492.0848.
EXAMPLE 277
4-(3-Cyclopentyl-indole-1-sulfonyl)-N-(5-fluoro-pyridin-2-yl-methyl)-benzamide
Stir mixture of 4-(3-Cyclopentyl-indole-1-sulfonyl)-benzoic acid (0.767 g, 0.0.21 m mol), C-(5-fluoro-pyridin-2yl)-methylamine (0.041 g, 0.25 mmol), and EDC (0.063 g, 0.33 mmol) in dry CH 2 Cl 2 (15 mL) under N 2 and add DMAP (0.061 g, 0.50 mmol.). Stir the resulting mixture at ambient temperature for 72 h Dilute the reaction mixture to 50 mL with CH 2 Cl 2 , wash with H 2 O, 1N NaOH, and brine sequentially. Dry the organic layer (MgSO 4 ), filter and evaporate to give 0.189 g of crude product. Chromatograph on the ISCO using a 12 g column and eluting with Hexane-EtOAc (0-100%) to gives the title compound 0.60 g as a foam:
Calcd. for: C 26 H 24 FN 3 O 3 ; C, 65.39; H, 5.066; N, 8.79. Found: C, 65.50; H, 5.26; N, 8.61.
EXAMPLE
CB1 and CB2 GTPγ 35 S Binding Assays
CB1 and CB2 GTPγ 35 S binding assays were run essentially as described in DeLapp et al. in pH 7.4 buffer containing 20 mM HEPES, 100 mM NaCl and 5 mM MgCl 2 (NaCl was omitted from rat brain membrane assay) in a final volume of 200 μl in 96-well Costar plates at 25° C. 100 μl of membrane preparation (25 μg protein per well for CB1 or CB2 Sf9 cell membranes, 15-18 μg per well for rat cerebellar membranes) containing the appropriate concentration of GDP (1 μM GDP for CB1 Sf9 cell membranes, 0.05 μM for CB2 Sf9 cell membranes, 25 μM GDP for rat cerebellar membrane assays) was added to each well followed by the addition of 50 μl of buffer±test compounds or controls and then the plates were incubated for 30 minutes. Next 50 μl of GTPγ 35 S was added to a final concentration of 400 pM in each well and the plates were incubated for another 30 minutes. After that, 20 μl of 0.27% Nonidet P-40 was added with a 30 minute incubation before the addition of 20 μl/well of a 1/400 to 1/100 final dilution anti-GαI(1-3) antibody (rabbit antibody to BSA-conjugated peptide KNNLKECGLY) with a 60 minute incubation. 50 μl of SPA beads (PVT; anti-rabbit antibody) resuspended in 20 mL assay buffer were then added to each well. After 180 min, plates are centrifuged at 900 g for 10 min and G-protein bound radioactivity was measured using a Wallac plate counter.
DeLapp N W. McKinzie J H. Sawyer B D. Vandergriff A. Falcone J. McClure D. Felder C C. Determination of [ 35 S]guanosine-5′-O-(3-thio)triphosphate binding mediated by cholinergic muscarinic receptors in membranes from Chinese hamster ovary cells and rat striatum using an anti-G protein scintillation proximity assay. [Journal Article] Journal of Pharmacology & Experimental Therapeutics. 289(2):946-55, 1999 May.
In this test, the IC 50 of the compounds of formula (I) is less than or equal to 5 μM.
The utilities of the present compounds in treating or preventing diseases or disorders may be demonstrated in animal disease models that have been reported in the literature. The following are examples of such animal disease models: a) suppression of food intake and resultant weight loss in rats (Life Sciences 1998, 63, 113-117); b) reduction of sweet food intake in marmosets (Behavioural Pharm. 1998, 9, 179-181); c) reduction of sucrose and ethanol intake in mice (Psychopharm 1997, 132, 104-106); d) increased motor activity and place conditioning in rats (Psychopharm. 1998, 135, 324-332; Psychopharmacol 2000, 151: 25-30); e) spontaneous locomotor activity in mice (J. Pharm. Exp. Ther. 1996, 277, 586-594); and f) reduction in opiate self-administration in mice (Sci. 1999, 283, 401-404).
The administration of the compound of structural formula I in order to practice the present methods of therapy is carried out by administering an effective amount of the compound of structural formula I to the patient in need of such treatment or prophylaxis. The need for a prophylactic administration according to the methods of the present invention is determined via the use of well-known risk factors. The effective amount of an individual compound is determined, in the final analysis, by the physician in charge of the case, but depends on factors such as the exact disease to be treated, the severity of the disease and other diseases or conditions from which the patient suffers, the chosen route of administration other drugs and treatments which the patient may concomitantly require, and other factors in the physician's judgment.
The magnitude of prophylactic or therapeutic dose of a compound of Formula I will, of course, vary with the nature of the severity of the condition to be treated and with the particular compound of Formula I and its route of administration. It will also vary according to the age, weight and response of the individual patient. In general, the daily dose range lie within the range of from about 0.001 mg to about 100 mg per kg body weight of a mammal, preferably 0.01 mg to about 50 mg per kg, and most preferably 0.1 to 10 mg per kg, in single or divided doses. On the other hand, it may be necessary to use dosages outside these limits in some cases.
For use where a composition for intravenous administration is employed, a suitable dosage range is from about 0.001 mg to about 25 mg (preferably from 0.01 mg to about 1 mg) of a compound of Formula I per kg of body weight per day and for cytoprotective use from about 0.1 mg to about 100 mg (preferably from about 1 mg to about 100 mg and more preferably from about 1 mg to about 10 mg) of a compound of Formula I per kg of body weight per day.
In the case where an oral composition is employed, a suitable dosage range is, e.g. from about 0.01 mg to about 100 mg of a compound of Formula I per day, preferably from about 0.1 mg to about 10 mg per day. For oral administration, the compositions are preferably provided in the form of tablets containing from 0.01 to 1,000 mg, preferably 0.01, 0.05, 0.1, 0.5, 1.0, 2.5, 5.0, 10.0, 15.0, 20.0, 25.0, 30.0, 40.0, 50.0 or 1000.0 milligrams of the active ingredient for the symptomatic adjustment of the dosage to the patient to be treated.
For the treatment of diseases of the eye, ophthalmic preparations for ocular administration comprising 0.001-1% by weight solutions or suspensions of the compounds of Formula I in an acceptable ophthalmic formulation may be used.
Another aspect of the present invention provides pharmaceutical compositions which comprises a compound of Formula I and a pharmaceutically acceptable carrier. The term “composition”, as in pharmaceutical composition, is intended to encompass a product comprising the active ingredient, preferably present in pharmaceutically effective amounts, and the inert ingredient(s) (pharmaceutically acceptable excipients) that make up the carrier, as well as any product which results, directly or indirectly, from combination, complexation or aggregation of any two or more of the ingredients, or from dissociation of one or more of the ingredients, or from other types of reactions or interactions of one or more of the ingredients. Accordingly, the pharmaceutical compositions of the present invention encompass any composition made by admixing a compound of Formula I and pharmaceutically acceptable excipients.
Any suitable route of administration may be employed for providing a mammal, especially a human with an effective dosage of a compound of the present invention. For example, oral, rectal, topical, parenteral, ocular, pulmonary, nasal, and the like may be employed. Dosage forms include tablets, troches, dispersions, suspensions, solutions, capsules, creams, ointments, aerosols, suppositories and the like.
The pharmaceutical compositions of the present invention comprise a compound of Formula I as an active ingredient or a pharmaceutically acceptable salt thereof, and may also contain a pharmaceutically acceptable carrier and optionally other therapeutic ingredients. By “pharmaceutically acceptable” it is meant the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof. In particular, the term “pharmaceutically acceptable salts” refers to salts prepared from pharmaceutically acceptable non-toxic bases or acids including inorganic bases or acids and organic bases or acids. The compound may be present in crystalline form or may be incorporated into the pharmaceutical composition as an amorphous solid. Alternatively, the compound may be rendered partially or totally amorphous by the manufacturing process.
The compositions include compositions suitable for oral, rectal, topical, parenteral (including subcutaneous, intramuscular, and intravenous), ocular (ophthalmic), pulmonary (aerosol inhalation), or nasal administration, although the most suitable route in any given case will depend on the nature and severity of the conditions being treated and on the nature of the active ingredient. They may be conveniently presented in unit dosage form and prepared by any of the methods well-known in the art of pharmacy.
For administration by inhalation, the compounds of the present invention are conveniently delivered in the form of an aerosol spray presentation from pressurized packs or nebulizers. The compounds may also be delivered as powders which may be formulated and the powder composition may be inhaled with the aid of an insufflation powder inhaler device. The preferred delivery systems for inhalation are metered dose inhalation (MDI) aerosol, which may be formulated as a suspension or solution of a compound of Formula I in suitable propellants, such as fluorocarbons or hydrocarbons and dry powder inhalation (DPI) aerosol, which may be formulated as a dry powder of a compound of Formula I with or without additional excipients.
Suitable topical formulations of a compound of formula I include transdermal devices, aerosols, creams, ointments, lotions, dusting powders, and the like. Topical preparations containing the active drug component can be admixed with a variety of carrier materials well known in the art such as, e.g., alcohols, aloe vera gel, allantoin, glycerine, vitamin A and E oils, mineral oil, PPG2 myristyl propionate, and the like. To be administered in the form of a transdermal delivery system, the dosage administration will, of course, be continuous rather than intermittent throughout the dosage regimen.
The compounds of the present invention can also be administered in the form of liposome delivery systems, such as small unilamellar vesicles, large unilamellar vesicles and multilamellar vesicles. Liposomes can be formed from a variety of phospholipids, such as cholesterol, sterylamine or phosphatidylcholines.
The compounds of the present invention may also be coupled with soluble polymers as targetable drug carriers. Such polymers can include polyvinylpyrrolidone, pyran copolymer, polyhydroxypropylmethacrylamide phenol, polyhydroxyethylasparamidepheon, or polyethyleneoxidepolylysine substituted with palmitoyl residues. Furthermore, the compounds of the present invention may be coupled to a class of biodegradable polymers useful in achieving controlled release of a drug, for example, polylactic acid, polyepsilon caprolactone, polyhydroxybutyric acid, polyorthoesters, polyacetals, polydihydropyrans, polycyanoacrylates and cross-linked or amphipathic block copolymers of hydrogels.
Compounds of the present invention may also be delivered as a suppository employing bases such as cocoa butter, glycerinated gelatin, hydrogenated vegetable oils, mixtures of polyethylene glycols of various molecular weights and fatty acid esters of polyethylene glycol.
In practical use, the compounds of Formula I can be combined as the active ingredient in intimate admixture with or solubilization in a pharmaceutical carrier according to conventional pharmaceutical compounding techniques. The carrier may take a wide variety of forms depending on the form of preparation desired for administration, e.g., oral or parenteral (including intravenous). In preparing the compositions for oral dosage form, any of the usual pharmaceutical media may be employed, such as, for example, water, glycols, simple oils, fractionated or chemically-modified glycerides, polyoxyethylene-polyoxypropylene co-polymers, alcohols, surface active agents, flavoring agents, preservatives, coloring agents and the like in the case of oral liquid preparations, such as, for example, suspensions, elixirs and solutions; or carriers such as starches, sugars, microcrystalline cellulose, diluents, granulating agents, lubricants, binders, disintegrating agents and the like in the case of oral solid preparations such as, for example, powders, capsules and tablets, with the solid oral preparations being preferred over the liquid preparations. The carrier may possess special properties for controlling or modifying the release and subsequent absorption profile of the drug substance, said properties including but not limited to self-emulsification, or controlled disintegration, dissolution or solubilization in vivo. Because of their ease of administration, tablets and capsules represent the most advantageous oral dosage unit form in which case solid pharmaceutical carriers are obviously employed. If desired, tablets may be coated by standard aqueous or nonaqueous techniques.
In addition to the common dosage forms set out above, the compounds of Formula I may also be administered by controlled release means and/or delivery devices such as those described in U.S. Pat. Nos. 3,845,770; 3,916,899; 3,536,809; 3,598,123; 3,630,200 and 4,008,719.
Pharmaceutical compositions of the present invention suitable for oral administration may be presented as discrete units such as capsules, cachets or tablets each containing a predetermined amount of the active ingredient, as a powder or granules or as a solution or a suspension in an aqueous liquid, a non-aqueous liquid, an oil-in-water emulsion or a water-in-oil liquid emulsion. Such compositions may be prepared by any of the methods of pharmacy but all methods include the step of bringing into association the active ingredient with the carrier which constitutes one or more necessary ingredients. In general, the compositions are prepared by uniformly and intimately admixing the active ingredient with liquid carriers or finely divided solid carriers or both, and then, if necessary, shaping the product into the desired presentation. For example, a tablet may be prepared by compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine, the active ingredient in a free-flowing form such as powder or granules, optionally mixed with a binder, lubricant, inert diluent, surface active or dispersing agent. Molded tablets may be made by molding in a suitable machine, a mixture of the powdered compound moistened with an inert liquid diluent. Hard or soft gelatin capsules may be prepared by filling either with dry powder or granule formulations or by filling with a liquid formulation compatible with the capsule shell. Desirably, each tablet contains from 0.01 to 500 mg, particularly 0.01, 0.05, 0.1, 0.5, 1.0, 2.5, 3.0, 5.0, 6.0, 10.0, 15.0, 25.0, 50.0, 75, 100, 125, 150, 175, 180, 200, 225, and 500 milligrams of the active ingredient for the symptomatic adjustment of the dosage to the patient to be treated. And each cachet or capsule contains from about 0.01 to 500 mg, particularly 0.01, 0.05, 0.1, 0.5, 1.0, 2.5, 3.0, 5.0, 6.0, 10.0, 15.0, 25.0, 50.0, 75, 100, 125, 150, 175, 180, 200, 225, and 500 milligrams of the active ingredient for the symptomatic adjustment of the dosage to the patient to be treated.
Exemplifying the invention is a pharmaceutical composition comprising any of the compounds described above and a pharmaceutically acceptable carrier. Also exemplifying the invention is a pharmaceutical composition made by combining any of the compounds described above and a pharmaceutically acceptable carrier. An illustration of the invention is a process for making a pharmaceutical composition comprising combining any of the compounds described above and a pharmaceutically acceptable carrier.
The dose may be administered in a single daily dose or the total daily dosage may be administered in divided doses of two, three or four times daily. Furthermore, based on the properties of the individual compound selected for administration and/or the characteristics of the dosage form (i.e., modified release), the dose may be administered less frequently, e.g., weekly, twice weekly, monthly, etc. The unit dosage may be correspondingly larger for the less frequent administration.
When administered via transdermal routes or through a continual intravenous solution, the dosage administration will, of course, be continuous rather than intermittent throughout the dosage regimen.
The following are examples of representative pharmaceutical dosage forms for the compounds of Formula I:
Injectable Suspension (I.M.)
mg/mL
Compound of Formula I
10
Methylcellulose
5.0
Tween 80
0.5
Benzyl alcohol
9.0
Benzalkonium chloride
1.0
Water for injection to a total volume of 1 mL
Tablet
mg/tablet
Compound of Formula I
25
Microcrystalline Cellulose
415
Povidone
14.0
Pregelatinized Starch
43.5
Magnesium Stearate
2.5
500
Capsule (Dry Fill)
mg/capsule
Compound of Formula I
25
Lactose Powder
573.5
Magnesium Stearate
1.5
600
Capsule (Liquid Fill)
mg/capsule
Compound of Formula I
25
Peanut oil
575
600
Capsule (Semi-solid Fill, self-emulsifying)
mg/capsule
Compound of Formula I
25
Gelucire 44/14
575
600
Capsule (Liquid Fill, Self-Emulsifying)
mg/capsule
Compound of Formula 1
25
Sesame Oil
125
Cremophor RH40
300
Peceol
150
600
Aerosol
Per canister
Compound of Formula I
24
mg
Lecithin, NF Liq. Conc.
1.2
mg
Trichlorofluoromethane, NF
4.025
g
Dichlorodifluoromethane, NF
12.15
g
The above dosage form examples are representative. The amount of the compound present in compositions is such that a suitable dosage will be obtained; Preferred compositions and preparations according to the present invention may be determined by a person skilled in the art. | Novel compounds of structural formula (I) are disclosed. As modulators of the Cannabinoid-1 (CB1) receptor, these compounds are useful in the treatment, prevention and suppression of diseases mediated by the CB1 receptor. As such, compounds of the present invention are useful as in the treatment, prevention and suppression of psychosis, memory deficits, cognitive disorders, migraine, neuropathy, neuro-inflammatory disorders (e.g., multiple sclerosis, Guillain-Barre syndrome and the inflammatory sequelae of viral encephalitis), cerebral vascular accidents, head trauma, anxiety disorders, stress, epilepsy, Parkinson's disease, and schizophrenia. The compounds are also useful for the treatment of substance abuse disorders, particularly to opiates, alcohol, and nicotine. The compounds are also useful for the treatment of obesity or eating disorders associated with excessive food intake and complications associated therewith | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2000-305402, filed Oct. 4, 2000, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a semiconductor integrated circuit device, more specifically, the invention relates to a semiconductor memory device capable of trimming of chip internal timing by fuse blow and redundancy replacement.
[0004] 2. Description of the Related Art
[0005] In recent year, along with the ultra fine level of semiconductor manufacturing processes and the high speed of semiconductor memory devices to meet the high speed of system clocks, action margin in circuits has become small and it has been very difficult to optimize circuit actions.
[0006] Further, process fluctuations owing to complicated manufacturing processes have caused characteristics of transistor and resister to go out of the initial design targets, which in turn has made it more difficult to optimize circuit actions.
[0007] For the purpose of the optimization of circuit actions and the improvement of yield, in ordinary cases, in consideration of the influences by these process fluctuations and the like, a fuse set for trimming circuit characteristics and a fuse set for replacing redundancy of queue addresses are arranged in a chip.
[0008] With respect to fuses, a laser fuse wherein a fuse of polysilicon, metal and the like is blown by a laser beam is generally employed, while with a laser fuse, it is not possible to trim a chip after packaging, as a result, in recent years, an electric fuse wherein a fuse can be blown electrically even after packaging has come to be employed in chips.
[0009] [0009]FIG. 15 is a block diagram showing a typical constitution of such semiconductor memory device described above.
[0010] As shown in FIG. 15, a semiconductor memory device includes the number n of fuses in total, and comprises a fuse set block (Fuse Block) 1 that outputs fuse data F<n> for trimming circuit characteristics, a clock generating circuit (Control Clock Generator) 2 that can trim the generation timing of an internal clocks CLK_P/CLK_O/CLK_I to control actions of chip inside, a peripheral circuit 3 that is controlled by the internal clocks CLK_P/CLK_O/CLK I generated from the clock generating circuit 2 , an I/O circuit 4 consisting of 2 circuits, i.e., a data output buffer (Data Out Buffer) and a data input buffer (Data In Buffer), and a memory cell array 5 in which data read and write are controlled by the circuits 3 and 4 controlled by the internal clocks.
[0011] In the device shown in FIG. 15, the internal clocks CLK_P/CLK_O/CLK_I generated from the clock generating circuit 2 are internal clocks for controlling the peripheral circuit 3 , the data output buffer in the I/O circuit 4 , and the data input buffer respectively.
[0012] The peripheral circuit 3 works in synchronization with the internal clock CLK_P, therefore, by changing the generating timing of the clock CLK_P, the action timing in the peripheral circuit 3 may be changed optionally.
[0013] The data output buffer is a circuit for reading data from the memory cell array to the outside of the chip in synchronization with a rise edge or a fall edge, or both the edges of the internal clock CLK_O, and by changing the generating timing of the clock CLK_O, it is possible to adjust the timing of data output in optional manners.
[0014] While, the data input buffer is a circuit for take data to be written into the memory cell array into the inside of the chip in synchronization with the rise edge, or the fall edge, or both the edges of the internal clock CLK_I, and by changing the generating timing of the clock CLK_I, it is possible to adjust the timing of data input in optional manners.
[0015] In the next place, the whole actions will be explained with the case of trimming of data input timing as an example.
[0016] [0016]FIG. 16A is a diagram showing a relation between an external clock CLK and data DQ, FIG. 16B is a diagram showing a relation between an internal clock CLK_I and an input data D_IN (before trimming), and FIG. 16C is a diagram showing a relation between an internal clock CLK_I and an input data D_IN (after trimming).
[0017] As shown in FIG. 16A, the write data to the memory cell array is input from DQ PAD in synchronization with both the rise edge and the fall edge of the external clock CLK. At this moment, data is input at the timing at which the circuit action margin of the data input buffer becomes maximum to the clock. Namely, when a clock cycle is referred to as T, data is input at the timing at which a set up time Ts of certain input data to the clock and a hold time Th should become T/4.
[0018] In this way, the relation between the clock and the data is optimized at the outside of the chip, however in the actual inside of the chip, such an ideal relation is in fact not attained. This is because there is delay in the generating timing of the internal clock CLK_I owing to process fluctuations, and under the influences of LCR inside of the chip.
[0019] Now, it is assumed that the timing of the internal clock CLK_I is displaced by +Δt from the factors mentioned above. In this case, as shown in FIG. 16B, a setup time Tsi of data input to the chip internal data D_IN becomes T/4+Δt, and the circuit action margin widens, while a hold time Thi of the data input becomes T/4−Δt, and the circuit action margin become small, different from the former case.
[0020] In order to correct such imbalance of the circuit action margin, a fuse that fastens the generating timing of the internal clock CLK_I by −Δt is blown, thereby the internal clock CLK_I is trimmed, and as shown in FIG. 16C, the internal timing is coordinated with the external timing, and thereby the circuit actions are optimized.
[0021] However, since an actual chip is subject to the influence of process fluctuations, even when an identical fuse is blown, a trimming value is not always same, which is the fact at present.
[0022] Accordingly, a trimming method by the fuse blow mentioned above has held a problem that the trimming effect by fuse blow, i.e., whether the blown fuse is actually optimized to the chip concerned or not, can be known only after the fuse concerned is actually blown. As a consequence, trimming amount may be in short, or to excess in cases.
[0023] In other words, in the method for trimming by fuse blow in the prior art, it has been extremely difficult to carry out the optimized trimming to a chip, which has been a problem in the prior art.
[0024] In the method by laser fuse blow carried out before packaging, it is easily confirmed whether a fuse concerned is blown correctly or not, while when using the electric fuse after packaging a chip, there is no means for judging whether the fuse is blown correctly or not, therefore, it is not to be known until the chip is tested in actual manners, which has been another problem with the prior art.
[0025] The above is the case concerning the trimming of clock generating timing, but the conditions are same also in the cases of redundancy replacement of queue addresses.
[0026] In general, in the replacement of queue addresses by redundancy, before carrying out fuse blow, a test is carried out on a redundancy array to be determined by the queue address to be replaced, and on the basis of the result thereof, redundancy replacement is carried out.
[0027] The redundancy cell test is only for testing whether a cell is valid or not, therefore, the test is nor carried out by making a chip work at the same timing as an actual test.
[0028] Consequently, there may be cases where a test is made after redundancy replacement, action is not made correctly owing to mismatch in timing and the like.
[0029] The above inconvenience, as well as the case of the above clock generating timing, comes from the fact that by the current trimming method by fuse blow and the method of redundancy replacement, it is not possible to judge the conditions of a chip after fuse blow, until the fuse is actually blown, which has been still another problem in the prior art.
BRIEF SUMMARY OF THE INVENTION
[0030] A semiconductor integrated circuit device according to an embodiment of the present invention comprises: an integrated circuit portion; a fuse element block including a programmable fuse element; and a data transfer selecting circuit that selects any one of transfer of data programmed in the fuse element to the integrated circuit portion, transfer of data input from outside to the integrated circuit portion, and transfer of data programmed in the fuse element to outside.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0031] [0031]FIG. 1 is a block diagram showing a configuration example of a semiconductor integrated circuit device according to a first embodiment of the present invention.
[0032] [0032]FIG. 2A is a signal waveform diagram showing an example of a relation between an external clock CLK and data DQ.
[0033] [0033]FIG. 2B is a signal waveform diagram showing an example of a relation between an internal clock CLK_I and input data D_IN (before trimming).
[0034] [0034]FIG. 2C is a signal waveform diagram showing an example of a relation between an internal clock CLK_I and input data D_IN (after trimming).
[0035] [0035]FIG. 3 is a circuit diagram showing a circuit example of a trimming register circuit 6 .
[0036] [0036]FIG. 4A is a circuit diagram showing a circuit example of a trimming block selecting circuit 13 .
[0037] [0037]FIG. 4B is a table showing an example of the results of calculations of a data transfer control logic section.
[0038] [0038]FIG. 5 is a diagram showing an example of a condition of a data transfer circuit 14 in a Normal state.
[0039] [0039]FIG. 6 is a diagram showing an example of a condition of a data transfer circuit 14 in a Write state.
[0040] [0040]FIG. 7 is a diagram showing an example of a condition of a data transfer circuit 14 in a Read state.
[0041] [0041]FIG. 8 is a circuit diagram showing a circuit example of a fuse set block 1 .
[0042] [0042]FIG. 9 is a block diagram showing an example of a relation between a trimming register 12 and a trimming block 11 .
[0043] [0043]FIG. 10 is a circuit diagram showing a circuit EXAMPLE of the trimming register 12 .
[0044] [0044]FIG. 11 is a flow chart showing an example of a trimming method using the semiconductor integrated circuit device according to the first embodiment of the present invention.
[0045] [0045]FIG. 12A is a block diagram showing a configuration example of a semiconductor integrated circuit device according to a second embodiment of the present invention.
[0046] [0046]FIG. 12B is a diagram showing a configuration example of a fuse set block which the semiconductor integrated circuit device according to the second embodiment of the present invention.
[0047] [0047]FIG. 13A is a block diagram showing a configuration example of a semiconductor integrated circuit device according to a third embodiment of the present invention.
[0048] [0048]FIG. 13B is a diagram showing a configuration example of a fuse set block which the semiconductor integrated circuit device according to the third embodiment of the present invention has.
[0049] [0049]FIG. 14 is a block diagram showing a configuration example of a semiconductor integrated circuit device according to a fourth embodiment of the present invention.
[0050] [0050]FIG. 15 is a block diagram showing a typical semiconductor integrated circuit device.
[0051] [0051]FIG. 16A is a diagram showing a relation between an external clock CLK and data DQ.
[0052] [0052]FIG. 16B is a diagram showing a relation between an internal clock CLK_I and input data D_IN (before trimming).
[0053] [0053]FIG. 16C is a diagram showing a relation between an internal clock CLK_I and input data D_IN (after trimming).
DETAILED DESCRIPTION OF THE INVENTION
[0054] Hereinafter, embodiments of the present invention will be explained with reference to the accompanying drawings. In the explanation, like parts in each of the several figures are identified by the same reference numerals.
[0055] (First Embodiment)
[0056] [0056]FIG. 1 is a block diagram showing a constitution of a semiconductor integrated circuit device according to a first embodiment of the present invention.
[0057] As shown in FIG. 1, a fuse set block (Fuse Block) 1 includes the number n in total of fuses to be blown by laser, or electric means such as electric current and the like, and outputs a parallel fuse data F<1:n> that shows whether the fuses are blown or not. The parallel fuse data F<1:n> is used as data for trimming circuit characteristics.
[0058] A clock generating circuit (Control Clock Generator) 2 receives an external clock signal CLK 1 , and generates a plurality of internal clock signals CLK_P/CLK_O/CLK_I that controls actions inside of a chip. The clock generating circuit 2 trims the generating timing of the above internal clocks CLK_P/CLK_O/CLK_I into the optimized value on the basis of the above fuse data F<1:n>.
[0059] A peripheral circuit 3 , whose actions are controlled by the internal clock signal CLK_P generated by the clock generating circuit 2 , takes in an external command signal in synchronization with the internal clock signal CLK_P, and carries out calculations, and generates a plurality of address signals of queue and a plurality of internal control signals.
[0060] An I/O circuit 4 includes: a data input buffer (Data In Buffer) that, in synchronization with the internal clock signal CLK_I generated by the clock generating circuit 2 , takes in an external serial data signal having a data width of, for example, q bits and transfers the external serial data signal to an internal serial data signal line having a data width of q bits; and a data output buffer (Data Out Buffer) that, in synchronization with the internal clock signal CLK_O generated by the clock generating circuit 2 , takes in an internal serial data signal having a data width of, for example, q bits and transfers the internal serial data signal to an external serial data signal line having a data width of q bits.
[0061] A memory cell array 5 comprises a plurality of memory cells selected by a plurality of address signals. Reading data from and writing data into the memory cell array 5 is controlled by the peripheral circuit 3 and the I/O circuit 4 .
[0062] Further, the device according to the present embodiment includes a trimming register circuit (Trimming Register Block) 6 that outputs a trimming data signal Ft<n> that trims the generating timing of the internal clock signals CLK_P/CLK_O/CLK_I generated by the clock generating circuit 2 .
[0063] The trimming register circuit 6 converts and outputs any one of the parallel fuse data F<1:n> output from the fuse set block 1 and a data-rewritable and parallel data R<1:n> transferred from a trimming register (whose detailed described hereinafter) arranged in the trimming register circuit 6 as a trimming data Ft<1:n>.
[0064] In the device shown in FIG. 1, the internal clocks CLK_P/CLK_O/CLK_I generated from the clock generating circuit 2 are internal clocks for controlling the peripheral circuit 3 , the data output buffer in the I/O circuit 4 , and the data input buffer respectively.
[0065] In the device according to the present embodiment, as shown in FIGS. 2A to 2 C, as same as in the prior art, by changing the internal clock generating timing, it is possible to adjust the action timing in the peripheral circuit 3 , the data input timing, and the data output timing to the optimized values.
[0066] Hereafter the trimming register circuit 6 in the present embodiment will be explained.
[0067] [0067]FIG. 3 is a circuit diagram showing a circuit constitution example of the trimming register circuit 6 according to the present invention.
[0068] As shown in FIG. 3, the trimming register circuit 6 in the present embodiment comprises three circuits, i.e., trimming blocks (Trimming Block 1 to Trimming Block 3 ) 11 - 1 to 11 - 3 , a trimming register (Trimming Register) 12 that can freely read and write data of n bits, and a trimming block (Trimming Block) selecting circuit 13 .
[0069] The trimming blocks (Trimming Block) 11 - 1 to 11 - 3 are divided for CLK_O, for CLK_I, and for CLK_P, and each of them comprises the number n of data (Data) transfer selecting circuits 14 - 1 to 14 -n same as the number of bits necessary for trimming the internal clocks CLK_O/CLK_P/CLK_I.
[0070] Each of the number n of the data transfer selecting circuits 14 - 1 to 14 -n that output the trimming data Ft<1:n> of n bits comprises two transfer gates, and controls outputting either the data F<1:n> from the fuse set or the data R<1:n> from the trimming register 12 as trimming data Ft<1:n>.
[0071] The control over a gate level of transfer gates in the data transfer selecting circuits 14 - 1 to 14 -n, and the selection of the trimming blocks 11 - 1 to 11 - 3 are made by four control signals PG 1 /NG 1 /PG 2 /NG 2 output from the trimming block selecting circuit 13 .
[0072] The trimming register 12 is a read and write register of bit of the same number as the number of bits necessary for trimming the internal clocks CLK_O/CLK_P/CLK_I.
[0073] The trimming block selecting circuit 13 creates control signals PG 1 /NG 1 /PG 2 /NG 2 for selecting the trimming blocks 11 - 1 to 11 - 3 corresponding to the internal clock that carries out trimming.
[0074] The trimming blocks 11 - 1 to 11 - 3 are divided into three states, i.e., (1) Normal state, (2) Write state, and (3) Read state according to the conditions of the above four control signals PG 1 /NG 1 /PG 2 /NG 2 .
[0075] In the next place, the trimming block selecting circuit 13 will be explained.
[0076] [0076]FIG. 4A is a diagram showing an example a circuit constitution of a trimming block selecting circuit 13 according to the present embodiment.
[0077] As shown in FIG. 4A, the trimming block selecting circuit 13 in the present embodiment comprises a trimming block selecting register (Trimming Block Selecting Register) 21 , and data transfer control logic sections (Data Transfer Control Logic section 1 to Data Transfer Control Logic section 3 ) 22 - 1 to 22 - 3 .
[0078] The data transfer control logic sections 22 - 1 to 22 - 3 are divided into three corresponding to the above trimming blocks 11 - 1 to 11 - 3 . The conditions of the data transfer control logic sections 22 - 1 to 22 - 3 are determined by address signals (Add 1 /Add 2 ) of 2 bits output from the trimming block selecting register 21 , and a mode signal Read that determines the conditions of the trimming blocks.
[0079] [0079]FIG. 4B shows an example of the results of calculations of the data transfer control logic section 22 - 3 to the trimming block 11 - 2 for the internal clock CLK_I.
[0080] As shown in FIG. 4B, when both the addresses Add 1 /Add 2 from the trimming block selecting register 21 are not “HIGH”, the trimming block 11 - 2 gets always in the Normal state. On the contrary, when both the addresses Add 1 /Add 2 are “HIGH”, the trimming block 11 - 2 gets in Read state if the mode signal Read is “HIGH”, while in Write state if the mode signal Read is “LOW”.
[0081] It is determined which of the trimming blocks 11 - 1 to 11 - 3 is selected according to the conditions of the addresses Add 1 /Add 2 input into a NAND logic circuit in the data transfer control logic sections 22 - 1 to 22 - 3 .
[0082] Hereafter there will be explained the three states of the trimming block 11 , i.e., (1) Normal state, (2) Write state, and (3) Read state.
[0083] First (1) Normal state will be explained. FIG. 5 shows a condition of the data transfer circuit 14 in the Normal state.
[0084] In the (1) Normal state, as shown in FIG. 5, a transfer gate TRS 1 is in an ON state, while a transfer gate TRS 2 is in an OFF state. For this reason, trimming data Ft output to the clock generating circuit 2 becomes data F from the fuse set block 1 , and the trimming of the internal clocks is made on the basis of the data F.
[0085] Next, the (2) Write state will be explained hereafter. FIG. 6 shows a condition of the data transfer selecting circuit 14 in the trimming clock 11 in the Write state.
[0086] In the (2) Write state, as shown in FIG. 6, the transfer gate TRS 1 is in the OFF state, while the transfer gate TRS 2 is in the ON state. For this reason, the trimming data Ft output to the clock generating circuit 2 becomes data R from the trimming register 12 . The data R from the trimming register 12 may be set freely by writing data into the trimming register 2 from, for example, an external pad RIO. Therefore, it is possible to freely carry out the trimming of the internal clocks.
[0087] In the next place, the (3) Read state will be explained. FIG. 7 shows a condition of the data transfer circuit 14 in the trimming block 11 in the Read state.
[0088] In the (3) Read state, as shown in FIG. 7, both the transfer gates TRS 1 and TRS 2 are in ON state. As a result, the trimming data Ft output to the clock generating circuit 2 becomes data F from the fuse set block 1 .
[0089] In this case, since the transfer gate TRS 2 is also in the ON state, it is possible to read the data F from the fuse set block 1 , namely, the trimming data Ft, by use of the trimming register 12 through, for example, the external pad RIO.
[0090] Then the fuse set block 1 will be explained.
[0091] [0091]FIG. 8 is a diagram showing an example of a circuit constitution of a fuse set block 1 according to the present embodiment.
[0092] As shown in FIG. 8, the fuse set of the present embodiment comprises a laser fuse block (Laser Fuse Block) 31 , and an electric fuse block (Electric Fuse Block) 32 . For example, a laser melt down type fuse is arranged on the laser fuse block 31 , while for example, a electric current melt down type fuse is arranged on the electric fuse block 32 .
[0093] By such a constitution mentioned above, after a chip is trimmed by a laser fuse before packaging, even if it is required to carry out re-trimming owing to influence by packaging, it is possible to carry out trimming.
[0094] Next, the trimming register 12 will be explained.
[0095] [0095]FIG. 9 is a diagram showing a relation between the trimming register 12 and the trimming block 11 in the present embodiment, while FIG. 10 is a diagram showing an example of a circuit constitution of the trimming register 12 . By the way, in this circuit configuration EXAMPLE , it is supposed that trimming data Ft is of 8 bits.
[0096] As shown in FIG. 9 and FIG. 10, the trimming register 12 includes eight flip flop (FF) circuits 41 - 1 to 41 - 8 , eight multiplex (MX) circuits 42 - 1 to 42 - 8 , eight Write output circuits 43 - 1 to 43 - 8 , and a Read output circuit 44 .
[0097] Each output node fuse<1:n> of the flip flop circuits 41 - 1 to 41 - 8 in this configuration example of the circuit is connected to a first input of the multiplex circuits 42 - 1 to 42 - 8 , and also connected to inputs of the Write output circuits 43 - 1 to 43 - 8 .
[0098] Each output of the Write output circuits 43 - 1 to 43 - 8 is connected to a connection node dREGbit<1:n> between the trimming register 12 and the trimming block. Further, the connection node dREGbit<1:n> is connected to a second input of the multiplex circuits 42 - 1 to 42 - 8 .
[0099] The multiplex circuits 42 - 1 to 42 - 8 respectively select any one of the output node fuse<1:n> and the connection node dREGbit<1:n> on the basis of a signal fuse data en, and connect to the inputs of the flip flop circuits 41 - 2 to 41 - 8 , and the input of the Read output circuit 44 .
[0100] The output of the Read output circuit 44 is connected to a connection node Core Data between the trimming register 12 and the external pad RIO. Further, the connection node Core Data is connected to the input of the flip flop circuit 41 - 1 at the first stage, among the flip flop circuits 41 - 1 to 41 - 8 .
[0101] In the next place, actions thereof will be explained.
[0102] At Write process, first, the flip flop circuits 41 - 1 to 41 - 8 are reset by use of a reset signal fuse rst.
[0103] Further, the signal fuse data en is set to, for EXAMPLE , “HIGH” so that the multiplex circuits 42 - 1 to 42 - 7 respectively select an output node fuse< 1 : 7 >. By the way, the multiplex circuit 42 - 8 at the final stage is controlled by a signal of phase opposite to that of the fuse data en, and at Write process, it does not select an output node fuse< 8 >.
[0104] In this state, data is input in serial manner to the input of the flip flop circuit 41 - 1 at the initial stage from the external pad RIO via the connection node Core Data. The flip flop circuits 41 - 1 to 41 - 8 respectively work in synchronization with a control clock fuse clk, and output the input data according to the fall or rise of the control clock fuse clk. For example, by toggling the control clock fuse clk eight times, data is set to the respective eight flip flop circuits 41 - 1 to 41 - 8 . After data is set, the signal write is set, for example, “HIGH” level, and the Write output circuits 43 - 1 to 43 - 8 are enabled respectively. As a result, the data set to the flip flop circuits 41 - 1 to 41 - 8 is output as data R<1:n> to the trimming block 11 . Thereby, from the trimming block 11 , as mentioned above, the data R<1:n> is output as a trimming data Ft<1:n> to the clock generating circuit 2 .
[0105] While, at Read process, the flip flop circuits 41 - 1 to 41 - 8 are reset by use of the reset signal fuse rst.
[0106] Further, the signal fuse data en is first set, for EXAMPLE , “LOW”, so that the multiplex circuits 42 - 1 to 42 - 7 respectively select the connection node dREGbit< 1 : 7 >. By the way, the multiplex circuit 42 - 8 at the final stage is controlled by a signal of phase opposite to that of the fuse data en, and at this moment, it does not select a connection node dREGbit< 8 >.
[0107] In this state, the data F< 1 : 7 > from the fuse set block 1 is input to the inputs of the flip flop circuits 41 - 2 to 41 - 8 at the initial stage, from the trimming block 11 , via the connection node dREGbit< 1 : 7 >.
[0108] Then, the signal fuse data en is set from “LOW” into “HIGH”, and the multiplex circuits 42 - 1 to 42 - 7 are made to select the output node fuse< 1 : 7 > respectively. At the same time, the multiplex circuit 42 - 8 at the final stage is made to select the connection node dREGbit< 8 >. Thereby, the data F< 8 > from the fuse set block 1 is input to the Read output circuit 44 . In this state, the signal Read is set, for example, “HIGH” level, and the Read output circuit 44 is enabled, thereby the data F< 8 > is output via the connection node Core Data to the external pad RIO.
[0109] Then, the signal fuse data en is set from “HIGH” into “LOW” once again, and the multiplex circuit 42 - 8 at the final stage is made to select the output node fuse< 8 >. Thereby, to the Read output circuit 44 , the data F< 7 > from the fuse set block 1 set in the flip flop circuit 41 - 8 is input, and following the data F< 8 >, the data F< 7 > is output via the connection node Core Data from the external pad RIO.
[0110] Hereafter, the above actions are repeated until the data F< 1 > is output, and thereby, the data F< 1 : 8 > set in the fuse set block 1 can be read.
[0111] In the next place, the entire actions of the present embodiment are explained hereafter.
[0112] First the case of trimming of data input timing will be explained. As same as the prior art, when the internal clock CLCK_I is delayed by +Δt in the chip inside as shown in FIG. 2B, it is required to carry out trimming to fasten by At the generation timing of the internal clock CLK_I by the clock generating circuit.
[0113] When carrying out trimming, in the prior art, it has been not possible to check actual trimming amount and the like until a fuse is actually blown, while according to the present invention, before a fuse if actually blown, the state of the trimming block 11 of the trimming register circuit 6 is set to the Write state, and trimming data same as a trimming forecast value by fuse blow is written in via the trimming register 12 . Thereby, it is possible to check trimming effects in the same conditions as fuse blown state.
[0114] At this stage, if it is judged that expected effects are attained as planned by the trimming data Ft from the trimming register circuit 6 , then a fuse may be blown first.
[0115] On the contrary, if it is judged that effects are insufficient or to excess, the trimming data Ft from the trimming register 6 may be adjusted and optimized, and on the basis of the value, a fuse may be blown.
[0116] [0116]FIG. 11 shows a-flow chart of trimming method in the present invention.
[0117] In the case of carrying out trimming by a laser fuse before a chip is packaged too, first, trimming is carried out on the basis of the data from the trimming register circuit 6 , and a fuse blow value is determined (ST. 1 ).
[0118] Then, according to the above fuse blow value, a laser fuse is blown (ST. 2 ), and it is checked whether the fuse has been blown correctly or not by use of the trimming register (ST. 3 ).
[0119] If the fuse has not been blown (NG), then the procedures go back to fuse blow process, where the fuse is blown once again. If it is found that the fuse has been blown correctly (OK), then the chip is filled into the package (ST. 4 ).
[0120] Then, product test is carried out (ST. 5 ), and if there is no problem, products are shipped (ST. 6 ).
[0121] If trimming is required once again owing to influence of packaging (NG), then by use of the trimming register circuit 6 , a fuse value of trimming by an electric fuse is determined (ST. 7 ).
[0122] In the next place, on the basis of the above fuse value, the electric fuse is blown (ST. 8 ), and it is checked whether the fuse has been blown correctly or not by use of the trimming register circuit 6 (ST. 9 ).
[0123] If the fuse has not blown (NG), then the procedures go back to fuse blow process, where the fuse is blown once again. If it is found that the fuse has been blown correctly (OK), product test is carried out (ST. 10 ), and if there is no problem, products are shipped (ST. 11 ).
[0124] If there is a problem, for example any nonconformity has been found (NG), by use of the trimming register circuit 6 , a fuse value may be determined once again.
[0125] From the above, according to the present invention, it is possible to carry out trimming with the optimized value to all the chips, different from the prior art where it can be found that trimming effects are insufficient or to excess only after a fuse is blown.
[0126] Further, according to the present invention, it is possible to check whether a fuse has been blown correctly or not even after packaging in easy manners by use of the trimming register circuit 6 , therefore, in the case of fuse blow by use of an electric fuse, the invention is also effective in verification of fuse blow.
[0127] By the trimming method shown in FIG. 11, it is possible to remedy a device where fuse blow has been incomplete, as a result, it is possible to increase yield further.
[0128] (Second Embodiment)
[0129] [0129]FIG. 12A is a block diagram showing a constitution of a semiconductor integrated circuit device according to a second embodiment of the present invention. FIG. 12B is a diagram showing a constitution of a fuse set block thereof.
[0130] As shown in FIG. 12A, the semiconductor memory device according to the second embodiment, as well as the first embodiment, includes a fuse set block 1 having fuse data F<n> of the number n in total of fuses for circuit characteristic trimming, a clock generating circuit 2 that can trim the clock generation timing to the optimized value by the fuse data F<n>, a trimming register circuit 6 that creates a trimming data signal Ft<n> to control clock generating circuits, a peripheral circuit 3 controlled by the internal clock generated by the clock generating circuit 2 , an I/O circuit 4 consisting of two circuits, i.e., a data output buffer (Data Out Buffer) and a data input buffer (Data In Buffer), and a memory cell array 5 whose data writing and reading are controlled by the two circuits controlled by the internal clocks.
[0131] However, in this second embodiment, as shown in FIG. 12B, different from the configuration of the fuse set block 1 in the first embodiment, the fuse comprises only a laser fuse 31 .
[0132] In the semiconductor memory device according to the second embodiment of the present invention, in the same manner as in the first embodiment, by use of the trimming register circuit 6 , it is possible to determine the most suitable fuse value by confirming fuse blow effects in advance, and it is possible to carry out trimming to all the chips with the most suitable value.
[0133] (Third Embodiment)
[0134] [0134]FIG. 13A is a block diagram showing a constitution of a semiconductor integrated circuit device according to a third embodiment of the present invention. FIG. 13B is a diagram showing a constitution of a fuse set block thereof.
[0135] As shown in FIG. 13A, the semiconductor memory device according to the second embodiment, as well as the first embodiment, includes a fuse set block 1 having fuse data F<n> of the number n in total of fuses for circuit characteristic trimming, a clock generating circuit 2 that can trim the clock generation timing to the optimized value by the fuse data F<n>, a trimming register circuit 6 that creates a trimming data signal Ft<n> to control clock generating circuits, a peripheral circuit 3 controlled by the internal clock generated by the clock generating circuit 2 , an I/O circuit 4 consisting of two circuits, i.e., a data output buffer (Data Out Buffer) and a data input buffer (Data In Buffer), and a memory cell array 5 whose data writing and reading are controlled by the two circuits controlled by the internal clocks.
[0136] However, in this third embodiment, as shown in FIG. 13B, different from the configuration of the fuse set block in the first and second embodiments, the fuse comprises only an electric fuse 32 .
[0137] In the semiconductor memory device according to the third embodiment of the present invention, in the same manners as in the first and second embodiments, by use of the trimming register circuit 6 , it is possible to determine the most suitable fuse value by confirming fuse blow effects in advance, and it is possible to carry out trimming to all the chips with the most suitable value.
[0138] (Fourth Embodiment)
[0139] [0139]FIG. 14 is a block diagram showing a constitution of a semiconductor integrated circuit device according to a fourth embodiment of the present invention.
[0140] As shown in FIG. 14, the semiconductor memory device according to the fourth embodiment includes a fuse set block 1 comprising of the number n in total of fuses having fuse data F<n> for circuit characteristic trimming, and the number m in total of fuses for redundancy replacement of queue address having fuse data F<m>, a clock generating circuit 2 that can trim the clock generation timing to the optimized value by the fuse data F<n>, a trimming register circuit 6 that creates a trimming data signal Ft<n> to control the clock generating circuits 2 , and a redundancy signal Fr<n> to control the redundancy replacement of queue address, a peripheral circuit 3 controlled by the internal clock generated by the clock generating circuit 2 , and the redundancy signal Fr<m> output from the trimming register circuit 6 , an I/O circuit 4 consisting of two circuits, i.e., a data output buffer (Data Out Buffer) and a data input buffer (Data In Buffer), and a memory cell array 5 whose data writing and reading are controlled by the two circuits controlled by the internal clocks.
[0141] In the semiconductor memory device according to the fourth embodiment of the present invention, in the same manners as in the first, second, and third embodiments, by use of the trimming register circuit 6 , it is possible to determine the most suitable fuse value by confirming fuse blow effects in advance, and it is possible to carry out trimming to all the chips with the most suitable value.
[0142] Furthermore, in the fourth embodiment, in the case of redundancy replacement of queue address too, it is possible to carry out testing in the same conditions as the case where redundancy replacement has been carried out, by the use of the trimming register circuit, therefore, it is possible to conduct a precise redundancy replacement.
[0143] According to the present invention mentioned heretofore with the above first to fourth embodiments, when carrying out the trimming of chip internal timing by fuse blow and the redundancy replacement of queue address, before a fuse if blown actually, trimming of internal timing and redundancy replacement are carried out by use of the register circuit, and on the basis of the results thereof, a fuse value for actual fuse blow is determined.
[0144] By reading the conditions of fuse by use of the above register circuit, it is possible to precisely judge whether fuse blow is successful or not, and to grasp the redundancy replacement information per chip. By this method shown and described heretofore, it is realized to obtain a semiconductor memory device that enables to determine the most suitable fuse value to carry out timing trimming per chip, and to carry out precise redundancy replacement to queue address.
[0145] As described heretofore, the present invention has been explained in reference to the first to fourth embodiments thereof, however, the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof.
[0146] It may be well understood by those skilled in the art that the above respective embodiments may be embodied by single or by combination.
[0147] Further, each of the embodiments mentioned above includes various steps of invention, and by appropriate combinations of a plurality of structural components disclosed in each of the embodiments, it is possible to extract various stages of invention, which is apparent to those skilled in the art.
[0148] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A semiconductor integrated circuit device comprises an integrated circuit portion, a fuse element block, and a data transfer selecting circuit. The fuse element block includes a programmable fuse element. The data transfer selecting circuit selects one of the transfer of data programmed in the fuse element to the integrated circuit portion, transfer of data input from outside to the integrated circuit portion, and transfer of data programmed in the fuse element to outside. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to screw extractors and more particularly to that class of unitary devices which dispose a pilot hole in the screw to be extracted.
2. Description of the Prior Art
The prior art abounds with screw extractors. U.S. Pat. No. 2,863,348 issued on Dec. 9, 1958 to D. L. Conger teaches a twisted surface forming a screw extractor adapted for use by placing the twisted surface in a pilot hole located in the screw.
U.S. Pat. No. 3,263,533 issued on Aug. 2, 1966 to R. H. Carlson discloses an elongated rod having a concentrically aligned cylindrical surface at one end. The cylindrical surface is of smaller diameter than the elongated rod and is provided with metal cutting tapping flutes extending along the length of the cylindrical surface. In use, the tapping threads tap into the walls of a pre-drilled pilot hole in the screw to be extracted, until the shoulder portion delineating the cylindrical surface and the elongated rod portions contact the surface of the screw adjacent the mouth of the hole. Continued rotation causes the screw to be extracted from the hole containing it.
Both of the aforementioned patents suffer the common deficiency of requiring the artisan to first drill the pilot hole and then either employ a manually or power driven screw extractor to remove the screw.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a screw extractor which utilizes a drill machine in a single operation, causing the pilot hole to be drilled and the screw to be then extracted.
Another object is to provide a screw extractor which utilizes a drill machine to rotate an extractible screw out of confinement.
Still another object is to provide a screw extractor which can be operated in an electric drill machine of the handheld variety.
Yet another object is to provide a screw extractor in accordance with the preceding objects which is simple in construction, relatively inexpensive and effective for its particular purposes.
Heretofore, it was necessary to first drill a pilot hole in a screw or bolt resistingly lodged within a body. The artisan could then utilize an electrically operated drill or a hand operated drill or a tapping wrench to apply a screw extracting bit to the hole. By rotating the bit in a preferred direction, the screw is removed from the body. These processes required the artisan to minimally utilize two separate devices, the drill bit and the extractor bit, matching them in size, and if an electrically operated drill machine were utilized for both, required him to sequentially chuck them to the drill machine. The present invention provides a unitary device which firstly drills a pilot hole and then applies the coextensive surface of the extractor bit to the walls of the hole. Size matching is automatic and multiple chucking operations are limited.
These objects, as well as other objects of the present invention, will become more readily apparent after reading the following description of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of the present invention shown adjacent to a body carrying a defective screw; and
FIG. 2 is a side elevation view of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The structure and method of fabrication of the present invention is applicable to a metal cutting twist drill having a flute extending along the entire length thereof. The end of the drill opposite to the end carrying the metal cutting tapered point is affixed to the apex end of a truncated conical metal extractor bit and co-axially aligned thereto. The extractor bit is secured to a shank-like rod at the base portion of the conical surface such that the shank, the extractor bit and the drill bit are each co-axially aligned with each other. The direction of the spiral of the flute of the drill bit and the direction of the spiral groove located in the surface of the extractor bit may be identical or opposed facilitating the removal of right handed and left handed threaded broken screws from within holes located in the body in which they reside. Since most electrically operated drill machines are now available with the capability of being operated in either clockwise or counterclockwise directions, one embodiment of the present invention employs right handed twist drill portions and left handed extractor bit portions. In use the twist drill would extend entirely through the length of the broken screw, so as to place the metal cutting tip of the twist drill beyond the distal end of the screw residing in the cavity in the hole in the body formed by the distal end of the screw and the walls and floor of the hole. Thus, the present invention may be advanced along the length of the pilot hole allowing the apex of the truncated conical surface of the extractor bit to contact the walls of the pilot hole. Reversing the electrically operated drill machine permits the grooves of the extractor bit to bite into the walls of the pilot hole, causing the screw to be threadingly removed from the hole in the body capturing the screw. Alternatively, another embodiment of the present invention is where the drill bit flutes and the extractor bit grooves both extend spirally in the same direction. Since most screws are right handed threads, this direction would be left handed. In use, the electrically operated drill machine would be operated in the counterclockwise direction permitting the drill bit to form a blind hole in the defective screw, if so desired. The metal cutting end of the drill bit would be advanced into or through the screw a sufficient distance to permit the apex of the conical surface of the extractor bit to engage the walls of the pilot hole, druing a period of continuous unidirectional rotation of the electrically operated drill. Left handed defective screws may be removed in similar fashion by utilizing a drill bit portion and an extractor bit portion of the present invention each having a conventional right hand twist. Both of the latter two embodiments do not require reversing the direction of rotation of the electrically operated drill machine or its equivalent.
The diameter of the apex of the conical surface of the extractor bit should substantially match the diameter of the drill bit insuring that the biting surfaces of the extractor bit easily engage the walls of the pilot hole. The rod portion affixed to the widest end of the extractor bit portion serves as a shank for the present invention and should be of a diameter substantially equivalent to the diameter of the base of the extractor bit thereby minimizing breakage due to the high forces required to extract broken screws. An elongated groove may be formed in the conical surface of the extractor bit, extending substantially along the entire length thereof, whose longitudinal axis falls in a plane that passes through the longitudinal axis of the extractor bit. The elongated groove serves to provide additional pilot hole wall grasping surfaces.
Now referring to the Figures, and more particularly to the embodiment illustrated in FIG. 1 showing the present invention 10 comprising a right handed twist drill portion 12 affixed to an extractor bit portion 14 which in turn is affixed to a cylindrical rod portion 16. Chuck 18 attached to an electrically or manually operated drill machine, not shown, provides a rotational force in the direction of arrow 20 to the present invention. Body 22 contains a threaded hole 24 in which a defective screw or bolt 26 threadingly resides. Advancing the present invention in the direction of arrow 28 causes the tapered cutting point 30 of drill portion 12 to contact screw 26 at point 32, drilling a hole therein. If the hole has sufficient depth, end 34 of extractor bit 14 is permitted to engage the walls of the hole so that screw 26 may be extracted from hole 24 by continued rotation of the present invention in the direction of arrow 20.
FIG. 2 shows drill bit portion 12 having a spirally wound flute 36 extending along the length thereof and communicating with cutting point 30. Extractor bit portion 14 is shown having a truncated conical surface 38 in which a spiral groove 40 is located. The apex end 34 of extractor bit portion 14 is shown secured to end 42 of the drill bit portion. Elongated groove 44 extends substantially along the entire length of extractor bit portion 14 providing pilot hole grasping surfaces 46. Rod 16 is shown secured to the base or widest end 48 of extractor bit portion 14.
One of the advantages is to provide a screw extractor which utilizes a drill machine in a single operation, causing the pilot hole to be drilled and the screw to be then extracted.
Another advantage is to provide a screw extractor which utilizes a drill machine to rotate an extractible screw out of confinement.
Still another advantage is to provide a screw extractor which can be operated in an electric drill machine of the handheld variety.
Yet another advantage is to provide a screw extractor in accordance with the preceding advantages which is simple in construction, relatively inexpensive and effective for its particular purposes.
Thus, there is disclosed in the above description and in the drawings, an embodiment of the invention which fully and effectively accomplishes the objects thereof. However, it will become apparent to those skilled in the art, how to make variations and modifications to the instant invention. Therefore, this invention is to be limited, not by the specific disclosure herein, but only by the appending claims. | A screw extractor utilizes a twist drill affixed to one end of an extractor bit having a shank portion suitable for grasping by the chuck end of an electric drill. In use, the drill causes a hole to be formed along the length of the body of the screw to be extracted. Continued rotation in a selected direction of the assembly causes the extractor bit to grasp the walls of the hole. The screw is easily removed without requiring the user to first drill a hole and then manually remove the screw utilizing a separate extractor bit. | 8 |
This is a continuation of application Ser. No. 932,224, filed Aug. 9, 1978.
BACKGROUND OF THE INVENTION
Paper making machines employ endless belt-type screens upon which the paper is deposited. Normally, the paper is deposited in a substantially uniform layer in the center of the screen and the marginal regions on either side, up to about 50 cms wide, do not carry paper. The edge regions of the screen may be in abrading contact with the upper edges of suction boxes and the like which are used to withdraw water from the paper material or for other purposes.
From German application (AS) No. 1,022,089 it has been known to artifically elongate the marginal region of a screen relative to the center thereof and to set the screen fabric in this state. Although this measure increases the lifetime of a screen for a papermaking machine, the lifetime is nevertheless limited by the greater wear on the marginal regions of the screen.
From German application (OS) No. 1,561,679 it has been known to increase the lifetime of a screen for a papermaking machine by selecting a material of higher wear resistance for the longitudinal threads in the marginal regions. However, this publication exclusively relates to screens made from metal alloys.
Consequently, conventional papermachine screens are subject to higher wear in a marginal region of about 50 cm width than in the central region used for papermaking which will be briefly referred to as paper region. Furthermore, there is especially high wear at the format confining strips. The term "marginal region" as used herein shall include also the region of wear caused by the format confining strips and, in general, all regions subject to especially high wear. The exact cause for this greater wear of the marginal regions is unknown. However, it seems to be significant that the marginal regions run outside the suction box openings or on top of the margin of the suction box openings. Attempts have been made to prevent the higher wear of the marginal regions, for instance, by designing the openings of the suction boxes such that the lateral confinements extend obliquely with respect to the travel of the paper machine screen. However, these measures have been only partially successful.
SUMMARY OF THE INVENTION
The invention has as its object to provide a screen for papermaking machines which is not subject to higher wear in the marginal regions that it is in the papermaking region, and to provide a method for producing a screen for papermaking machines which has these properties.
A further object of the invention is a paper machine screen for a paper machine woven of longitudinal and transverse filaments comprising at least said longitudinal filaments being synthetic material capable of elongation under stress; said screen having a paper region and at least one marginal region between said paper region and a lateral edge of said screen; and the longitudinal filaments in said at least one marginal region having lower longitudinal stress when mounted and stressed for operation in said paper machine than the longitudinal filaments in said paper region.
A still further object of the invention is a process for making a paper machine screen comprising the steps of weaving said screen of weft strands and longitudinal warp strands; and tensioning said warp strands in a paper region at a higher stress than said wrap strands in at least one marginal region adjacent said paper region during said weaving.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a paper machine screen according to an embodiment of the present invention.
FIG. 2 is a transverse cross-section of a portion of a paper machine screen taken along II--II in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a paper machine screen 10 is shown according to the invention. The paper machine screen 10 includes a paper region 12 and marginal regions 14. Both regions preferably consist of synthetic resin wires, i.e. of monofilaments, but may also contain multifilament threads. It may be made in any weave, e.g. plain weave, twill and satin weave, and also in multilayer weaves. The marginal region 14 of the screen may contain longitudinal threads interwoven at different tension, longitudinal threads of various materials or of various diameters interwoven alternatingly or in any other sequence.
If another weave is used for the marginal region 14, namely a fewer-stranded weave, a greater volume is available for wear in the marginal region on account of the differently shaped warp and filling arcs.
The advantages attainable by the invention especially reside in the fact that the screen margin or the marginal regions 14 are more elastic than is the main or paper region 12 of the screen, and that the edge in the region of the suction box confinement (not shown) does not rise up and does not arch upwards, which is commonly designated as tunnelling.
In the papermaking machine a tension of about 100 N/cm (Newton/cm) is exerted on the screen 10 in the longitudinal direction 16 which stretches or elongates the screen 10. The elongation is substantially equal for the longitudinal threads in the paper region 12 and in the marginal region 14, but in the screen of the invention the longitudinal threads in the paper region 12 are maintained under higher tension than are the longitudinal threads in the marginal region 14 at a given elongation.
This may be explained also such that in the marginal region 14 the longitudinal threads undergo higher elongation at the screen tension occurring during use than do the longitudinal threads in the paper region 12, with equal length of the longitudinal threads in the marginal region 14 and in the paper region 12 of the screen 10. The elongation is determined such that strips of 1 cm width and equal length are cut from the paper region 12 and from the marginal region 14 and the increase in the strip length is determined by applying a force corresponding to the screen tension during use. Upon the exertion of a force of 100 N on strips of 1 cm width the elongation or increase in length of the strips cut from the marginal region is about 1.5 times that of the strips cut from the paper region. Such measurements are suitably made on strips of a certain width rather than on individual threads because with individual threads the measuring results are subject to excessive deviation and the measurement of strips will better reflect the condition prevailing during actual operation.
The higher extensibility of the longitudinal threads in the marginal region may be achieved, for example, in that there is a greater length of the starting thread within a given section of screen length, the longitudinal threads in the paper region and in the marginal regions having been identical prior to weaving, or that different longitudinal threads are used for the marginal regions, namely threads having a lower stress/strain quotient; generally polyester threads are used both in the paper region and in the marginal region, while the threads for the marginal regions have been given a greater elongation, e.g. by drawing to a lesser degree.
However, it is also possible to use longitudinal polyester threads in the paper region and polyamide threads in the marginal regions.
If the same threads are used both for the paper region and for the marginal regions, the paper machine screen of the invention may be produced by subjecting, during the manufacture of the screen, the longitudinal threads to lesser tension so that in the marginal region the warp tension is less if the screen is woven in ordinary weave. If the longitudinal threads are different in the paper region and in the marginal region, they may also be woven at equal tension.
The paper machine screens of the invention cannot be produced on conventional looms for ordinary weave screens if identical longitudinal threads are employed, because with the conventional looms all the warp threads are fed from a warp beam so that they are all under equal tension. Although it is possible to feed each individual warp thread from a bobbin creel, the threads then run about a tensioning device consisting of rolls extending across the entire width of the fabric so that they uniformly affect all threads. For the manufacture of the paper machine screens of the invention special bobbins or disks are provided beside the warp beam to feed the warp threads for the marginal regions.
Another problem arises from the circumstances that the marginal regions become thicker if the warp threads in these regions are supplied at lower tension, or if thicker warp threads are used in the marginal region. However, it has been surprisingly found that, upon setting of the papermaking screen by stretching, the marginal regions assume the same thickness as the paper region. When equal longitudinal threads are used, the marginal regions prior to setting are about 10 to 30% thicker than the paper region on account of the warp woven at lower tension. During stretching the marginal regions and the paper region first grew thinner. Since in the papermaking region the warp threads are woven under higher tension, the paper region reaches the monoplanar state earlier, i.e. the state when the bends of the weft threads on the warp side are disposed in the same plane as the warp threads, and vice versa. As seen in FIG. 2, upon continued stretching of the screen the warp or longitudinal threads 24 tend to lie in one plane so that the bends of the weft threads or transverse threads 22 rise over the warp threads, i.e. on the paper side of the weft threads 22 come to lie in a higher plane by an amount indicated by the arrows 20 than do the warp threads 24, so that the paper region 12 of the screen 10 grows thicker again. The marginal regions 14 reach the monoplanar state later since in these regions the warp threads 24 are woven more loosely. At a given screen stretching tension the marginal regions then have equal thickness indicated by the arrows 18 as the paper region. At this stretching tension the marginal regions 14 have not yet or have just reached the monoplanar state, while the paper region 12 is already past said state, i.e. it has exceeded the monoplanar state and has already become thicker again by an amount indicated by the arrows 20. The extra thickness defined by the arrows 20 just compensates for the extra thickness imparted to the marginal region 14 by the looser weaving or by the thicker filaments therein . In order to avoid marks in the paper it is essential that the marginal regions 14 and the paper region have equal thickness. This condition is fulfilled with the papermaking screen of the invention, which is surprising because the marginal regions 14 are markedly thicker after weaving but before stretching on a paper machine.
In special cases a thicker marginal region could offer advantages, the above described measures allowing precise predetermination of the thickness ratio between marginal region and paper region in the final screen.
Even if longitudinal threads having a lesser stress/strain quotient are used for the marginal regions, these regions can be adjusted to the same thickness as the paper region because in that case, too, the marginal regions reach the monoplanar state later than does the paper region.
EXAMPLE 1
On a four stranded cross-twill screen having 28 longitudinal (warp) filaments/cm and 21 transverse (weft) filaments/cm (measured after setting) the marginal region was woven in the same material as the paper region, but with 30% less tension than in the paper region. The marginal web thickness was approximately 10 to 20% thicker than the web thickness of the paper region measured near it. At a stress which produced an elongation of 14% the web thickness in the marginal region and in the paper region were approximately equal. The stress/strain diagram for identical samples cut from the marginal and paper regions showed a greater elongation for the marginal region. At a tension of 100 N/cm, an elongation of 1.4% was measured in the sample from the paper region and an elongation of 2.3% was measured in the sample from the marginal region.
EXAMPLE 2
In a four stranded cross-twill screen having 31 longitudinal (warp) filaments/cm and 22 transverse (weft) filaments/cm (measured after setting) approximately 6.25% more longitudinal filament was woven into a marginal region using the same material as in the paper region. According to the stress/strain diagram on identical samples cut from the screen the marginal elongation was greater than the elongation of the paper region measured at a stress of 120 N/cm. Measured at a stress of 400 N/cm, the elongation of the sample from the paper region amounted to 5.4%, while the elongation of the sample from the marginal region was 7.4%.
EXAMPLE 3
A four stranded cross-twill screen having approximately 32 longitudinal (warp) filaments/cm and 21 transverse (weft) filaments/cm, (measured after setting) was woven using longitudinal strands at its margin made of different material and with approximately 3.7% more longitudinal filament woven in. According to the stress/strain diagram the elongation values for the individual filaments of the marginal region were greater than for those of the paper region by over 50%.
It will be understood that the claims are intended to cover all changes and modifications of the preferred embodiments of the invention, herein chosen for the purpose of illustration which do not constitute departures from the spirit and scope of the invention. | The longitudinal marginal regions of a synthetic fabric endless belt-type screen for a paper making machine are formed to permit less wear of the marginal regions due to greater elongation as compared to the central region. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to German Patent Application Serial No. 102007051945.3 filed Oct. 31, 2007, the entirety of which is incorporated herein by reference thereto.
BACKGROUND
[0002] The invention relates to a method for controlling the feed of sheets to a sheet-fed printing press having a sheet feeder comprising multiple components, each component being assigned an individual drive and these components being provided for supplying the sheets in a sheet stack, for separating the sheets from a sheet stack and for feeding the sheets to the sheet-fed printing press.
[0003] DE 195 05 560 A1 discloses a method for controlling the sheet feed in a sheet processing printing press. In this printing press, the sheets to be printed are taken from the top of a feeder unit stack and conveyed to the installation of the printing press over a predefined conveyor path. At the beginning of the conveyor path, a sheet inspection is performed with regard to double sheets and defective sheets and the sheet conveyance is stopped, depending on the result of the sheet inspection. On detection of a double sheet or defective sheet, withdrawal of additional sheets from the feeder unit stack is stopped immediately and the number of sheets that can still be conveyed into the printing press and printed there before the double sheet or defective sheet in the direction of sheet on the conveyor path reaches the front mark of the installation conveyance is determined. The ink feed is stopped even before the last sheet situated upstream from the double sheet or defective sheet in the direction in conveyance of the sheet enters the printing press. After withdrawal of a sheet from the feeder unit stack has been stopped, sheet conveyance is stopped exactly when the double sheet or defective sheet has reached the installation. Then the number of sheets yet to be fed into the printing press is determined from the distance between the installation and the sheet inspection in combination with the degree of underfeeding in the case of underfed sheet feeding and the format length of the sheets.
[0004] One disadvantage of this approach is that in shutdown of the sheet conveyor belt, the underfed sheets may be displaced with respect to one another and cannot approach the printing press again in this state without problems.
[0005] EP 1 281 647 B1 therefore presents a method for conveying sheets in a sheet feeder unit of a sheet processing machine by means of which this disadvantage is to be avoided. With this printing press, the rate of travel of the conveyor belt for conveying the fed sheets is variable, independent of the operating speed of the machine in accordance with the predefined speed profiles, so that when starting or stopping of the feeder unit, the conveyor belt can be stopped and/or started in accordance with a predetermined acceleration profile.
[0006] DE 102 16 135 A1 discloses a method for controlling the sheet feed to a sheet processing machine having a sheet feeder unit which comprises, among other things, a sheet separator for separating the sheets from a stack and a table with belts or a suction table with belts. The sheets are conveyed to the machine and inspected with regard to double sheets, defective sheets or skewed sheets. If there is such a sheet or if there is a disturbance in the downstream machine, the sheet feed is stopped, in which a sampling device that detects the height level of the stack is provided and the drive of the sheet feeder unit is provided by individual drives, which are controlled by means of an electronic processing unit that is connected to a control unit of the downstream machine. After breaking the connection between the electronic processing unit and the machine control unit, the synchronization of the individual drives is eliminated, so that the individual drives can be operated at will. The individual drives may also be operated optionally in different directions of rotation or brought to a standstill.
[0007] This process takes places directly on stoppage of the feeder unit. The disadvantage here is that other driven components of the feeder unit are stopped in an undefined position which makes renewed startup difficult.
[0008] Therefore, the object of the present invention is to develop a method by means of which at least two drives of components of the feeder unit are brought to a standstill in a defined position in a targeted manner when the feeder unit is shut down.
SUMMARY
[0009] According to the invention, this object is achieved by a method for controlling the feed of sheets to a sheet-fed printing press with a sheet feeder unit comprising multiple components such that these components are provided for supplying the sheets in a stack for separating the sheets from the stack and for conveying the sheets to the feeder printing mechanism of the sheet-fed printing press. An individual drive is assignable to each of these components. These individual drives are operable in synchronization with one another during the printing by the sheet-fed printing press. The synchronization between at least two individual drives is eliminated when the sheet feeder is shut down, wherein these individual drives are shut down individually and synchronized in relation to one another again in resuming operation of the sheet feeder unit such that they assume a predefinable position for each individual drive when the individual drives are shut down.
[0010] The invention has the advantage that an optimal stop point is achieved for the components of the sheet feeder so that operation can be resumed without problems.
[0011] The invention will now be explained in greater detail below on the basis of an exemplary embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a sheet-fed printing press formed in accordance with the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0013] The respective drawing shows a sheet feeder unit 1 with a table with belts 2 . The table with belts 2 is designed as a suction table with belts 2 . 1 . The inventive approach is explained on the example of a sheet feeder unit 1 with a suction table with belts 2 . 1 , in which sheets 8 are held by vacuum on suction belts 26 . 1 , such that the inventive approach may also be implemented on a sheet feeder unit 1 with a table with belts 2 in which the sheets 8 are guided in a known way through pressure rollers arranged on a rod grating against conveyor belts 26 of the table with belts. A feeder table 3 with front marks 4 , a vibrating system 5 and a feed cylinder 6 of a feed printing mechanism 7 of a sheet-fed printing press are arranged downstream from the suction table with belts 2 . 1 .
[0014] The sheet feeder unit 1 consists of multiple components, each component being assigned an individual drive 19 , 28 , 31 .
[0015] A stack 9 consisting of the sheets 8 is positioned on a stack plate 10 in the sheet feeder unit 1 . The stack plate 10 is attached to conveyor means 11 , which are connected to a lift (not shown). A sheet separator 12 is assigned as an additional component to the top of the stack 9 . The sheet separator 12 has separation suction cups 13 and conveyor suction cups 14 as well as undercut edge stops 15 . The sheet separator 12 is provided so that it is adjustable in height by means of an actuator drive 16 in the sheet feeder unit 1 . In addition, the sheet separator 12 may be displaced in or against a direction of conveyance 17 for adaptation of the format. In the exemplary embodiment, a sampling device 18 is assigned to the sheet separator 12 to detect the height level of the stack 9 . The sampling device 18 may also be provided at any other location on the sheet feeder unit 1 . The sheet separator 12 is driven by means of a first individual drive 19 , which may be designed as an electric motor, for example. Blowers 36 are also provided on the rear side and optionally on the sides of the stack 9 for predrying the sheets 8 on the stack 9 and for blowing under the sheets 8 during conveyance. To be able to form an air cushion that will support the sheets 8 , side plates 20 are arranged on the sides of the stack 9 . However, it is also possible to assign laterally bordering guide elements 20 . 1 to the stack 9 .
[0016] On the front side of the stack 9 , a shaft 21 extends over the width of the stack 9 as an additional component of the sheet feeder unit 1 , its drive being provided by a third individual drive 31 . Downstream from this a blow pipe 22 whose direction of blowing runs approximately opposite a direction of conveyance 17 .
[0017] The suction table with belts 2 . 1 as an additional component of the sheet feeder unit 1 comprises a drive roller 23 and a reversing roller 24 , between which a suction box 25 is provided, at least one suction belt 26 . 1 being wrapped around the rollers 23 , 24 . The suction belt 26 . 1 is put under tension by tension rollers 27 . The suction belt 26 . 1 is provided with suction openings in a known way, coming into operative connection with suction bores provided in the suction box 25 in their movement in the direction of conveyance 17 , driven by the drive roller 23 . The drive roller 23 is driven by a second individual drive 28 , e.g., an electric motor. Stepping wheels 29 correspond to the drive roller 23 and are controlled periodically against the drive roller 23 within an operating cycle.
[0018] The front marks 4 are controlled into an operating position against the feeder table 3 downstream from the suction table with belts 2 . 1 from a catch position beneath the feeder table 3 . An inspection device 32 is provided for the feeder table 3 . The vibrating system 5 arranged downstream from the feeder table 3 has a sheet holding system 30 and executes a pivoting movement between the feeder table 3 and the feeder cylinder 6 of the feeder printing mechanism 7 .
[0019] The individual drives 19 , 28 , 31 that drive the sheet separator as well as the sheet conveyor means, the actuator drive 16 and the inspection device 32 are connected to an electronic processing unit 33 of the sheet feeder unit 1 which is in turn connected to a control unit 34 of the downstream sheet-fed printing press. The sheet feeder unit 1 is readjusted in synchronization with the sheet-fed printing press via the machine control unit 34 and the electronic process unit 33 .
[0020] To do so, a rotary angle sensor 35 may be assigned, for example, to the feed cylinder 6 , which is connected to the machine control unit 34 . The individual drives 19 , 28 , 31 run in synchronization with one another over 360° of a single-turn shaft as well as within a unit of time.
[0021] In synchronized readjustment of the sheet feeder unit 1 , the top sheet 8 is separated from the stack 9 by the separating suction cups 13 driven by the first individual drive 19 assigned to the sheet separator 12 and is transferred to the conveyor suction cups 14 which convey the separated sheets 8 in the direction of conveyance 17 . The separation of the sheets 8 is supported by the fact that the stack 9 is loosened by blowers 36 and air is blown by the additional blowers 36 under the respective sheets 8 conveyed by the conveyor suction cups 14 . The sheets 8 conveyed by the conveyor suction cups 14 are guided by the stepping wheels 29 that make contact in cycles against the drive roller 23 and are then released by the conveyor suction cups 14 . The shaft 21 driven by the third individual drive 31 is pivoted out of the path of the sheets 8 and the blowing air feed to the blow pipe 22 is interrupted. The sheets 8 guided by the stepping wheels 29 against the drive roller 23 are picked up by the suction belts 26 . 1 , which are constantly being acted upon by a vacuum via the suction box 26 , and then are conveyed as a stack of sheets onto the feeder table 3 and with the front edge toward the front marks 4 in the working position. In the exemplary embodiment, an inspection device 32 which detects the sheets 8 is provided for the feeder table 3 . It is also possible to provide multiple measurement devices that inspect the sheets 8 and distribute them over the path of the sheets 8 as they travel from the sheet feeder unit 1 to the front marks 4 .
[0022] If no sheets 8 that are subject to defects are detected by the inspection device 32 , then the sheet 8 in contact with the front marks is transferred by the sheet holding system 30 of the vibrating system 5 and conveyed to the feed cylinder 6 whereby the front marks 4 are pivoted into their position beneath the feeder table 3 . If a sheet 8 subject to defects is detected by the inspection device 32 , a signal is supplied from the inspection device 32 to the electronic processing unit 33 and the synchronization between at least two individual drives 19 , 28 , 31 is canceled thereby. In the exemplary embodiment, these include the first individual drive 19 and the second individual drive 28 . It is also possible to eliminate the synchronization of all individual drives 19 , 28 , 31 .
[0023] The individual drives 19 , 28 are shut down individually. The conveyor belt 26 is stopped within the shortest possible amount of time in a process that is optimized for acceleration. This takes place in such a way that the conveyor belt 26 experiences a negative acceleration when stopped such that it comes to standstill in a technologically minimal time while maintaining the distance between the sheet 8 of the stack of sheets.
[0024] In shutdown of the individual drives 19 , 28 , they assume a position predefined for each individual drive 19 , 28 . Thus, for example, the sheet separator 12 moves into a position which allows it to start up again with no problem. The goal here is for the sheet separator 12 to reach this predefinable position within a technologically minimal amount of time. The sheet separator 12 may move in the direction of conveyance 17 or opposite the direction of conveyance 17 .
[0025] After removing the defective sheet 8 from the feeder table 3 , removal of the sheets 8 on the suction table with belts 2 . 1 is initiated by a startup signal supplied manually to the electronic processing unit 33 . In doing so the blowing air and suction air supply to the sheet separator 12 as well as the blowing air supplied to the blowers 36 are interrupted and the blow pipe 22 is acted upon by blowing air.
[0026] When the sheet feeder unit 1 is started up again, the first individual drive 19 and the second individual drives 28 are synchronized with one another again. The actuator drive 16 of the sheet separator 12 is lowered into its working position, the suction air and blowing air supplied to the sheet separator 12 and the blowing air supplied to the blowers 36 are activated and the blowing air supplied to the blow pipe 22 is interrupted. At the same time, the individual drives 19 , 28 are activated such that the original direction of rotation of the second individual drive 28 is restored, so that the sheets 8 are removed from the stack 9 in the direction of conveyance 17 and can be sent to the front marks 4 . After aligning the first sheet 8 with the front marks 4 , the connection between the electronic processing unit 33 and the machine control unit 34 is restored and the sheet feeder unit 1 is connected to the suction table with belts 2 within one working cycle.
[0027] The present invention is not limited just to the exemplary embodiment described above. Other components of the sheet feeder unit 1 , not specified in the exemplary embodiment but provided with individual drives, may be operated in the manner described here. | A method for controlling the feed of sheets to a sheet-fed printing press is provided for a sheet feeder unit comprising an individual drive assigned to each of a plurality of components provided for supplying the sheets in a stack, separating the sheets from a stack and supplying the sheets to the press. The method provides a means by which at least two of the individual drives are brought to a standstill in a defined position in a targeted manner by shutting down the feeder unit. The individual drives are operated in synchronization with one another during printing operation. The synchronization between the at least two individual drives is canceled when the sheet feeder unit is shut down. These drives are shut down individually and synchronized with one another when the sheet feeder unit is started up again such that in shutdown, each individual drive assumes a predefinable position. | 1 |
TECHNICAL FIELD
[0001] The present invention relates to a seam welding method and a seam welding device for performing seam welding with respect to a stacked assembly, which is formed by stacking a plurality of workpieces (includes a plurality of workpieces stacked), wherein among the workpieces, a thinnest workpiece having a minimum thickness is arranged on an outermost side of the stacked assembly.
BACKGROUND ART
[0002] Seam welding is widely known as a technique for joining metal plates together (for example, see Japanese Laid-Open Patent Publication No. 2007-167896). Using seam welding, after stacked metal plates (stacked assembly) are sandwiched between a pair of roller electrodes, a current is applied between the roller electrodes. More specifically, within the stacked assembly, a current pathway is formed along the stacking direction. A current that flows out from the plus electrode is conducted successively through the metal plate in contact with the plus electrode, contact sites between the metal plates, and the metal plate in contact with the minus electrode, whereupon the current reaches the minus electrode.
[0003] During application of current, resistance heating (Joule heat) is generated at the contact sites between the metal plates. Thus, melting takes place at such sites.
[0004] Thereafter, by the stacked assembly being moved relative to the pair of roller electrodes, the current pathway also moves, so that ultimately, the sites at which resistance heating occurs in the stacked assembly move as well. That is, the current moves away from the sites that have been melted prior to such movement, and therefore, resistance heating of the sites is completed. As a result, the temperature at the sites decreases, whereby the sites become solidified and acquire a solid phase. Such solidified sites are referred to primarily as nuggets.
[0005] On the other hand, at the sites corresponding to the newly formed current pathway, in the same manner as described above, the contact sites between the metal plates undergo melting. Thereafter, by sequentially repeating the above-described phenomenon, the metal plates are joined continuously to each other.
SUMMARY OF INVENTION
[0006] Incidentally, as the stacked assembly, a structure exists in which plural metal plates of different thicknesses are stacked. In addition, in the case that the workpiece (thinnest workpiece) with the smallest thickness is seam welded while being stacked on the outermost side of the stacked assembly, a situation occurs in which nuggets do not grow sufficiently between the thinnest workpiece and the other workpiece adjacent to the thinnest workpiece. The reason therefor is assumed to be that adequate resistance heating does not occur, due to the fact that the specific resistance is minimal as a result of the thickness of the thinnest workpiece being smallest. Although it can be considered to increase the current value so that nuggets grow sufficiently large in the vicinity of the thinnest workpiece, in this case, a defect is brought about in that so-called spatter (welding debris), a phenomenon that the workpiece is melted and undergoes scattering, is easily caused.
[0007] The present invention has been devised taking into consideration the aforementioned problems, and has the object of providing a seam welding method and a seam welding device, which enable nuggets of sufficient size to be formed between a thinnest workpiece arranged on an outermost side of a stacked assembly and a workpiece adjacent to the thinnest workpiece, while also dispelling any concerns over generation of welding debris.
[0008] [1] A seam welding method according to the present invention is characterized by performing seam welding by sandwiching a stacked assembly between a pair of roller electrodes, the stacked assembly comprising a plurality of workpieces stacked, together with arranging a thinnest workpiece having a smallest thickness on an outermost side, wherein, in a state in which one of the roller electrodes in contact with the thinnest workpiece is arranged more forwardly in the welding direction than the other roller electrode, supply of current is carried out between the pair of roller electrodes while the pair of roller electrodes is moved relatively with respect to the stacked assembly.
[0009] In accordance with the seam welding method according to the present invention, since the one roller electrode in contact with the thinnest workpiece is disposed more forwardly in the welding direction than the other roller electrode, in the stacked assembly, a current pathway, which is inclined in a direction opposite to the welding direction, is formed from the one roller electrode toward the other roller electrode. When this is done, in the current pathway, at a certain point in time T 1 , resistance heating occurs at a contact site (first contact site) between the thinnest workpiece and the workpiece adjacent to the thinnest workpiece. In addition, at a point in time T 2 at which the pair of roller electrodes is moved relatively with respect to the stacked assembly, a second site adjacent to the first site in the welding direction is heated, together with a third site adjacent to the other roller electrode side of the first site being heated. At this time, the first site, which already has been heated, is increased in heat further by the second site and the third site, and therefore, a nugget (well-proportioned nugget) of a sufficient size is formed at the first site. Consequently, a joint is obtained which is superior in bonding strength.
[0010] Further, in the case that the one roller electrode is arranged more forwardly in the welding direction than the other roller electrode, in comparison with a situation in which the two roller electrodes are aligned at the same position in the welding direction, the contact area of the respective roller electrodes with respect to the stacked assembly becomes larger, together with the contact area between the workpieces becoming larger. Consequently, since the current density of the current pathway is comparatively small, even in the case that the current value flowing between the pair of roller electrodes is increased, the occurrence of welding debris can suitably be suppressed.
[0011] [2] In the aforementioned seam welding method, there may be carried out a calculating step of calculating a ratio of a thickness of the stacked assembly with respect to the thickness of the thinnest workpiece, and a setting step of setting an angle of inclination along the welding direction of a line segment that passes through axes of rotation of the respective roller electrodes with respect to a line segment along a stacking direction of the stacked assembly, depending on the ratio calculated in the calculating step.
[0012] According to such a method, since the angle of inclination is set corresponding to the ratio of the thickness of the stacked assembly with respect to the thickness of the thinnest workpiece, nuggets that are sufficiently large in size can efficiently be formed in the stacked assembly.
[0013] [3] In the aforementioned seam welding method, in the setting step, the angle of inclination may be set to 5° or less. According to such a method, since the angle of inclination is set to 5° or less, it is possible to prevent the pair of roller electrodes from becoming excessively distanced from one another. Consequently, nuggets of sufficient size can be formed more effectively in the stacked assembly.
[0014] [4] A seam welding device according to the present invention is characterized by performing seam welding by sandwiching a stacked assembly between a pair of roller electrodes, the stacked assembly comprising a plurality of workpieces stacked, together with arranging a thinnest workpiece having a smallest thickness on an outermost side, wherein one of the roller electrodes in contact with the thinnest workpiece is arranged more forwardly in the welding direction than the other roller electrode.
[0015] In accordance with the seam welding device according to the present invention, since the one roller electrode in contact with the thinnest workpiece is disposed more forwardly in the welding direction than the other roller electrode, the same effects as those of the aforementioned seam welding method can be offered.
[0016] [5] In the aforementioned seam welding device, there may be provided a ratio calculating unit configured to calculate a ratio of a thickness of the stacked assembly with respect to the thickness of the thinnest workpiece, and an inclination angle setting unit configured to set an angle of inclination along the welding direction of a line segment that passes through axes of rotation of the respective roller electrodes with respect to a line segment along a stacking direction of the stacked assembly, based on the ratio calculated by the ratio calculating unit.
[0017] According to such a device, since the angle of inclination is set based on the ratio that is calculated by the ratio calculating unit, nuggets that are sufficiently large in size can efficiently be formed in the stacked assembly.
[0018] [6] In the aforementioned seam welding device, the inclination angle setting unit may set the angle of inclination to 5° or less. According to such a device, since the angle of inclination is set to 5° or less, it is possible to prevent the pair of roller electrodes from becoming excessively distanced from one another. Consequently, nuggets of sufficient size can be formed more effectively in the stacked assembly.
[0019] As has been described above, according to the present invention, since the one roller electrode in contact with the thinnest workpiece is disposed more forwardly in the welding direction than the other roller electrode, nuggets of sufficient size can be formed in the stacked assembly between the thinnest workpiece arranged on the outermost side and a workpiece that lies adjacent to the thinnest workpiece. In addition, since the contact area between the workpieces and the contact area of the respective roller electrodes with respect to the stacked assembly can be made larger, any concerns over generation of welding debris can be dispensed with.
BRIEF DESCRIPTION OF DRAWINGS
[0020] FIG. 1 is an overall side view in outline form of a seam welding device according to an embodiment of the present invention;
[0021] FIG. 2 is a perspective view of a seam welding machine shown in FIG. 1 ;
[0022] FIG. 3 is a schematic partial front view of the seam welding machine;
[0023] FIG. 4 is a flowchart for describing a seam welding method according to an embodiment of the present invention;
[0024] FIG. 5 is an explanatory drawing for describing a state in which a site within a stacked assembly is sandwiched by a first roller electrode and a second roller electrode, and the site is warped;
[0025] FIG. 6 is a schematic explanatory drawing for describing a contact area of the first roller electrode with respect to a first workpiece, and a contact area of the second roller electrode with respect to a third workpiece;
[0026] FIG. 7A is an explanatory diagram showing a heated site of the stacked assembly at a time T 1 ;
[0027] FIG. 7B is an explanatory diagram showing a heated site at a time T 2 that is advanced beyond time T 1 ;
[0028] FIG. 7C is an explanatory diagram showing a heated site at a time T 3 that is advanced beyond time T 2 ;
[0029] FIG. 8 is a schematic view of a seam welding device according to a first exemplary embodiment of the present invention;
[0030] FIG. 9 is a cross-sectional view taken along line IX-IX of FIG. 8 ;
[0031] FIG. 10 is a graph showing experimental results of the exemplary embodiment of FIG. 8 ; and
[0032] FIG. 11 is an explanatory drawing for describing a seam welding method according to a modified example of the present invention.
DESCRIPTION OF EMBODIMENTS
[0033] In relation to a seam welding method and a seam welding device that implements such a method according to the present invention, preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
[0034] As shown in FIGS. 1 and 2 , a seam welding device 10 according to an embodiment of the present invention performs seam welding on a stacked assembly 100 that serves as an object to be welded, and is equipped with a multi-jointed articulated robot 12 , a seam welding machine 16 supported on a distal end arm 14 of the articulated robot 12 , an input unit 17 , and a control unit 18 .
[0035] First, a description will be given concerning the stacked assembly 100 . The stacked assembly 100 according to the present invention is a member that is used as a door opening portion of an automobile, which is formed by stacking three workpieces (metal plates) W 1 , W 2 , W 3 .
[0036] The workpiece W 1 , for example, is made up from high-tensile steel such as JAC590, JAC780 or JAC980 (high-performance high-tensile steel sheets defined according to the Japan Iron and Steel Federation Standard), and forms one outermost layer (outermost surface) of the stacked assembly 100 . The workpiece W 2 is made up from the same material (high-tensile material) as the aforementioned workpiece W 1 , and forms a middle layer of the stacked assembly 100 . The workpiece W 3 , for example, is made up from JAC270 (a so-called mild steel, which is a high-performance steel sheet for press-forming defined according to the Japan Iron and Steel Federation Standard), and forms the other outermost layer (outermost surface) of the stacked assembly 100 .
[0037] Therefore, in the stacked assembly 100 of the present embodiment, in comparison with the workpiece W 1 and the workpiece W 2 , which are high-tensile steel materials, the workpiece W 3 , which is a mild steel material, has a characteristic of being relatively difficult to generate heat therein, due to the fact that the specific resistance thereof is low and the thermal conductivity thereof is high.
[0038] As understood from FIG. 3 , the thickness of the workpiece W 1 and the thickness of the workpiece W 2 are set to Dl (e.g., roughly 1 mm to roughly 2 mm), whereas the thickness of the workpiece W 3 is set to a smaller dimension D 2 (e.g., roughly 0.5 mm to roughly 0.7 mm) than the thickness D 1 . Stated otherwise, the workpiece W 3 is the thinnest workpiece of the stacked assembly 100 . The thickness of the workpiece W 1 and the thickness of the workpiece W 2 need not be the same and may differ from each other.
[0039] The articulated robot 12 is configured as a so-called industrial robot. Under the action of the control unit 18 , the articulated robot 12 can move the seam welding machine 16 in an arbitrary posture and at an arbitrary position (see FIG. 1 ).
[0040] The seam welding machine 16 includes a guide rail 20 , which is fixed through a mount 19 with respect to the distal end arm 14 of the articulated robot 12 , a first drive mechanism 22 and a second drive mechanism 24 , which are disposed on the guide rail 20 , a first roller electrode 26 , which is disposed on the first drive mechanism 22 , and a second roller electrode 28 , which is disposed on the second drive mechanism 24 .
[0041] The guide rail 20 is configured in a rectangular parallelepiped shape, and substantially in a central part in the widthwise direction (the direction of the arrow Z in FIG. 2 ) of a surface on an opposite side from the side on which the distal end arm 14 is positioned, a protrusion 30 is formed that spans across the entire length thereof.
[0042] The first drive mechanism 22 includes a first moving table 32 disposed movably with respect to the guide rail 20 along the direction of extension (the direction of the arrow Y) of the guide rail 20 , and a first rotary shaft 34 disposed on the first moving table 32 and to which the first roller electrode 26 is fixed.
[0043] A recess 36 , which engages slidably with the protrusion 30 of the guide rail 20 , is formed on the first moving table 32 . By a first cylinder and a first rod (not illustrated), for example, which are provided on the guide rail 20 , the first moving table 32 is capable of moving with respect to the guide rail 20 along the direction of extension of the guide rail 20 .
[0044] The first rotary shaft 34 extends along the thickness direction (the direction perpendicular to the direction of the arrow Y and the direction of the arrow Z) of the guide rail 20 , and is capable of being rotated by a non-illustrated first rotary motor that is disposed on the first moving table 32 .
[0045] The second drive mechanism 24 includes a second moving table 38 disposed movably with respect to the guide rail 20 along the direction of extension (the direction of the arrow Y) of the guide rail 20 , a third moving table 40 disposed movably with respect to the second moving table 38 along the widthwise direction (the direction of the arrow Z in FIG. 2 ) of the guide rail 20 , and a second rotary shaft 42 disposed on the third moving table 40 and to which the second roller electrode 28 is fixed.
[0046] A recess 44 , which engages slidably with the protrusion 30 of the guide rail 20 , is formed on the second moving table 38 . By a second cylinder and a second rod (not illustrated), for example, which are provided on the guide rail 20 , the second moving table 38 is capable of moving with respect to the guide rail 20 along the direction of extension of the guide rail 20 . On a surface on an opposite side from the surface on which the recess 44 is formed in the second moving table 38 , a protrusion 46 is formed that spans across the entire length of the guide rail 20 .
[0047] A recess 48 , which engages slidably with the protrusion 46 of the second moving table 38 , is formed on the third moving table 40 . By a third cylinder and a third rod (not illustrated), for example, which are provided on the second moving table 38 , the third moving table 40 is capable of moving with respect to the second moving table 38 along the widthwise direction (the direction of the arrow Z) of the guide rail 20 .
[0048] The second rotary shaft 42 is capable of being rotated by a non-illustrated second rotary motor that is disposed on the third moving table 40 in a state of being arranged parallel to the first rotary shaft 34 .
[0049] Each of the first roller electrode 26 and the second roller electrode 28 is formed in a disc shape. As understood from FIGS. 2 and 3 , an outer circumferential surface of the first roller electrode 26 contacts one surface of the stacked assembly 100 (workpiece W 1 ), and an outer circumferential surface of the second roller electrode 28 contacts the other surface of the stacked assembly 100 (workpiece W 3 ). The first roller electrode 26 and the second roller electrode 28 may be formed with the same structure, and may be formed such that the two electrodes differ in a dimension in the diametrical direction or in the widthwise direction .
[0050] The seam welding machine 16 includes a welding power source unit 50 , a first lead wire (power line) 52 that electrically connects the first roller electrode 26 and a negative electrode of the welding power source unit 50 , and a second lead wire (power line) 54 that electrically connects the second roller electrode 28 and a positive electrode of the welding power source unit 50 (see FIGS. 1 and 3 ).
[0051] The welding power source unit 50 is constituted to include an AC power source and a welding transformer, etc., and performs supply of current between the first roller electrode 26 and the second roller electrode 28 through the first lead wire 52 and the second lead wire 54 .
[0052] The input unit 17 is capable of inputting information with respect to the control unit 18 , such as the plate thicknesses of the respective workpieces W 1 to W 3 that make up the stacked assembly 100 .
[0053] The control unit 18 includes a robot controller 58 , a plate thickness ratio calculating unit 59 , an inclination angle setting unit 60 , and a welding machine controller 62 . The robot controller 58 controls driving of the articulated robot 12 .
[0054] The plate thickness ratio calculating unit 59 calculates the ratio (plate thickness ratio R=D 2 /D 0 ) of the thickness D 0 of the stacked assembly 100 with respect to the thickness D 2 of the workpiece (thinnest workpiece) W 3 , based on the thickness information, etc., of the respective workpieces W 1 to W 3 , which is input from the input unit 17 .
[0055] The inclination angle setting unit 60 sets the angle of inclination θ of a line segment B along the welding direction with respect to a line segment A along the stacking direction (the direction of the arrow Y) of the stacked assembly 100 , based on the plate thickness ratio R calculated by the plate thickness ratio calculating unit 59 (see FIG. 3 ). The line segment B passes through the axis of rotation Ax 1 of the first roller electrode 26 and the axis of rotation Ax 2 of the second roller electrode 28 . More specifically, the inclination angle setting unit 60 sets the angle of inclination θ to become larger as the plate thickness ratio R becomes larger. By setting the angle of inclination θ in this manner, the second roller electrode 28 is arranged more forwardly in the welding direction than the first roller electrode 26 .
[0056] According to the present embodiment, the inclination angle setting unit 60 sets the angle of inclination θ to less than or equal to 7°, and more preferably, to less than or equal to 5°. By setting the angle of inclination in this manner, excessive separation between the first roller electrode 26 and the second roller electrode 28 can be suppressed.
[0057] Further, in the case that the plate thickness ratio R is greater than 5, the inclination angle setting unit 60 preferably sets the angle of inclination θ within a range of 3°≦θ≦5°, and in the case that the plate thickness ratio R is less than or equal to 3 , the inclination angle setting unit 60 preferably sets the angle of inclination θ to be approximately 1°.
[0058] This is because, if the angle of inclination θ is too small, it becomes difficult for the contact site between the workpiece W 2 and the workpiece W 3 to be sufficiently heated, whereas if the angle of inclination θ is too large, the current pathway formed in the stacked assembly 100 becomes excessively long (the interval between the first roller electrode 26 and the second roller electrode 28 is too wide), and the welding current value needed to perform seam welding becomes excessively large.
[0059] The welding machine controller 62 controls the first through third cylinders, the first and second rotary motors, and the welding power source unit 50 .
[0060] The seam welding device 10 according to the present embodiment is constructed basically as has been described above. Next, effects and advantages of the seam welding device 10 will be described in relation to a seam welding method according to the embodiment.
[0061] First, the plate thickness ratio calculating unit 59 calculates the plate thickness ratio R by obtaining information of the thickness dimensions of the respective workpieces W 1 to W 3 (step S 1 of FIG. 4 ). The thickness dimensions of the respective workpieces W 1 to W 3 may be obtained by the operator making an input to the input unit 17 , or may be obtained from workpiece information (information of the thickness dimensions of each of the workpieces) stored in advance in a storage unit or the like of the control unit 18 .
[0062] Next, the inclination angle setting unit 60 sets the angle of inclination θ based on the calculated thickness ratio R (step S 2 ). More specifically, the inclination angle setting unit 60 sets the angle of inclination θ to become larger as the plate thickness ratio R becomes larger. At this time, the inclination angle setting unit 60 sets the angle of inclination θ within a range of 3°≦θ≦5°, for example.
[0063] Next, the relative positions of the first roller electrode 26 and the second roller electrode 28 are adjusted so as to bring about the set angle of inclination θ (step S 3 ). More specifically, by controlling the pressure in the third cylinder, the welding machine controller 62 moves the third moving table 40 in the direction of the arrow Z, whereby the second roller electrode 28 is moved more forwardly in the welding direction than the first roller electrode 26 , and the angle of inclination θ is placed at the set value.
[0064] Thereafter, the stacked assembly 100 is sandwiched and gripped between the first roller electrode 26 and the second roller electrode 28 (step S 4 ). More specifically, at first, the robot controller 58 controls the articulated robot 12 , moves the seam welding machine 16 to the vicinity of a welding starting point of the stacked assembly 100 , and adjusts the posture of the seam welding machine 16 to position the first roller electrode 26 on the side of the workpiece W 1 and to position the second roller electrode 28 on the side of the workpiece W 3 . In addition, by controlling the pressures in the first and second cylinders, the welding machine controller 62 causes the first roller electrode 26 and the second roller electrode 28 to approach one another mutually. Consequently, the outer circumferential surface of the first roller electrode 26 contacts one surface of the workpiece W 1 , together with the outer circumferential surface of the second roller electrode 28 contacting the other surface of the workpiece W 3 .
[0065] As a result, the stacked assembly 100 is pressed and sandwiched by the first roller electrode 26 and the second roller electrode 28 . Part of the stacked assembly 100 which has been sandwiched is warped corresponding to the shapes of the roller electrodes 26 , 28 (see FIG. 5 ). Therefore, compared to the case where the roller electrodes 26 , 28 are aligned in the welding direction, a contact area S 1 of the first electrode 26 on the workpiece W 1 increases along the welding direction and the widthwise direction of the first roller electrode 26 , and a contact area S 2 of the second roller electrode 26 on the workpiece W 3 also increases along the opposite direction of the welding direction and the widthwise direction of the second roller electrode 28 (see FIG. 6 ).
[0066] Subsequently, seam welding is carried out by supplying current while the first roller electrode 26 and the second roller electrode 28 undergo rotation (rolling) (step S 5 ). More specifically, the robot controller 58 controls the articulated robot 12 , and while the seam welding machine 16 is moved, the welding machine controller 62 rotates the first roller electrode 26 by driving the first rotary motor, and rotates the second roller electrode 28 by driving the second rotary motor. At roughly the same time, the welding machine controller 62 carries out supply of current between the first roller electrode 26 and the second roller electrode 28 by driving the welding power source unit 50 .
[0067] Upon doing so, in the stacked assembly 100 , an inclined current pathway, which is inclined in a direction opposite to the welding direction, is formed from the second roller electrode 28 toward the first roller electrode 26 . Therefore, as shown in FIG. 7A , at a certain point in time T 1 , in the current pathway, resistance heating takes place at a contact site (first site) H 1 a between the workpiece W 2 and the workpiece W 3 , at a site H 1 b in the workpiece W 2 slightly more rearwardly than the contact site H 1 a, and at a contact site H 1 c between the workpiece W 1 and the workpiece W 2 slightly more rearwardly than the site H 1 b.
[0068] In addition, as shown in FIG. 7B , at a point in time T 2 after time T 1 , since the first roller electrode 26 and the second roller electrode 28 are moved slightly in the welding direction with respect to the stacked assembly 100 , resistance heating then takes place at a contact site (second site) H 2 a, which is shifted slightly in the welding direction from the contact site H 1 a, at a site H 2 b (third site), which is shifted slightly in the welding direction from the site H 1 b, and at a contact site H 2 c, which is shifted slightly in the welding direction from the contact site H 1 c. At this time, the contact site H 1 a, which has already been heated, is subjected to further heating by the contact site H 2 a and the contact site H 2 b.
[0069] In addition, as shown in FIG. 7C , at a point in time T 3 after time T 2 , similar to the case of time T 2 , resistance heating then takes place at a contact site H 3 a , which is shifted slightly in the welding direction from the contact site H 2 a, at a contact site H 3 b, which is shifted slightly in the welding direction from the site H 2 b, and at a contact site H 3 c, which is shifted slightly in the welding direction from the contact site H 2 c.
[0070] At this time, since the contact site H 3 c is a contact site between the workpiece W 1 and the workpiece W 2 , which are greater in thickness and greater in specific resistance than the workpiece W 3 , sufficient resistance heating takes place.
[0071] In the foregoing manner, by performing seam welding in a state in which the second roller electrode 28 is arranged more forwardly than the first roller electrode 26 , since the contact site H 1 a between the workpiece (thinnest workpiece) W 3 and the workpiece W 2 for which inadequate heating is easy to occur are sufficiently heated and melted, nuggets that are sufficiently large in size can be formed at the contact site between the workpiece W 2 and the workpiece W 3 .
[0072] Further, according to the present embodiment, because the nuggets that are formed at the contact site H 3 c grow up to the contact site between the workpiece W 2 and the workpiece W 3 , nuggets which are well-proportioned as a whole can be obtained. Consequently, this leads to the workpiece W 1 and the workpiece W 2 being bonded together firmly, as well as the workpiece W 2 and the workpiece W 3 being bonded together firmly.
[0073] Thereafter, at a point in time that completion of welding by the first roller electrode 26 and the second roller electrode 28 is reached, seam welding is brought to an end (step S 6 ). More specifically, the welding machine controller 62 controls the welding power source unit 50 and stops current between the first roller electrode 26 and the second roller electrode 28 . Further, by adjusting the pressures inside the first and second cylinders, the first roller electrode 26 and the second roller electrode 28 are separated away from the stacked assembly 100 . At this time, the current cycle of seam welding is brought to an end.
[0074] According to the present embodiment, since the second roller electrode 28 in contact with the workpiece (thinnest workpiece) W 3 is disposed more forwardly in the welding direction than the first roller electrode 26 , in the stacked assembly 100 , a current pathway, which is inclined in a direction opposite to the welding direction, is formed from the second roller electrode 28 toward the first roller electrode 26 . When this is done, in the current pathway, at a certain point in time T 1 , resistance heating occurs at the contact site (first contact site) H 1 a between the workpiece W 3 and the workpiece W 2 adjacent to the workpiece W 3 . In addition, at the point in time T 2 that the first roller electrode 26 and the second roller electrode 28 are moved relatively with respect to the stacked assembly 100 , the second site H 2 a adjacent to the first site H 1 a in the welding direction is heated, together with the third site H 2 b adjacent to the first roller electrode 26 side of the first site H 1 a being heated. At this time, the first site H 1 a , which already has been heated, is increased in heat further by the second site H 2 a and the third site H 2 b, and therefore, a nugget (well-proportioned nugget) of a sufficient size is formed at the first site H 1 a . Consequently, a joint is obtained which is superior in bonding strength.
[0075] Further, according to the present embodiment, compared to a situation in which the positions of the first roller electrode 26 and the second roller electrode 28 in the welding direction are aligned, the contact area S 1 of the first roller electrode 26 with respect to the workpiece W 1 , and the contact area S 2 of the second roller electrode 28 with respect to the workpiece W 3 can be increased. Consequently, since the current density of the current pathway is comparatively small, even in the case that the current value flowing between the first roller electrode 26 and the second roller electrode 28 is increased, the occurrence of welding debris can suitably be suppressed.
[0076] Furthermore, according to the present embodiment, since the angle of inclination θ is set corresponding to the ratio R of the thickness D 0 of the stacked assembly 100 with respect to the thickness D 2 of the workpiece W 3 , nuggets that are sufficiently large in size can efficiently be formed in the stacked assembly 100 . In addition, since the angle of inclination θ is set to 5° or less, excessive separation between the first roller electrode 26 and the second roller electrode 28 can be suppressed. Consequently, nuggets of sufficient size can be formed more effectively in the stacked assembly 100 .
[0077] The present invention will be described in greater detail by presenting the following exemplary embodiment according to the present invention.
First Example
[0078] With the present exemplary embodiment, as shown in FIGS. 8 and 9 , using a seam welding device 200 having the same structure as the above-described seam welding device 10 , after seam welding was performed on a stacked assembly 202 as an object to be welded, a shear strength test was performed.
[0079] As the stacked assembly 202 , there were stacked in this order a workpiece W 10 (JAC270F) with a plate thickness of 0.65 mm, a workpiece W 20 (JSC590R) with a plate thickness of 1.80 mm, and a workpiece W 30 (JSC590R) with a plate thickness of 1.40 mm. More specifically, the plate thickness R of the stacked assembly 202 was greater than 5 at roughly 5.9, as determined from the equation R=(1.40+1.80+0.65)/0.65.
[0080] With the seam welding device 200 according to the present exemplary embodiment, a first roller electrode 204 was arranged on the side of the workpiece (thinnest workpiece) W 10 , and a second roller electrode 206 was arranged on the side of the workpiece W 30 .
[0081] For each of the first roller electrode 204 and the second roller electrode 206 , water-cooled roller electrodes constituted from a copper chromium alloy (CrCu) were used. Further, a thickness t 1 of the first roller electrode 204 was set to 10 mm, and the radius of curvature r 1 of the outer circumferential surface thereof was set to 15 mm. A thickness t 2 of the second roller electrode 206 was set to 10 mm, and the radius of curvature r 2 of the outer circumferential surface thereof was set to 100 mm.
[0082] As welding conditions for the present exemplary embodiment, the welding speed was set to 4 m/min, the applied pressure was 450 kgf, a current-supplying cycle with an energization time of 6 msec and a rest time 6 msec was used, and the up-slope time was set to 150 msec.
[0083] Test results according to the present exemplary embodiment are shown in FIG. 10 . In FIG. 10 , the welding current is shown on the horizontal axis, and the angle of inclination is shown on the vertical axis. In FIG. 10 , ⊚ indicates a base material fractured sample in which debris was not generated, ◯ indicates an interfacial fractured sample in which debris was not generated, Δ indicates a base material fractured sample in which debris was generated, and X indicates a sample in which peeling occurred without generation of debris. More specifically, the portions indicated by ⊚ and ◯ imply that the heat input balance of the respective workpieces W 10 , W 20 , W 30 was favorable.
[0084] According to the test results, in the case that the second roller electrode 206 was disposed more forwardly than the first roller electrode 204 (i.e., in the case that the angle of inclination was −1 degrees and −3 degrees), compared to a case in which the angle of inclination is zero degrees, the welding current width became narrow with the sample ◯.
[0085] In the case that the angle of inclination was +1 degrees, compared to the angle of inclination being zero degrees, although the welding current width for the sample ◯ was the same, the region for the sample ◯ was shifted toward the high current side. In the case that the angle of inclination was +3 degrees, compared to the angle of inclination being + 1 degrees, the region for the sample ◯ was shifted further toward the high current side, while in part, the results of the sample ⊚ could be obtained. In the case that the angle of inclination was +5 degrees, compared to the angle of inclination being +3 degrees, the welding current width for the sample ⊚ was widened. In the case that the angle of inclination was +7 degrees, the results for samples ◯ and ⊚ could not be obtained.
[0086] In the foregoing manner, in the case that the plate thickness ratio R is greater than 5 , rather than with the angle of inclination being zero degrees, it was proven that weldability was improved when the angle of inclination resided within a range of 0°≦θ≦5°. Further, it was proven that weldability was further improved when the angle of inclination resided within the range of 3°≦θ≦5°.
[0087] The present invention is not limited to the embodiments described above, and it is a matter of course that various additional or modified structures could be adopted therein without deviating from the essential gist of the present invention.
[0088] For example, the seam welding method according to the present invention is not limited to the example of performing seam welding with respect to a stacked assembly 100 that is made up by stacking three workpieces W 1 , W 2 , W 3 . For example, as shown in FIG. 11 , the same effects and advantages of the aforementioned embodiment can be offered, even in the case that seam welding is carried out with respect to a stacked assembly 102 that is constituted by stacking two workpieces W 1 and W 3 . The same holds true for a case in which seam welding is carried out with respect to a stacked assembly that is constituted by stacking four or more workpieces. | A seam welding device sandwiches between a first roller electrode and a second roller electrode a laminate, which is formed by laminating a plurality of workpieces and disposing the thinnest workpiece, which has the smallest thickness among the workpieces, on the outside, to carry out seam welding. The second roller electrode, which is in contact with the thinnest workpiece, is disposed further along the direction of welding progress than the first roller electrode. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for venting residual vapors from a liquid storage vessel. More particularly, the present invention relates to a method and apparatus for venting residual vapors from a liquid storage vessel by introducing a gas to the storage vessel after removal of all liquids to provide a motive force to vent the vapors.
2. Description of the Prior Art
Volatile liquids, such as benzene, petroleum and the like, are often stored in tanks at bulk terminals, refineries and end-user facilities, and transported in tanks aboard barges or ships, tank trucks and rail cars. All such containers shall be referred to herein as liquid storage vessels. While resident in these liquid storage vessels, volatilization of the liquid occurs leaving residual vapors which must be removed before workmen can be permitted to enter the vessel and before the vessel can be filled with a different liquid.
Currently, such residual vapors are purged by flooding liquid storage vessels with a sufficient volume of water or air to entrain the vapors and carry them out of the vessel. The resulting mixture of diluted vapors, in many cases, are simply emitted to the atmosphere and surrounding water supply where they pollute the environment. Emissions handled in this manner lead to severe environmental hazards. For example, the inhalation of benzene vapors may cause depression of bone marrow activity, convulsions and paralysis. In addition, hydrocarbons are a major contributor to the formation of smog which has been proven to increase respiratory disorders among the population.
In addition to these environmental problems, water flushing facilities must overcome many economic hurdles. Adequate water for such facilities may be expensive due to limited water resources or to restrictions concerning the reuse or recycling of the water. If the water must be reused or recycled, it must be treated to remove contaminants that might pollute the environment or contaminate the next vessel to be flushed.
The environmental problems associated with air flushing could be eliminated by sending the mixture of vented air and vapors to a combustion device where the harmful vapors would be destroyed rather than emitted to the atmosphere. Unfortunately, as much as three times the liquid storage vessel volume of air must be cycled through the vessel to ensure that all of the residual vapors are purged from the vessel. Clearly, such a solution is impractical because of the large amount of air which would have to be heated in a combustion device before the volatiles they carry would be destroyed. The size of the collection piping and combustion equipment associated with such a process, in addition to the amount of fuel required to combust the vapors, similarly would be quite large, thereby prohibitively increasing the cost of such a process.
There have been several patents in the prior art which attempted to address the problem of removing vapors from storage tanks and collecting the gases which are forced out of the storage tank to reuse such gases for combustion.
U.S. Pat. No. 291,085 shows apparatus for removing flammable gases from oil tanks which includes devices for causing an induced current of air to pass into a storage tank above the surface of the fluid (such as fuel oil) and at the same time conduct displaced gases to a point where they may be used as fuel or discharged with safety into the atmosphere. The patent which issued in 1884 teaches the use of air as a medium for forcing gaseous vapors from a storage tank.
It has been learned over the past hundred years that air is an unsafe medium for use in cleansing storage tanks and also can result in corrosion of the tank. The device shown by the patent is relatively simple and primitive and does not include the safety features or efficient means for recapture of vapors for other use as is claimed by the present invention.
U.S. Pat. No. 1,918,100 shows a gas-gathering system which is basically a closed system in which vapors which collect in a storage tank are pumped into a secondary vapor storage tank partially filled with water and from the vapor storage tank are recaptured through a compression and condensing process to provide dry gas for other uses such as combustion. The patent states as its primary objective the provision of a method and apparatus for maintaining a hydrocarbon gas at all times within the storage tanks above the liquid levels thereof with the specific end in view of preventing air or oxygen from entering the tanks and mixing with the gases contained therein.
It should be noted at this point that this patent specifically teaches away from the method and apparatus of the 291,085 patent in that 291,085 teaches the use of air as a medium for moving vapors out of a storage tank, and 1,918,100 specifically provides a method to prevent air or oxygen from entering the tank and mixing with the gases.
Although the 1,918,100 patent is a more modern gas collection system apparatus and method, it does not show nor suggest the present invention which includes control of the flow of a purge medium to provide a laminar flow to create a continuous stratified interface between the volatile vapors and the purge medium. Nor does 1,918,100 teach or suggest any mechanism for detection of completion of the purging operation nor mixing with a high BTU material for later combustion. Nor does either prior art patent introduce gas at the bottom of the tank as is shown and claimed with respect to one embodiment of the present invention.
SUMMARY OF THE INVENTION
The method and apparatus for venting a liquid storage vessel of the present invention overcome the above-noted disadvantages and drawbacks which are characteristic of the prior art.
The present invention is directed to a method which comprises the steps of introducing a purge medium to a liquid storage vessel containing volatile organic compound vapors and establishing a uniform and continuous stratified interface between the purge medium and the volatile organic compound vapors. The introduction of the purge medium is continued causing the continuous stratified interface to move within the vessel purging the undiluted volatile organic compound vapors from the vessel.
In a preferred embodiment, a purge medium, preferably carbon dioxide, is introduced to the bottom of a liquid storage vessel containing relatively light volatile organic compound vapors establishing a uniform and continuous stratified interface between the purge medium and the volatile organic compound vapors. The introduction of the purge medium is continued causing the continuous stratified interface to rise within the vessel purging the undiluted volatile organic compound vapors from the top of the vessel.
In an alternate preferred embodiment, a purge medium, preferably nitrogen, is introduced to the top of a liquid storage vessel containing relatively heavy volatile organic compound vapors establishing a uniform and continuous stratified interface between the purge medium and the volatile organic compound vapors. The introduction of the purge medium is continued causing the continuous stratified interface to descend within the vessel purging the undiluted volatile organic compound vapors from the bottom of the vessel.
In a preferred embodiment, the undiluted volatile organic compound vapors are purged into a vapor recovery line which delivers the volatile organic compound vapors to a vapor handling device.
The present invention also is directed to apparatus for performing the above-described methods.
BRIEF DESCRIPTION OF THE DRAWINGS
Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following disclosure when taken in conjunction with the accompanying drawings, in which:
FIG. 1 shows a schematic view of apparatus for performing the storage tank venting method of the present invention;
FIG. 2 shows a schematic view of a modified version of the apparatus depicted in FIG. 1;
FIG. 3 shows a schematic view of apparatus for performing the storage tank venting method of the present invention; and
FIG. 4 shows a schematic view of a modified version of the apparatus depicted in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and particularly to FIG. 1, a schematic representation of a preferred embodiment of a liquid storage vessel venting apparatus arranged to perform the method of the present invention is generally shown at 8. A liquid storage vessel 10 of typical construction has apertures for receiving and dispensing various fluids, including volatile organic compounds such as benzene and petroleum products which generate vapors 12.
According to this embodiment, a gas 14 is introduced at or near the bottom of the vessel 10 to provide a motive force to purge the vapors 12 from the vessel 10. The gas 14 preferably is heavier than and inert with respect to the vapors 12, and is introduced to the vessel 10 in a laminar, or near laminar, flow with little or no turbulence. As the gas 14 enters the vessel 10, an uniform stratification develops with the vapors 12 forming a layer above a layer formed by the gas 14. In this manner, mixing of the gas 14 with the vapors 12 is avoided and the vapors 12 remain undiluted. As shown in FIG. 1, an uniform interface 16 develops between the gas 14 and the vapors 12. As more gas 14 is introduced to the vessel 10, the interface 16 approaches the top of the vessel 10 driving the undiluted vapors 12 from the vessel 10. Preferably, the gas 14 is such that it may be dispersed into the environment without contaminating the surrounding area. Preferably, the gas 14 comprises carbon dioxide. Those of ordinary skill in the art will recognize that other gases that are heavier than the vapors 12 may also be utilized as the gas 14.
A supply of gas 14 is provided in an insulated tank 18. Preferably, the gas 14 is stored in the tank 18 in a chilled liquid state. The gas 14 is delivered to the vessel 10 through a fill line 20. The fill line 20, preferably, introduces the gas 14 to the vessel 10 via an opening 22 disposed near the bottom of the vessel 10. A valve 24 is provided in the fill line 20 to control the flow of the gas 14 from the tank 18.
Preferably, the gas 14 is stored as a liquid under high pressure. The gas 14 undergoes a pressure reduction as it leaves the tank 18 causing the gas to auto-refrigerate in the fill line 20. A heat exchanger 26 is provided to interact thermally with the gas 14 as it passes through the fill line 20 to raise the temperature of the gas 14 to a desired point, preferably to about 0° F.
As shown in FIG. 2, the gas 14 may alternately be delivered to the vessel 10 through a fill line 20, which extends through an opening 22, disposed on the top of the vessel 10. The distal end of the fill line 20, is disposed near the bottom of the vessel 10 to introduce the gas 14 beneath the vapors 12.
Referring to both FIGS. 1 and 2, a vapor recovery line 28 extends from an opening 30 disposed in the roof of the vessel 10 to receive the vapors 12 that are purged from the vessel 10 as it is filled with the gas 14. A gas detector 32 may be provided in the recovery line 28 to monitor the gas purged from the vessel 10 to check for the presence of the gas 14. When the gas 14 is detected by the gas detector 32, the venting process has been completed.
A low pressure blower 34 may be provided to receive the Vapors 12 exiting detector 32 and to direct the vapors 12 to a vapor handling device described below. To prevent the vessel 10 from collapsing, care must be taken to prevent the blower 34 from creating an excessive vacuum within the vessel 10.
The vapors 12 may be directed by the blower 34 through a filter 36 for extracting condensed liquids from the vapors 12 flowing through the recovery line 28. After passing through the filter 36, the vapors 12 may be passed to a vapor handling device 38 where the vapors 12 are processed for further handling. Preferably, the vapors are combusted and destroyed prior to their emission to the atmosphere. If the combustibility of the vapors 12 is insufficient for adequate burning, a supply of natural gas, propane, butane or other high BTU source material may be provided under the control of a valve to increase the BTU level of the vapors 12. Alternatively, the vapors 12 can be condensed or cooled to a liquid form by a refrigeration system. The recovered liquids can be deposited in a storage tank for further handling. The vapors 12 can also be sent to a system in which the vapors 12 are compressed and refrigerated for further handling. Another possibility is that the vapors 12 can be passed through a molecular sieve material that absorbs hydrocarbons. Those of ordinary skill in the art will recognize that other vapor handling devices may be utilized as the circumstances may dictate.
The gas 14 which now fills the vessel 10 may be dispersed from the vessel 10 directly to the atmosphere Either immediately, or upon the refilling of the vessel 10.
Referring now to FIG. 3, a schematic of another preferred embodiment of the present invention is shown and referred to in general by the reference numeral 40. A liquid storage vessel 42 of typical construction has apertures for receiving and dispensing various fluids, including volatile organic compounds such as benzene and petroleum products which generate vapors 44.
According to this embodiment, a gas 46 is introduced at or near the top of the vessel 42 to provide a motive force to purge the vapors 44 from the vessel 42. The gas 46 preferably is lighter than and inert with respect to the vapors 44, and introduced to the vessel 42 in a laminar, or near laminar, flow with little or no turbulence. As the gas 46 enters the vessel 42, an uniform stratification develops with the gas 46 forming a layer above a layer comprised of the vapors 44. In this manner, mixing of the gas 46 with the vapors 44 is avoided and the vapors 44 remain undiluted. As shown in FIG. 3, an uniform interface 48 develops between the gas 46 and the vapors 44. As more gas 46 is introduced to the vessel 42, the interface 48 approaches the bottom of the vessel 42 driving the undiluted vapors 44 from the vessel 42. Preferably, the gas 46 is such that it may be dispersed into the environment without contaminating the surrounding area. Preferably, the gas 46 comprises nitrogen, but those of ordinary skill in the art will recognize that other gases that are lighter than the vapors 44 may also be utilized as the gas 46.
A supply of gas 46 is provided in an insulated tank 50. Preferably, the gas 46 is stored in the tank 50 in a chilled liquid state. The gas 46 is delivered to the vessel 42 through a fill line 52. The fill line 52, preferably, introduces the gas 46 to the vessel 42 via an opening 54 disposed near the top of the vessel 42. A valve 56 is provided in the fill line 52 to control the flow of the gas 46 from the tank 50.
Preferably, the gas 46 is stored as a liquid under high pressure. The gas 46 undergoes a pressure reduction as it leaves the tank 50 causing the gas to auto-refrigerate in the fill line 52. A heat exchanger 58 is provided to interact thermally with the gas 46 as it passes through the fill line 52 to raise the temperature of the gas 46 to a desired point, preferably to about 0° F.
A vapor recovery line 60 extends from an opening 62 disposed near the bottom of the vessel 42 to receive the vapors 44 that are purged from the vessel 42 as it is filled with the gas 46. Alternatively, and as shown in FIG. 4, a vapor recovery line 60, extends into the vessel 42 through an opening 62, disposed on the top of the vessel 42. The proximal end of the recovery line 60, is disposed near the bottom of the vessel 42 to receive the vapors 44 as the vessel 42 fills with the gas 46.
Referring to both FIGS. 3 and 4, a gas detector 64 may be provided in the recovery line 60 or 60, to monitor the gas purged from the vessel 42 to check for the presence of the gas 46. When the gas 46 is detected by the gas detector 64, the venting process has been completed.
A low pressure blower 66, a filter 68, and a vapor handling device 70 may be provided to receive the vapors 44 exiting the detector 64 to process them for further handling. Since these devices are the same as the corresponding devices described in connection with the previous embodiment, they will not be described here in detail.
The present invention will be further illustrated by the following specific examples, it being understood that while these examples may describe in detail some of the preferred features of the invention, they are merely provided for the purpose of illustration and are not intended to limit the broader aspects of the present invention.
EXAMPLE 1
A test of the present invention was conducted to vent the gaseous contents of a liquid storage vessel carried aboard a barge. For the purpose of this test, volatile organic compound vapors were removed from the tank so that it contained only air.
Liquid carbon dioxide stored in a refrigerated tank truck at about about 0° F. and about 300 psia was released into a fill line, which reduced the pressure of the gas from 300 psia to about 100 psia causing the carbon dioxide gas to auto-refrigerate to about -35° F. The temperature of the carbon dioxide gas was raised to about 30° F. by passing the gas through a steam heat exchanger. From this point the pressure of the carbon dioxide within the fill line was dropped to atmospheric pressure without forming solids. This pressure reduction, however, again caused the carbon dioxide gas to auto-refrigerate to about 0° F.
The carbon dioxide gas was then introduced to the bottom of the vessel through an 8 inch line at a flow rate of approximately 7,000 cfh. It was admitted in a nonturbulent, metered flow to create an even and uniform stratification between the air present in the vessel and the incoming carbon dioxide gas. An air-carbon dioxide gas interface formed in the vessel and continually rose toward the roof of the vessel as more carbon dioxide gas was admitted. As the interface rose, the air in the vessel was forced toward and through an opening in the roof of the vessel without experiencing any significant mixing of the air and carbon dioxide gas, leaving the vessel completely void of air and full of carbon dioxide gas.
EXAMPLE 2
All liquids are removed from a liquid storage vessel carried aboard a barge. The liquid storage vessel contains volatile organic compound vapors.
Liquid carbon dioxide stored in a refrigerated tank truck at and about 0° F. and about 300 psia is released into a fill line, which reduces the pressure of the gas from 300 psia to about 100 psia causing the carbon dioxide gas to auto-refrigerate to about -35° F. The temperature of the carbon dioxide gas is raised to about 30° F. by passing the gas though a steam heat exchanger. From this point the pressure of the carbon dioxide within the fill line is dropped to atmospheric pressure without forming solids. This pressure reduction, however, again causes the carbon dioxide gas to auto-refrigerate to about 0° F.
The carbon dioxide gas is then introduced to the bottom of the vessel through an 8 inch line at a flow rate of approximately 7,000 cfh. It is admitted in a nonturbulent, metered flow to create an even and uniform stratification between the volatile organic compound vapors present in the vessel and the incoming carbon dioxide gas. A volatile organic compound vapor-carbon dioxide gas interface forms in the vessel and continually rises toward the roof of the vessel as more carbon dioxide gas is admitted. As the interface rises, the air in the vessel is forced toward and through an opening in the roof of the vessel without experiencing any significant mixing of the volatile organic compound vapors and carbon dioxide gas, leaving the vessel completely void of volatile organic compound vapors and full of carbon dioxide gas.
The purged volatile organic compound vapors, undiluted by employing the present invention, are forced into a recovery line connected to the vessel. The carbon dioxide gas is introduced into the vessel until a detector in the recovery line detects the presence of the carbon dioxide gas. At this point, due to the uniform stratification maintained within the vessel, all of the residual vapors originally in the vessel are purged from the vessel, and the vessel is filled solely with carbon dioxide gas. A blower attached to the recovery line directs the vapors through a filter to remove any condensed liquids within the vapor stream. The blower also directs the vapors to a combustion device where, if needed, the vapors are mixed with natural gas or other high BTU source and combusted prior to their emission to the atmosphere.
It is thus seen that the method and apparatus of the present invention provides several advantages. In general, the present invention reduces the amount of purge medium necessary to vent residual vapors from all types of liquid storage vessels to nearly a single vessel volume. In addition, since the present invention eliminates the need for flushing water or air, it is an environmentally safe and efficient way to vent residual vapors. Further, since the vapors are not diluted, the combustibility of the vapors might be sufficiently high for burning, or at the very least they can be combusted with a minimal addition of fuel. The present invention can also be used to purge residual vapors that are either heavier or lighter than the purge medium.
It is understood that variations of the foregoing can be made within the scope of the present invention. For example, numerous purging mediums can be used to provide the motive force to vent the vessel 10 or 42. Further, the present invention can be used to vent more than just volatile organic compound vapors from liquid storage vessels. It is applicable for venting any type of gaseous fluid from any type of enclosure.
Further, the gas detector can be replaced by a flow meter which measures the amount of purging medium introduced into the vessel. A single turnover of the vessel volume plus 10% extra gas will sufficiently vent the vapors from the vessel. Since the volume flow rate of the gas and the volume of the vessel are known, the flow meter can also be eliminated, by calculating and using the time needed to introduce enough gas to equal 1.1 times the volume of the vessel. In addition, the blower can be eliminated if the structural design of the vessel is sufficiently high to allow for pushing the vented vapors through the collection piping.
A latitude of modification, change and substitution is intended in the foregoing disclosure and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | A method and apparatus for venting volatile organic compound vapors from a liquid storage vessel which includes the steps of introducing a purge medium to a liquid storage vessel containing volatile organic compound vapors and establishing an uniform and continuous stratified interface between the purge medium and the volatile organic compound vapors. The introduction of the purge medium is continued causing the continuous stratified interface to move within the vessel purging the undiluted volatile organic compound vapors from the vessel and into a vapor recovery line which delivers the volatile organic compound vapors to a vapor handling device. Preferably, the purge medium comprises carbon dioxide or nitrogen. | 1 |
PRIORITY
The present application is a divisional application of U.S. patent application Ser. No. 08/886,217 filed on Jul. 1, 1997, now U.S. Pat. No. 5,904,659 issued on May 18, 1999, which is a continuation application of U.S. patent application Ser. No. 08/799,240 filed on Feb. 14, 1997 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This disclosure relates to the non-invasive application of ultrasonic energy to enhance and/or accelerate the process of wound healing, and more particular, to the healing of wounds including ulcers, such as venous ulcers.
2. Description of the Related Art
Venous ulcers on human legs have proven difficult to treat, for example, because of the lack of vascularization in and around the wound.
The term “wound” for the purposes of “wound healing”, as used throughout the present disclosure, includes ulcers such as venous ulcers as well as burns, ulcerated wounds due to, for example, diabetes, surgical incisions or other surgical cuttings including stitched surgical cuttings, skin grafts, hair transplants, re-vascularization, bed sores, tissue dehiscence, and ligament and tendon repair and reconstruction. In general, as used throughout the present disclosure, the term “wound healing” encompasses addressing damage to, repair of, or restoration of soft tissue.
U.S. Pat. No. 4,530,360 to Duarte (hereafter “Duarte”), describes a basic therapeutic technique and apparatus for applying ultrasonic pulses from an ultrasonic applicator placed on the skin at a location adjacent a bone injury. Duarte gives a range of radio frequency (RF) signals for creating the ultrasound, ultrasonic power density levels, a range of duration of each ultrasonic pulse, and a range of ultrasonic pulse frequencies. The length of daily treatment is also described in Dart. The Dart patent is incorporated herein by reference.
U.S. Pat. Nos. 5,003,965 and 5,186,162, both to Tallish and Lifshey (hereafter “Tallish '965” and “Tallish '162”, respectively) describe an ultrasonic delivery system in which the RF generator and transducer are both part of a modular applicator unit which is placed at the skin location. The signals controlling the duration of ultrasonic pulses and the pulse repetition frequency are generated apart from the applicator unit. Tallish '965 and Tallish '162 also describe fixture apparatus for attaching the applicator unit so that the operative surface is adjacent to the skin location. In one application described in Tallish '965 and Tallish '162, the skin is surrounded by a cast.
U.S. Pat. No. 5,211,160 to Tallish and Lifshey (hereafter “Tallish '160”) also describes a fixture apparatus which is mounted on uncovered body parts; i.e. without a cast or other medical wrapping. Tallish '160 also describes various improvements to the applicator unit. Each of Tallish '965, Tallish '162, and Tallish '160 is incorporated herein by reference.
U.S. Pat. No. 5,755,746 to Lifshey and Talish (hereafter “Lifshey '746”); U.S. Pat. No. 5,626,554 to Ryaby, Talish and McCabe (hereafter “Ryaby '554”); U.S. Pat. No. 5,556,372 to Talish, Ryaby, Scowen and Urgovitch (hereafter “Talish '372”); and U.S. Pat. No. 5,520,612 to Winder, Talish and Ryaby (hereafter “Winder '612”), entitled Locator Method and Apparatus, Gel Containment Structure, Apparatus for Ultrasonic Bone Treatment, and Acoustic System for Bone-fracture Therapy, respectively, provides ultrasonic apparatus and methods which are applicable to wound healing. Lifshey '746, Ryaby '554, Talish '372, and Winder '612 are incorporated herein by reference.
In general, an ultrasound carrier frequency between 20 kHz and 10 MHZ coupled with a relatively low-frequency modulating signal, such as 5 Hz to 10 kHz, and a spatial peak temporal average acoustic intensity, such as an intensity less than about 100 milliwatts/cm 2 , should aid in and should be effective in wound healing.
Heretofore, such techniques have not been applied to heal wounds by internal application of ultrasound, such as using reflection of ultrasonic waves by reflection from internal tissue such as bone.
SUMMARY
It is herein recognized that both longitudinally propagating ultrasound and shear waves generated by a transducer mechanism and/or by such longitudinally propagating ultrasound provide effective healing of wounds.
A portable therapeutic device and method of use thereof for healing a wound includes a transducer having an operative surface, with the transducer, disposed substantially adjacent to the wound to emit ultrasound to propagate in the direction of the wound for the healing thereof. Reflections of the ultrasound by bone tissue and by skin layers propagate toward the wound as longitudinal waves for the healing thereof, and shear waves are generated by the longitudinal waves and/or the reflected longitudinal waves for the healing of the wound.
The transducer may include an axis and a focusing element for focusing the propagation of the ultrasound at a predetermined angle with respect to the axis, with the focused ultrasound propagating toward the wound for the healing thereof.
Alternative configurations of the operative surface of the transducer include an annularly shaped operative surface for emitting the ultrasound therefrom, with the wound encircled by the operative surface for receiving the ultrasound and/or reflected ultrasound.
A housing may be provided for positioning the transducer substantially adjacent to a portion of the skin substantially adjacent to the wound, and for causing the portion of the skin to form a cavity, with the operative surface of the transducer disposed in the cavity to emit the ultrasound to an internal surface of the wound for the healing thereof.
Reflective media may be internally disposed within the body having the wound for reflecting the ultrasound from the transducer to propagate toward the wound for the healing thereof. Fixture structures, extending about a portion of the body having the wound, may also be provided for positioning the transducer substantially adjacent to the skin substantially adjacent to the wound. The fixture structure may include an adjustable strap.
In other embodiments, the transducer may be a rod-shaped operative surface having an axis for emitting the ultrasound radially toward the wound for the healing thereof.
Using the disclosed therapeutic devices, wounds are safely and simply treated, with such wounds as venous ulcers responsive to therapeutic ultrasound to be healed effectively. Such therapeutic devices and methods of use provide for wound treatment by modest adaption of existing devices for delivering ultrasound in therapeutic settings.
In one embodiment, a device is provided for delivering an ultra-high-frequency carrier signal for low power excitation of an acoustic transducer which is acoustically coupled to a limb or other part of a living body. The transducer is positioned adjacent an external skin location in the vicinity of the external border of the wound on the skin to provide a surgical, non-invasive transcutaneous delivery of at least part of its acoustic energy directed from the external skin location toward a portion of a bone located within the body in the vicinity of the boundary of the wound internal to the body. The boundary of the wound internal to the body is also referred to herein as the internal or interior surface of the wound.
Once the acoustic energy enters the body, it passes into internal body tissue and/or fluids. The acoustic energy, in the form of ultrasonic pulses, is reflected off the surface of underlying bone or other ultrasound reflective material, and the reflected ultrasound travels toward at least part of the internal surface or underside of the wound. Healing of the wound at the internal surface by the generation of epithelial cells is enhanced via the acoustic stimulation.
Preferably, a low frequency signal which is present as a modulation of the carrier frequency is transmitted from the ultrasonic transducer, through interposed soft tissue, and onto the surface of the bone. The carrier wave incident on the bone surface, or other reflection surfaces in the body, is reflected toward the internal surface of the wound. When the carrier wave impinges the internal surface of the wound, at least a portion of the carrier wave is converted into therapeutically beneficial shear waves of acoustic energy, flooding a region of the internal surface of the wound. The shear waves increase vascularization at the internal surface of the wound, thus enhancing growth of epithelial cells. The epithelial cell growth represents healing of the wound. The technique thus promotes healing of the wound from the internal surface of the wound.
The number, position, and size of ultrasonic applicators used at the external skin location are chosen based on the size and position of the wound, and the relative position and proximity of the bone from which the ultrasonic waves are reflected. One or more ultrasonic therapy treatments per day, each having a duration of approximately 20 minutes, is suitable.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the disclosed therapeutic ultrasound apparatus and method will become more readily apparent and may be better understood by referring to the following detailed description of an illustrative embodiment of the present invention, taken in conjunction with the accompanying drawings, where:
FIG. 1 is a cut-away perspective view showing a device and method of use thereof for wound healing;
FIG. 2 is a side view of an embodiment of an ultrasound transducer;
FIG. 3 is a side cross-sectional view of the device using a focusing attachment;
FIG. 3A is a cut-away perspective view of an alternative embodiment of the transducer configured to have an annular shape and a woven fabric covering;
FIG. 4 is a frontal view of a typical wound disposed on a torso;
FIG. 5 is a cut-away perspective view of the wound healing device disposed near the wound in the torso;
FIG. 6 is a cut-away perspective view of the wound healing device applied to a wound in conjunction with a gel bladder;
FIG. 7 is a cut-away perspective view of the wound healing device causing an indentation of the torso to orient the transducer for healing the wound;
FIG. 8 is a cut-away perspective view of the wound healing device operating in conjunction with an internally disposed reflecting medium;
FIG. 9 is a cut-away perspective view of an alternative configuration of the wound healing device having an annular configuration and a woven fabric covering and operating in conjunction with an internally disposed reflecting medium;
FIG. 10 is a cut-away perspective view of an alternative configuration of the wound healing device having a rod-like configuration;
FIG. 11 is a cut-away perspective view of an alternative configuration of the wound healing device having an annular configuration without a woven fabric covering; and
FIG. 12 is a perspective view of an alternative configuration of the wound healing device attachable to a thigh for healing a wound thereupon.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in specific detail to the drawings, with like reference numerals identifying similar or identical elements, as shown in FIG. 1, the present disclosure describes an apparatus 10 and method of use thereof for wound healing, which includes an ultrasonic generator 12 and one or more ultrasonic applicators 14 , which include ultrasonic transducers 16 known in the art, for applying ultrasonic waves 18 , 20 to a wound 22 , such as an ulcer. More than one applicator 14 or transducer 16 may be used to stimulate larger wounds, as needed. The spatial peak temporal average acoustic intensity of the applicators 14 is between about 5 mW/cm 2 and about 100 mW/cm 2 . The carrier frequency and intensity of the ultrasonic treatment is selected by taking into account such factors as: (1) the amount of soft tissue interposed between the external skin location, where the ultrasonic applicator 14 is positioned, (2) the position and cross-section of the bone site 24 from which the ultrasonic waves 18 are reflected, (3) the amount of soft tissue interposed between the bone 26 and the internal surface 28 of the wound 20 , and (4) the size, topography and medical characteristics of the internal surface 28 of the wound 20 , and, consequently, shear waves or surface acoustic waves (SAW) and longitudinal waves to be generated at the site.
The carrier wave is modulated with an audio signal approximately between 5 Hz and 10 Khz. Low level ultrasound delivers a primary wave called the longitudinal wave 30 , which is emitted by the transducer 16 of the applicator 14 as shown in FIG. 1 . There are also shear waves or SAW 32 generated by the ultrasound from the transducer 16 which radiate outward along the skin surface. The primary longitudinal wave 30 is partially incident on a bone 26 in the body, and so is partially reflected at a reflection site 24 to generate a reflected portion 34 , with the reflected portion 34 directed toward the internal surface 28 of the wound 22 . The primary longitudinal wave 30 may also be reflected by other surfaces. For example, as shown in FIG. 1, the internal layer 36 of skin on the opposite side of a limb to the transducer 16 may provide a reflective surface to thus generate additional reflected longitudinal waves 38 directed from the opposite internal skin layer 36 to the wound 22 .
When the reflected longitudinal waves 34 , 38 impinge on the internal surface 28 of the wound 22 , such reflected longitudinal waves 34 , 38 are at least partially converted to shear waves or SAW 32 in and around the internal surface 28 of the wound 22 , which enhance wound healing at the internal surface 28 by stimulating cell production by the mesenchymal line, thus promoting vascularization and epithelialization.
As shown in the illustrative embodiment in FIG. 1, the ultrasonic applicator 14 , including the transducer 16 configured as a modular unit, is placed adjacent an external skin location 40 in the vicinity of the external border of the wound 22 . A gel bladder 42 , or alternatively a loose conducting gel or other ultrasound conducting media, is positioned between the transducer 16 and the external skin location 40 . As shown in FIG. 1, the ultrasound which is transmitted into the soft tissue medium in the form of longitudinal waves 30 diverges as it moves toward the bone 26 or other surfaces such as the skin layer 36 providing reflection. The reflected ultrasound, in the form of longitudinal waves 34 , 38 , continues to diverge as it approaches the internal surface 28 of the wound 22 , so that the ultrasonic treatment delivered to the general site of the wound 22 covers a relatively large region of the internal surface 28 of the wound 22 .
Alternatively, as shown in FIG. 2, the transducer 16 may have an attachment, typically positioned between the operative surface 46 of the transducer 16 and the gel bladder 42 , which acts as a focusing element to focus the ultrasound emitted from the operative surface 46 into the soft tissue. In another embodiment, the transducer 16 may be configured to have the focusing element integrally formed with the transducer 16 . FIG. 3 shows a side view of the transducer housing of FIG. 2 showing the transducer 16 including the focusing element, illustratively embodied as the attachment 44 . Thus, the ultrasound emitted from the transducer 16 in the form of a primary longitudinal wave 30 may be directed at an angle 48 with respect to an axis 50 associated with the transducer and thence toward the bone 26 or other reflective surfaces when the ultrasound enters the soft tissue. The reflected waves 34 , 38 also remain relatively focused.
The reflected longitudinal waves 34 , 38 may generate respective sets of shear waves or SAW for providing a combined therapeutic treatment to the wound 22 . As shown in FIG. 3, the reflected longitudinal wave 34 created by reflection of the primary longitudinal wave 30 off the bone 26 is incident on a portion of the internal surface 28 of the wound 22 , thus creating a first set of shear waves 52 . The reflected longitudinal wave 38 created by the reflection of the primary longitudinal wave 30 off the opposite side layer 36 of tissue is incident on a separate portion of the wound 22 , thus creating a second set of shear waves 54 . In addition to this technique, the angle 48 of the ultrasonic emission may be swept and/or modified, either physically or electronically, so that different regions of the internal wound surface 28 may be treated.
In either technique, two or more transducers may be used, as determined by the size, length, etc. of the wound 22 . Generally, multiple transducers may be provided at a number of external skin locations around the wound 22 in order to increase the effectiveness of the ultrasonic therapy reflected to the internal surface 28 of the wound 22 .
In the illustrative embodiments of FIGS. 1-3, the ultrasonic head module of the ultrasonic applicator 14 includes the transducer 16 of an ultrasonic treatment apparatus. For clarity, the fixture structure which holds the head module adjacent the external skin location 40 is omitted. Also omitted are the electronics and other features which ultimately provide the excitation signals for the transducer 16 . These are described in further detail in the above-referenced patents and patent applications, which have been incorporated by reference.
Alternatively, or in conjunction, the at least one ultrasonic applicator 14 may be moved, or may be configured to be movable, to a different external skin location adjacent the wound 22 in order to provide treatment to various portions of the wound 22 . Varying the position of the at least one ultrasonic applicator, including moving the transducer 16 circularly or linearly along the skin, also provides treatment of varying intensity at portions of the wound 22 .
The transducer 16 itself may also be configured to vibrate with respect to a given external skin location, so that the longitudinal waves 30 generated therefrom and transmitted through the soft tissue are more uniform, thus providing more uniform treatment, including more uniform shear waves, at the internal wound surface 28 where the reflected longitudinal waves 34 , 38 impinge. The transducer 16 may be made to vibrate with respect to a housing (not shown in FIGS. 1-3 for clarity) which holds the transducer 16 adjacent an external skin location to accomplish such uniformity of longitudinal waves 30 .
The focusing of ultrasonic waves described with respect to FIGS. 2-3 above is illustratively shown with a substantially planar operative surface 46 and a substantially conical attachment 44 . In alternative embodiments, the focusing of ultrasonic waves may be provided by configuring the transducer 16 with non-planar surfaces such as non-planar operative surfaces or non-planar segments to generate and emit ultrasound with different propagation characteristics in order to allow differing patterns and intensities of ultrasonic waves to be transmitted toward the internal surface 28 of the wound 22 . This provides a variety of therapeutic ultrasonic stimulation and treatment at the internal surface 28 .
For example, the transducer segments may be pie shaped, annular rings, or other configurations, which may be activated separately or in unison. Alternatively, or in conjunction, the transducer 16 may be provided with a modal converter or transducer lens, which may also change the pattern of the ultrasound emitted from the transducer 16 .
The carrier frequency and/or the modulating frequency may also be varied or swept through a range of frequencies in order to provide a variety of treatments to the internal wound surface 28 . The frequencies may be varied either in a continuous manner, or discrete changes may be made in the applied frequency. Varying the carrier and/or modulating frequency is especially useful in applying ultrasonic treatment to promote a variety of stages of cell regeneration in approximately the same region during the same therapy session.
In an alternative embodiment, FIG. 3A illustrates treatment of a wound 22 such as a venous ulcer as in FIGS. 1-3, but utilizing an annular-shaped transducer 56 having a curved operative surface 58 (shown in a cut-away perspective view in FIG. 3A) composed of a composite piezoelectric material attached by a connector 60 to an ultrasonic generator (not 9 shown in FIG. 3 A), in which the composite piezoelectric material disposed in a woven fabric 62 or a semi-permeable member provides ultrasonic conductivity between the transducer 56 and the skin of the patient. The woven fabric 60 may have either a hard or a pliable construction, and may be composed of material conductive of ultrasound. Alternatively, the woven fabric 60 may be porous for retaining and releasing ultrasound conductive gel.
The transducer 56 is cut or constructed to surround the external surface of the wound 22 . When the appropriate RF signals are applied, the composite piezoelectric material of the transducer 56 emits ultrasonic waves having the therapeutic parameters previously described. Primary longitudinal waves 64 , 66 are emitted from the composite piezoelectric material into the body, as shown in FIG. 3A, and reflected from the surface of the bone 26 or from other reflective interfaces, to generate reflected longitudinal waves 68 , 70 , respectively, which are directed onto the internal surface 28 of the wound 22 , thus creating therapeutic shear waves 72 , 74 , respectively. It is understood that the composite piezoelectric material may completely surround the wound 22 ; thus, the primary longitudinal waves 64 , 66 are emitted from around the entire wound, reflected from the reflecting material, and incident on the internal surface 28 of the wound 22 , thereby flooding the internal surface 28 of the wound 22 with the induced shear waves 72 , 74 .
While the embodiments of the present invention described above refer to the reflection of a primary longitudinal wave from a bone to an internal surface of a wound, the present invention also encompasses delivery of ultrasound to the internal surface of the wound where there is no bone or other reflecting surface in the vicinity of the wound, as described below in further detail with reference to FIGS. 4-11.
FIG. 4 illustrates the front of a male torso 76 having a wound 78 on the stomach. The views illustrated in FIGS. 5-11 are cross-sectional views of FIG. 4 taken across lines 5 — 5 . As shown in FIG. 5, a transducer 80 is positioned in a transducer housing 82 disposed upon the external skin of the torso 76 adjacent to the external border of the wound 78 , and a longitudinal wave 84 emitted from the transducer 80 penetrates far into the body before it is reflected off a surface internal to the torso 76 such as the spine or any internal organs such as the lungs, stomach, or intestines, which may contain gases such as air, with reflected longitudinal waves then directed onto the internal surface 86 of the wound 78 . This is especially true when the person is overweight, or when the cross-section of available reflecting surfaces is small and/or uneven. The longitudinal wave 84 may provide some therapeutic healing of the wound 78 , but the intensity of the reflected wave incident on the internal surface 86 of the wound 78 may be too attenuated to provide the necessary therapeutic treatment.
FIG. 6 shows an alternative method and embodiment of treating such wounds of the torso 76 , in which a gel bladder 88 is interposed between the external surface of the wound 78 and the operative surface of the transducer 80 . The longitudinal wave 84 emitted from the transducer 80 travels directly through the gel bladder 88 and into the wound 78 , thus creating a shear wave 90 when the longitudinal wave 84 is incident on the internal surface of the wound 78 . The gel bladder 88 is to be sterile, especially if the wound 78 is open, and may be impregnated with medication, such as an antibacterial ointment, which flows into the wound 78 and/or its surface during the ultrasonic treatment.
FIG. 7 illustrates another method and device for treating the wound 78 of a torso 76 , in which the transducer 80 is pressed against the external surface of the lower torso, such as approximately adjacent the stomach, to be positioned near the wound 78 . By pressing the transducer housing 82 against the external region of the stomach, a local indentation 92 is created. The transducer housing 82 may be turned as it is pressed inward, so that the operative surface 94 of the transducer 80 is directed in the general direction toward the internal surface 96 of the wound 78 within the indentation 92 . As shown, the longitudinal wave 98 emitted is incident directly on at least a portion of the internal surface 96 of the wound 78 , thus inducing therapeutic shear waves 100 . If a specially configured transducer, or alternatively a transducer attachment 102 , is used, such as shown in FIG. 3, for focusing the ultrasound in a specific direction, the longitudinal wave 98 may be emitted off of a center axis 104 of the transducer 80 , for example, in a direction toward the internal surface 96 of the wound 78 , without the need for turning the transducer housing 82 as it is pressed against the skin.
FIG. 8 illustrates another method and device for treating a wound 78 , in which a reflecting medium 106 is inserted into the body in the proximity of the internal surface 96 of the wound 78 . The properties of the reflecting medium 106 provide for the reflection of the longitudinal wave 108 toward the internal surface 96 of the wound 96 , as if a bone were present, such as described above with reference to FIGS. 1-3A. The reflecting medium 106 may be composed of a variety of materials, and may be fixed in the body or inserted temporarily. For example, the reflecting medium 106 may be a metallic plate, a gas filled pouch, or other quasi-permanent inserts. The reflecting medium 106 may be also be, for example, a contrast agent composed of, for example, bubbles in a gelatin, which is injected intravenously prior to the treatment. In one embodiment, the contrast agent may be absorbable by the body in a relatively short period, thus the contrast agent acts as a temporarily inserted reflecting medium.
An inserted reflecting medium 106 , as described with respect to FIG. 8 above, performs particularly well in conjunction with a piezoelectric ultrasonic material or device. As shown in FIG. 9, the piezoelectric ultrasonic device 110 may be embodied as the device 56 described above with respect to FIG. 3 A. The piezoelectric ultrasonic device 110 may be configured to surround the exterior boundary of the wound 78 . As shown in FIG. 9, illustrative examples of the longitudinal waves 112 , 114 generated from the piezoelectric ultrasonic device 110 surrounding the wound 78 are reflected off of an internally disposed medium 116 and onto the internal surface 96 of the wound 78 , thereby generating therapeutic shear waves (not shown in FIG. 9) at the internal surface 96 of the wound 78 . It is understood that the piezoelectric ultrasonic device 110 completely surrounds the wound 78 ; thus, longitudinal waves not limited to the illustrative examples of longitudinal waves 112 , 114 are emitted around the entire wound 78 , reflected from the reflecting material 116 , and incident on the internal surface 96 of the wound 78 , to flood the internal surface 96 of the wound 78 with induced shear waves.
In an alternative embodiment shown in FIG. 10, an ultrasonic transmitting rod 118 is provided which emits at least one longitudinal wave 120 radially from the axis of the ultrasonic transmitting rod 118 . The rod 118 may be composed of, for example, a composite piezoelectric material, and the rod 118 is secured to the patient by a harness apparatus 122 , 124 such that the rod 118 is pressed against the skin adjacent the wound 10 , and a portion of the longitudinal wave 120 is incident on the internal surface 96 of the wound 78 , thus inducing therapeutic shear waves (not shown in FIG. 10 ).
In another alternative embodiment shown in FIG. 11, an ultrasonic transmitting ring 126 is provided which emits longitudinal waves 128 , 130 radially from the surface of the ring 126 . The ring may be composed of, for example, a composite piezoelectric material, and may be configured in a manner similar to the piezoelectric ultrasonic devices 56 and 110 in FIGS. 3A and 9, respectively, without the woven fabric to act as an ultrasonic conductor. Accordingly, ultrasonic conductive gel may be used with the ring 126 of FIG. 11 . With the ring pressed against the skin surrounding the wound 78 , a portion of the longitudinal waves 128 , 130 emitted from the ring 126 is incident on the internal surface 96 of the wound 78 , thus inducing therapeutic shear waves 132 , 134 . It is understood that the ring 126 may be configured to completely surrounds the wound 78 ; thus, longitudinal waves including the illustrative longitudinal waves 128 , 130 are emitted from around the entire wound 78 and incident on the internal surface 96 of the wound 78 , to flood the internal surface 96 of the wound 78 with induced shear waves 132 , 134 .
In an alternative configuration shown in FIG. 12, the wound healing device 136 includes a transducer 138 positioned in a housing 140 which is secured by an adjustable securing structure 142 to a thigh for healing a wound 78 thereupon, with the transducer 138 emitting longitudinal ultrasonic waves 144 which generate shear waves (not shown in FIG. 12) upon contact with the internal surface of the wound 78 . In an illustrative embodiment, the adjustable securing structure 142 shown in FIG. 12 includes an adjustable strap 146 having a first portion 148 engaging a second portion 150 using hook and link fasteners. Alternatively, a belt with a buckle and notches may be used, or a sterile adhesive strip for adhering to the thigh.
As noted above, the term “wound” as used herein, has a broad meaning, generally encompassing addressing damage to, repair of, or restoration of soft tissue. The present invention may be used, for example, to prevent surgical adhesions, by stimulating the proper repair of surgical incisions. It may also prevent or arrest wound dehiscence, by promoting vascularization at the surfaces adjacent surgical incisions. It may also be used in cosmetic surgery, for example, by enhancing the healing of hair transplants, or by directly stimulating regeneration of cells.
Accordingly, modifications such as those suggested above, but not limited thereto, are to be considered within the scope of the invention. | A portable therapeutic device and method of use generate longitudinally propagating ultrasound and shear waves generated by such longitudinally propagating ultrasound to provide effective healing of wounds. A transducer having an operative surface is disposed substantially adjacent to the wound to emit ultrasound to propagate in the direction of the wound to promote healing. Reflections of the ultrasound by bone tissue, by skin layers, or by internally disposed reflective media propagate toward the wound as longitudinal waves, with shear waves generated by the longitudinal waves for the healing of the wound. A focusing element is used for focusing the propagation of the ultrasound at a predetermined angle toward the wound. The operative surface of the transducer may be annularly shaped to encircle the wound to convey the ultrasound and/or reflected ultrasound thereto. A housing may be provided for positioning the transducer near a portion of the skin near the wound, and for indenting the skin to form a cavity, with the transducer disposed in the cavity to emit the ultrasound toward an internal surface of the wound. Fixture structures, such as adjustable straps, may extend about a portion of the body to position the transducer near the wound. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
Our copending application Ser. No. 685,372, filed concurrently herewith, and assigned to the assignee hereof.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the preparation of bromobenzaldehydes bearing hydroxy and/or alkoxy substituents, and in particular the compound 5-bromovanillin.
2. Description of the Prior Art
Bromobenzaldehydes bearing hydroxy and/or alkoxy substituents are known to this art as valuable industrial compounds useful as intermediates in various organic syntheses. Thus, 5-bromovanillin (3-bromo-4-hydroxy-5-methoxybenzaldehyde), bromoprotocatechuic aldehyde (3-bromo-4,5-dihydroxybenzaldehyde) and 3-bromo-4,5-dimethoxybenzaldehyde are useful as intermediates in the preparation of 3,4,5-trimethoxybenzaldehyde which is itself an intermediate for the preparation of such pharmaceuticals as trimethoprim 2,4-diamino-5-(3,4,5-trimethoxybenzyl)pyrimidine. These bromobenzaldehydes are also useful in the preparation of bromophenylalanines having hypotensive activity (cf. French Pat. No. 1,592,518).
The alkoxy and/or hydroxy substituted bromobenzaldehydes are typically prepared by reacting bromine with the corresponding aldehyde.
And a variety of methods are known for brominating aromatic aldehydes. Thus, it has been proposed to carry out the bromination of hydroxy and/or alkoxybenzaldehydes in various reaction media. The solvent employed most generally is glacial acetic acid containing, if appropriate, an alkali metal acetate, such as sodium acetate (cf. Dakin, Am. Chem. Journal, 42, 477-98 (1909); Torrey et al, J. Am. Chem. Soc., 31, 583-585 (1909); O. S. Brady et al, J. Chem. Soc., 107, 1858-62 (1915); E. I. Shriner et al, J. Am. Chem. Soc., 51, 2194 (1929); R. A. McIvor et al, Can. J. of Chem., 32, 298-302 (1953); Henry et al, J. Chem. Soc., 2279-89 (1930); F. Misani et al, J. Org. Chem., 10, 356 (1945); R. Pschorr, Ann., 391, 23-39 (1912); French Pat. No. 1,592,518). Although this process results in excellent yields of bromobenzaldehydes, particularly in the case of vanillin, it suffers from various disadvantages which make it unattractive from an industrial standpoint. In particular, upon completion of the reaction this process gives rise to a solution of hydrobromic acid in acetic acid from which it is difficult, if not impossible in practice, to recover HBr.
It has also been proposed (cf. R. Pschorr, loc. cit.) to replace the glacial acetic acid with chloroform; in this instance it is difficult to separate the bromobenzaldehyde from the hydrobromic acid contained therein by washing with chloroform, which suggests using a third solvent for the washing and thus making the process too complicated to exploit industrially.
In French Pat. No. 72/38,410, published under No. 2,177,693, a process for brominating vanillin has been described, consisting of adding a solution of vanillin in hydrobromic acid, containing 48% by weight of HBr, to bromine.
Lower alcohols, and particularly ethanol, have also been employed as bromination reaction media (cf. F. Tiemann et al, Ber, 7, 615 [1874]). The conjoint formation of irrecoverable methyl bromide or ethyl bromide which may be difficult to justify economically in large-scale production of bromovanillin makes this process unattractive.
In every instance the reaction leads to the formation of one molecule of hydrobromic acid per molecule of bromobenzaldehydes produced in accordance with the following reaction scheme: ##STR1##
It is found that in such a process only one half of the bromine employed is consumed to form bromobenzaldehydes, with the other half forming hydrobromic acid or, depending upon the solvent employed, alkyl bromides. Recovery and/or economical disposition of these by-products reduce the industrial interest of this process, whatever its application.
From this analysis of the state of the art it follows, therefore, that the conjoint formation of HBr resulting from the use of bromine as a brominating agent presents a serious problem in the industrial application of the known processes.
SUMMARY OF THE INVENTION
Accordingly, a major object of the present invention is the provision of an improved process for the bromination of substituted benzaldehydes, which improved process completely avoids those disadvantages and drawbacks above outlined with respect to the conjoint production of hydrobromic acid.
Briefly, the present invention features the preparation of substituted bromobenzaldehydes having the formula: ##STR2## in which R and R', which are identical or different, denote a hydrogen atom or a methyl or ethyl radical, and comprising reacting a substituted aldehyde of the general formula: ##STR3## with bromine, which bromination is initially carried out utilizing an amount of bromine which is less than the stoichiometric amount required for complete reaction and in which the bromination reaction is completed by using the pair or couple which comprises the hydrobromic acid generated during the initial reaction and an oxidizer for bromide ions.
DETAILED DESCRIPTION OF THE INVENTION
More particularly according to the present invention, the bromide ion oxidizer is advantageously any compound suited for such purpose, especially hydrogen peroxide, nitric acid, and hypochlorite ions, particularly in the form of the alkali metal hypochlorites.
Although it is generally known to this art to oxidize bromide ions to bromine with the aid of certain oxidants, the use of the HBr/oxidizer pair to effect bromination of hydroxy and/or alkoxy benzaldehydes would have been a cause for concern about the course of the oxidation and/or substitution reactions of the starting products. Thus, the prior art teaches oxidation of the aldehyde group with hydrogen peroxide according to a reaction of the Baeyer and Williger type (cf. C. H. Hassal, Organic Reactions, 9, pages 73 to 106 [1957]; J. E. Leffler, Chem. Rev., 45, pages 385 to 410 [1949]. Accordingly, it would not have been expected that the hydroxy and/or alkoxy substituted aromatic aldehydes could be brominated consistent with the reaction mechanism hereof, without concomitant oxidation of the aldehyde functions.
Without wishing to be bound to any particular theory or explanation, it is considered that the overall mechanism of the invention proceeds according to the following reactions:
(a) partial bromination of the aldehyde utilizing a stoichiometric deficit of bromine according to the reaction scheme: ##STR4##
(b) complete bromination of the unconverted aldehyde using the HBr/oxidizer pair; thus, in the instance where the latter comprises hydrogen peroxide, the reaction may be represented by the scheme: ##STR5##
The overall balanced reaction may then be represented by the scheme: ##STR6##
The process according to the invention thus makes it possible to completely brominate substituted benzaldehydes with bromine and to directly utilize the bromine comprising the hydrobromic acid initial reaction by-product.
Although the bromination according to the invention may be carried out in water and/or an inert, preferably water-immiscible organic solvent, such as halogenated aliphatic hydrocarbons or ethers, it is preferable, to obtain the highest yields and degrees of conversion to carry out the reaction in the presence of an aliphatic or inorganic acid which is inert to bromine or the oxidizer. In this instance the amount of acid expressed as molar equivalent per mole of benzaldehyde is preferably at least equal to 0.001 equivalent per mole of benzaldehyde and more preferably at least 0.01 equivalent per mole of benzaldehyde. There is no critical upper limit on the amount of acid, the latter being capable of forming the reaction medium.
In one particular embodiment, the process according to the invention is carried out in an alkanoic acid containing from 2 to 7 carbon atoms, such as acetic, propionic, butyric, n-pentanoic or n-hexanoic acids. Preferably, acetic acid is used, in which the starting material benzaldehydes are soluble and which may constitute the reaction medium. Equally well, an aqueous solution of acid may be used, the concentration of which is not critical, or an anhydrous acid.
In a second embodiment the process is carried out in the presence of an inorganic acid which may also at least partially constitute the reaction medium. Preferably, aqueous solutions of hydrobromic and sulfuric acids are used, the concentrations of which are not critical and may vary over wide limits. Thus, it is possible to use aqueous solutions of sulfuric acid containing from 5 to 65% by weight of H 2 SO 4 or aqueous solutions of hydrobromic acid containing from 5 to 60% by weight of HBr. In the latter instance solutions are preferably used containing from 45 to 55% by weight of HBr because the solubility of the starting material aldehydes increases with the HBr concentration. In a preferred embodiment of the invention the aqueous solution of inorganic acid at least partially constitutes the reaction medium. Thus, the bromination may be carried out on a suspension of benzaldehyde in an aqueous solution of H 2 SO 4 or of HBr or on a solution of benzaldehydes in a concentrated solution of HBr. It is also possible to employ together with the acidic aqueous solution an organic solvent for benzaldehyde and for bromine, which is inert under the reaction conditions, and preferably water-immiscible; an organic phase containing the benzaldehyde is then contacted with an acidic aqueous phase in which the bromide ions are oxidized. This is a preferred embodiment of the process according to the invention. The embodiment comprising the use of an aqueous solution of hydrobromic acid and an organic solvent is particularly highly suitable according to the invention. Among the solvents which are suitable for implementing this embodiment, representative are the halogenated hydrocarbons (e.g., methylene chloride, chloroform, carbon tetrachloride), and the aliphatic ethers (e.g., isopropyl ether, amyl ether, butyl ethyl ether, t-butyl ethyl ether, n-butyl ether, n-propyl ether, and n-butyl methyl ether).
The concentration of the starting aromatic aldehyde in the reaction medium selected is also not critical and may vary over wide limits. This depends mainly on practical factors such as the stirrability of the reaction mixture and the productivity of the process.
Although the amount of bromine employed in the process according to the invention, expressed in moles per mole of aldehyde, may vary somewhat provided that it remains below the stoichiometric amount resulting from the scheme (a), it is preferable that this amount remains close to one half of such stoichiometric amount when the intention is to avoid or reduce as much as possible the loss of bromine in the form of hydrobromic acid. Thus, the amount of bromine preferably ranges from 0.45 to 0.65 mole of bromine per mole of benzaldehyde. It is of course within the ambit of the invention to at least slightly depart from the limits of this range. Using an amount of bromine below 0.45 mole per mole of benzaldehyde would result, however, in incomplete conversion of the starting material, and using an amount of bromine above 0.65 mole per mole of aldehyde would proportionately increase the formation of irrecoverable hydrobromic acid during bromination. The reaction is preferably carried out using 0.5 to 0.6 mole of bromine per mole of benzaldehyde.
The amount of oxidizing agent employed obviously depends upon the amount of bromine employed and upon the nature of the oxidizer. It is preferable that it should in any event be sufficient to ensure the additional bromination of the benzaldehyde formed by the hydrobromic acid which is produced. The amount of oxidizer would be expressed in the following in moles per mole of bromine, since the amount of hydrobromic acid which is formed naturally depends upon the amount of bromine employed.
When the oxidizing agent is hydrogen peroxide the amount of H 2 O 2 is preferably close to the stoichiometric amount reflected by the reaction scheme (iii), namely, approximately 1 mole per mole of bromine. It is possible to vary somewhat from this amount without departing from the scope of the present invention.
In practice, this amount preferably ranges from 0.8 to 1.2 mole per mole of bromine and depends to some extent on the nature of the reaction medium and upon the acid employed. When an aqueous solution of hydrobromic acid is employed as the acid, a slight excess of hydrogen peroxide may be used. In the other cases, it is preferable not to exceed 1 mole of H 2 O 2 per mole of bromine and even to operate using a slight deficiency of hydrogen peroxide.
The concentration of the aqueous solution of H 2 O 2 employed is also not critical. Its selection is dictated by practical aspects which are well known to this art (for example, concern over not increasing the volume of the reaction mixture). In general, this concentration may range from 20 to 90% by weight of H 2 O 2 .
When an alkali metal hypochlorite is employed as the oxidizer, the bromination of the excess benzaldehyde by the HBr/hypochlorite pair or couple may be represented by the reaction scheme: ##STR7## in which M denotes an alkali metal. In this instance the amount of hypochlorite is also preferably close to that stoichiometrically required by the reaction, namely, 1 mole per mole of bromine. In practice, amounts of hypochlorite are used ranging from 0.7 to 1.1 mole per mole of bromine and preferably from 0.7 to 1 mole per mole of bromine. The concentration of the aqueous solutions of hypochlorite is also not critical.
When nitric acid is used as oxidizer, the reaction is represented by the following scheme: ##STR8##
The amount of nitric acid employed to ensure the oxidation of the bromides to bromine is preferably approximately that amount stoichiometrically required by the reaction represented by the scheme (v), namely, close to 2/3 of a mole of HNO 3 per 1 mole of Br 2 . It is possible, however, to depart appreciably from the aforesaid stoichiometry without, nevertheless, departing from the scope of the invention. Thus, the amount of nitric acid may vary from 0.3 to 0.8 mole of HNO 3 per mole of bromine or, preferably, from 0.6 to 0.7 mole of HNO 3 per mole of bromine.
The concentration of the aqueous solution of nitric acid employed for completing the bromination too is not critical and may range from 20 to 90% by weight of HNO 3 . Nevertheless, it is advantageous to employ concentrated solutions in order not to increase the volume of the reaction mixture. Solutions containing from 55 to 70% by weight of HNO 3 are especially suitable.
It has been found that it is advantageous to employ, jointly with the nitric acid, a small amount of nitrous acid which ensures a prompt starting of the reaction. In this instance, an alkali metal nitrite (NaNO 2 , KNO 2 ) is used as an initiator. An amount on the order of 0.01 mole of nitrite per mole of aldehyde is sufficient to initiate the reaction. In general it is unnecessary to use more than 0.2 mole of nitrite per mole of benzaldehyde. Amounts ranging from 0.05 to 0.15 mole of nitrite per mole of benzaldehyde are especially suitable.
The temperature at which the bromination reaction is carried out advantageously ranges from 0° to 100° C. and preferably from 5° to 60° C.
Among the aldehydes of formula (I) which may be brominated by the process of the invention, exemplary are protocatechuic aldehyde (3,4-dihydroxybenzaldehyde), vanillin, ethylvanillin, isovanillin and veratraldehyde (3,4-dimethoxybenzaldehyde). Protocatechuic aldehyde, vanillin and ethylvanillin provide bromobenzaldehydes containing a bromine atom in a meta-position relative to the aldehyde group. Veratraldehyde is used to prepare 2-bromo-4-hydroxy-3-methoxybenzaldehyde and isovanillin to prepare 2-bromo-4-methoxy-5-hydroxybenzaldehyde. The process according to the invention is particularly highly suitable for the bromination of vanillin to 5-bromovanillin.
The present process is also particularly suitable for continuous operation.
In order to further illustrate the present invention and the advantages thereof, the following specific examples are given, it being understood that same are intended only as illustrative and in nowise limitative.
EXAMPLE 1
Anhydrous acetic acid (20 ml) followed by vanillin (7.5 g; 0.05 mole) were charged into a 100-ml round glass flask equipped with a stirring system, thermometer, a dropping funnel and cooled with a water bath at 20° C. Stirring was begun and then, when the vanillin had dissolved, a solution of bromine (4.8 g; 0.03 mole) in acetic acid (10 ml) was added dropwise. The temperature gradually increased to 30° C. When the bromine addition was complete, acetic acid (20 ml) was added, followed, dropwise, by hydrogen peroxide at a concentration of 30% of H 2 O 2 (2.26 g; 0.02 mole). Stirring was continued for 10 min upon completion of the addition and the heterogeneous reaction mixture was cooled to 20° C. It was next filtered and the cake was washed on the filter with fresh acetic acid (10 ml) followed by ice water (30 ml). After drying under vacuum, a product (10.8 g) melting at 162 ° C. was obtained, in which 5-bromovanillin (10.60 g) was determined by high pressure liquid chromatography. Unconverted vanillin (0.45 g) was determined in the filtrate and the acetic acid wash.
The degree of conversion of vanillin was 94% and the yield of 5-bromovanillin relative to the vanillin converted was 98%.
EXAMPLES 2 AND 3
The procedure of Example 1 was repeated in 50 ml of acetic acid, but using the following vanillin/bromine/H 2 O 2 molar ratios:
______________________________________ Vanillin Br.sub.2 H.sub.2 O.sub.2 DC (1) YC (2)EXAMPLES (moles) (mole) (mole) (%) (%)______________________________________2 2 1 1.04 96.6 903 2 1.1 1 92.6 92.7______________________________________ (1) Degree of conversion of vanillin; (2) Yield of bromovanillin relative to vanillin converted.
EXAMPLE 4
A 2N aqueous solution of sulfuric acid (100 ml), followed by vanillin (15.15 g; 0.1 mole) were charged into a 250-ml round flask equipped as in Example 1. Stirring was begun and then bromine (9.6 g; 0.6 mole) was added dropwise to the vanillin suspension thus obtained; the temperature gradually increased to 30° C. When the addition was complete an aqueous solution containing 30.8% by weight of H 2 O 2 (4.42 g, i.e. 0.04 mole) was introduced in the same manner. Upon completion of the addition, stirring was continued for an additional 5 min. The heterogeneous reaction mixture was cooled to 20° C. and then the solid phase was separated by filtration, washed on the filter with water and then dried at 60° C. under reduced pressure. The filtrate was extracted with methylene chloride (3×150 ml). The unconverted vanillin and the bromovanillin in the solid phase and in the methylene chloride washings was determined by high pressure liquid chromatography.
In this manner, 2.92 g of vanillin (i.e., a degree of conversion of 80.7%) and 16.42 g of 5-bromovanillin (0.071 mole), corresponding to a yield of 88.1% of theoretical relative to the vanillin converted, were determined.
EXAMPLE 5
Chloroform (110 ml) followed by vanillin (15.15 g) were charged into the apparatus of Example 4 and stirring was begun. When the vanillin had dissolved a 2N aqueous solution of H 2 SO 4 (20 ml) was added. Bromine (9.6 g; 0.06 mole) was then added dropwise to the heterogeneous mixture thus obtained. The temperature gradually increased to 30° C. When the addition of bromine was complete, an aqueous solution containing 30% by weight of H 2 O 2 (4.42 g, i.e., 0.04 mole) was charged in the same manner. The 5-bromovanillin which had precipitated as it was formed was separated off by filtration. The liquid phases of the filtrate were separated by decantation and the aqueous phase was extracted with methylene chloride (3×150 ml each time).
By employing the same procedure as in the previous examples, a total of 1.21 g of unconverted vanillin (corresponding to a degree of conversion of 92%) and 21.07 g of 5-bromovanillin, which represents a yield of 99.5% relative to the vanillin converted, were determined.
EXAMPLE 6
The procedure employed was under the same conditions as in Example 5, but with sulfuric acid replaced by a 2N aqueous solution of hydrobromic acid (50 ml), the volume of chloroform being 100 ml.
Under these conditions the degree of conversion of vanillin was 94.84% and the yield of 5-bromovanillin relative to the vanillin converted was 96.4%.
EXAMPLE 7
The procedure of Example 6 was repeated, except that a vanillin/bromine/H 2 O 2 molar ratio of 2/1/1.1 was employed.
Under these conditions the degree of conversion of vanillin was 95.5% and the yield of 5-bromovanillin relative to the vanillin converted was 98.1%.
EXAMPLE 8
The procedure of Example 7 was repeated, except that the 2N hydrobromic acid was replaced by an aqueous solution containing 48% by weight of HBr (40 ml).
Under these conditions the degree of conversion of vanillin was 95.5% and the yield of 5-bromovanillin relative to the vanillin converted was 94.7%.
EXAMPLE 9
Example 7 was repeated, except that the temperature was permitted to increase to 50° C. at completion of the reaction.
Under these conditions the degree of conversion of vanillin was 94.8% and the yield of 5-bromovanillin relative to the vanillin converted was 95.7%.
EXAMPLE 10
Example 7 was repeated, except that the temperature was reduced to 0° C.
Under these conditions the degree of conversion of vanillin was 82.26% and the yield of 5-bromovanillin relative to the vanillin converted was 96.6%.
EXAMPLE 11
Example 7 was repeated, except that the hydrogen peroxide was replaced by HNO 3 (aqueous solution containing 65% by weight of HNO 3 ; 0.0187 mole) and sodium nitrite (0.01 mole).
Under these conditions the degree of conversion of vanillin was 75.6% and the yield of 5-bromovanillin relative to the vanillin converted was 91.02%.
EXAMPLE 12
Example 7 was repeated, except that the hydrogen peroxide was replaced by NaOCl (2N aqueous solution; 0.0277 mole).
Under these conditions the degree of conversion of vanillin was 76.8% and the yield of 5-bromovanillin relative to the vanillin converted was 89.2%.
EXAMPLE 13
The procedure of Example 7 was repeated, but with the bromine and hydrogen peroxide being added simultaneously.
Under these conditions the degree of conversion of vanillin was 97.4% and the yield of 5-bromovanillin relative to the vanillin converted was 94.1%.
EXAMPLE 14
Example 7 was repeated, except that the chloroform was replaced by isopropyl ether (250 ml).
Under these conditions the degree of conversion of vanillin was 86.2% and the yield of 5-bromovanillin relative to the vanillin converted was 94.1%.
EXAMPLE 15
The procedure of Example 7 was repeated, except that the 2N aqueous solution of HBr was replaced by a 0.5N aqueous solution of HBr (same volume: 50 ml).
Under these conditions a degree of conversion of vanillin of 71.5% and a yield of 5-bromovanillin relative to the vanillin converted of 86.2% were obtained.
EXAMPLE 16
The procedure of Example 7 was repeated, except that the 2N aqueous solution of HBr was replaced by water alone.
A degree of conversion of vanillin of 64.2% and a yield of 5-bromovanillin relative to the vanillin of 82.9% were obtained.
EXAMPLE 17
Example 11 was repeated, but with the addition of HNO 3 in the form of 65% strength aqueous solution (0.050 mole) and NaNO 2 (0.01 mole).
Under these conditions a degree of conversion of vanillin of 96.7% and a yield of 5-bromovanillin relative to the vanillin converted of 83% were obtained.
EXAMPLE 18
Example 13 was repeated, but with the addition of NaOCl (2N aqueous solution; 0.050 mole).
Under these conditions, the degree of conversion of vanillin was 81.1% and the yield of 5-bromovanillin relative to the vanillin converted was 85.7%.
While the invention has been described in terms of various preferred embodiments, the skilled artisan will appreciate that various modifications, substitutions, omissions, and changes may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the present invention be limited solely by the scope of the following claims. | Substituted bromobenzaldehydes, e.g., 5-bromovanillin, are facilely prepared with overall avoidance of HBr by-product, by (i) first brominating the corresponding benzaldehyde with a less than stoichiometric amount of bromine, and (ii) completing said bromination reaction with a brominating couple which comprises (1) the hydrobromic acid generated in situ in the step (i) and (2) a bromide ion oxidizer. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is related to concurrently filed, co-pending and commonly assigned United States patent applications serial number [200300033-1] entitled “System and Method for Determining Transaction Time-Out Circuit,” serial number [200300034-1] entitled “Systems and Methods Controlling Transaction Draining for Error Recovery,” and serial number [200300012-1] entitled “System and Method for In-Order Queue Draining,” the disclosures of which are hereby incorporated herein by reference.
BACKGROUND
[0002] It is not uncommon today for a computer system to be quite complex, often including multiple processors configured to provide parallel and/or distributed processing. For example, multi-processor computer systems often include not only multiple main processing units (MPUs), but may also include multiple support processors or agents, such as memory processors and the like. These various processors, as well as other system resources such as memory, input/output devices, disk devices, and the like, may be distributed throughout the computer system with communication provided by various buses. For example, a computer system may comprise a number of sub-modules, referred to herein as cells or cell cards, having a number of system resources, such as main processing units (MPUs), memory processors, agents, and/or memories, and buses disposed thereon. System resources of a sub-module may make and/or service requests to and/or from other system resources. Such system resources may be associated with the same sub-module and/or other sub-modules of the system.
[0003] If an error in operation of any aspect of the system, such as with respect to any one of the aforementioned system resources, is detected by the system, an error signal may be generated to notify the appropriate system resources. Such errors may be non-critical, such as isolated to the operation of a single system resource and/or associated with a recoverable operation. However, such errors may be critical in nature, such as requiring initialization of an entire bus and, therefore, the system resources thereon.
[0004] Irrespective of the severity of the error, it is generally desirable to log such errors to facilitate identifying the source of the error, the affected system resources, etcetera. However, the aforementioned complex system architectures can introduce difficulties with respect to identifying, capturing, and/or logging errors. For example, errors may be detected at various stages of processing particular data packets, resulting in information useful in error logging not being available when an error is detected.
SUMMARY
[0005] A system for logging errors, the system comprising, at least one register for storing header packet information, a controller operable to determine if a received packet of one or more packets forming an information communication comprises a header packet and to store the header packet in the at least one register, and error logging circuitry coupled to the register operable to create an error log entry using header information retrieved from the register when an error is detected with respect to any of the one or more packets of the information communication.
[0006] A method for logging errors, the method comprising, receiving one or more packets of an information communication via a multi-channel bus at an interface for outputting on a second bus, storing a received header packet of the information communication in a register corresponding to a channel of the multi-channel bus the header packet was received on, passing at least a portion of the header packet for processing by the interface for outputting on the second bus, and creating an error log entry using header information retrieved from the register in response to detecting an error with respect to any of the one or more packets of the information communication by the interface.
[0007] A method for logging errors, the method comprising, receiving one or more packets of an information communication at an interface, determining if a received packet comprises a header packet and storing the header packet in a corresponding register, passing at least a portion of the header packet for processing by the interface prior to receipt of any corresponding data packets of the information communication, generating an error signal if an error is detected by the interface with respect to any of the one or more packets, and creating an error log entry using header information retrieved from the register in response to the generated error signals.
[0008] A computer program product having a computer readable medium having computer program logic recorded thereon for logging errors, the computer program product comprising, code for storing header packet information in an appropriate register of a plurality of registers, registers of the plurality of registers being assigned to different channels of a communication protocol, wherein the header packet information corresponds to a header packet of an information communication comprising one or more packets, and code for creating an error log entry using header information retrieved from the register when an error is detected with respect to any of the one or more packets of the information communication.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 shows a bus implementing channelized information communication according to an embodiment of the present invention;
[0010] [0010]FIG. 2 shows a portion of a multi-processor system in which an embodiment of the present invention is implemented;
[0011] [0011]FIG. 3A shows a flow diagram of an aspect of header/data processing control operation according to an embodiment of the present invention; and
[0012] [0012]FIG. 3B shows a flow diagram of an aspect of header/data processing error logging and processing operation according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0013] Embodiments of the present invention provide systems and methods in which data processing header information, such as may be associated with data packets of memory returns or other transactions performed within a computer system, is held during processing of the header, and perhaps associated data packets, to facilitate error logging. According to a preferred embodiment, when an error is detected with respect to a header or any associated data packet, the aforementioned header information may be utilized in intelligently logging the error, such as to include the source of the header/data, the destination of the header/data, the type of data, the type of transaction, etcetera.
[0014] Embodiments of the invention are particularly well suited for use in providing error capture and/or logging in association with multi-channel architectures. For example, various resources of complex host systems, such as the aforementioned multi-processor systems, may be shared in order to improve operating efficiency, reduce latencies, etcetera. Accordingly, a bus or buses may be shared between various system resources, including processors and memories. Particular systems may, for example, provide a very wide bus, such as on the order of 288 bits wide, for facilitating high bandwidth communication between system resources. However, such system resources, although utilizing such bandwidth in bursts such as associated with data packet transmission, may be unable to continually utilize the available bandwidth. For example, a system resource may receive a data packet over such a bus, and during processing of the received data packet be unable to utilize available bus bandwidth. Accordingly, systems may implement a bus protocol in which bus channelization schemes provide multiple access techniques, e.g., time division multiple access. Embodiments of the present invention may provide for header information storage for error capture and/or logging irrespective of a number of channels implemented with respect to a resource.
[0015] Generally speaking, information flowing between various system resources in a computer system will be provided to an interface for processing, etcetera (see e.g., the processor interfaces shown and described in the above referenced patent applications entitled “Systems and Methods Controlling Transaction Draining for Error Recovery” and “System and Method for In-Order Queue Draining”). Such information may be packetized for communication in manageable blocks. These packets may comprise a data packet or packets, such as may contain the actual data payload of the information communication and perhaps including overhead data, such as error checking and correction (ECC) data, routing data, etcetera. Additionally or alternatively, these packets may comprise a header packet, such as may include information with respect to the source of data, a destination of data, a type of data, transaction identification, etcetera, and perhaps including overhead data, such as ECC data. According to one embodiment, the aforementioned header packets may be transmitted without corresponding data packets, such as for a read to memory or a recall to a processor. However, according to this embodiment, data packets will not be transmitted without a corresponding header packet, so as to facilitate proper processing and/or handling of data packets.
[0016] When implementing an embodiment of the aforementioned bus channelization technique, packets of the various channels may be interleaved as received by an interface. Accordingly, information transmission may comprise one or more packets, as may be separated by packets of various other channels sharing a particular resource.
[0017] Although a simplified technique may have a particular interface await all associated packets of an information communication, e.g., a header packet perhaps followed by one or more data packets, such a technique can result in less than optimized system performance and, in particular, result in appreciable latencies associated with awaiting receipt of all data packets associated with a particular header. Bus channelization techniques further aggravate the aforementioned latencies as receipt of data packets associated with a particular header may be further delayed due to interleaving of packets of a separate channel.
[0018] Accordingly, embodiments provide for processing of received packets by an interface irrespective of whether all packets associated with a particular information communication have been received. For example, once a header packet is received, the interface may process the header information to request a particular bus for providing the associated data (not yet received by the interface) to a proper system resource. Such requests may require time to fulfill and, therefore, processing the header information to invoke the request prior to actual receipt and/or processing of associated data packets may optimize system performance.
[0019] However, it should be appreciated that errors may be detected at various stages of processing the aforementioned header packet. For example, an error may be detected in the header itself during its receipt by the interface, such as through ECC data checking. Additionally, an error may be detected in the header during its processing by the interface, such as determining that the header is associated with a tracked transaction that has already ostensibly been completed or that the header is associated with a source which is not allowed to provide data communication via the interface. An error may also be detected with respect to one or more data packets associated with a header. For example, an error may be detected in a data packet during its receipt by the interface, such as through ECC data checking.
[0020] According to embodiments, a header packet could be in a number of different places when an associated error is detected. When such an error is detected, however, it is desirable to log that error in an intelligent way, such as to include information available only in the header packet. Accordingly, embodiments of the present invention implement a header information slot for storing information with respect to a particular information communication received at an interface. Preferably, such a header information slot is provided for each of a plurality of channels in a channelization scheme, to thereby facilitate error logging with respect to each such channel.
[0021] Directing attention to FIG. 1, a multi-channel bus protocol is illustrated with respect to information communication via bus 100 . The illustrated embodiment provides channels 120 and 121 , wherein information associated with various system resources may be communicated via bus 100 separately. Specifically, alternate time slots are assigned to each channel of the illustrated embodiment to provide a time division multiplexing (TDM) or time division multiple access (TDMA) bus channelization protocol. Of course, although only 2 channels are shown, any number of channels may be accommodated according to the concepts of the present invention. Moreover, embodiments of the present invention are not limited to use with time division channelization techniques and, therefore, may be implemented with respect to any number of channelization schemes and combinations thereof.
[0022] In the illustrated embodiment of bus 100 , packets denoted as “H” represent header packets and packets denoted as other letters, e.g., “A”, “B”, “C”, and “D”, represent data packets, where packets denoted as “0” are associated with a first channel, e.g., channel 0 , and packets denoted as “1” are associated with a second channel, e.g., channel 1 . Accordingly, it can be seen that the illustrated two channel interface provides for information associated with channel 0 in a first cycle or time slot, information associated with channel 1 in a second cycle or time slot, information associated with channel 0 in a third cycle or time slot, and so on.
[0023] This channelization scheme facilitates optimized use of a resource, such as a very wide bus which is not economically duplicable within the host system, by effectively allowing multiple decoupled information communications simultaneously. For instance, if a memory system can only produce a packet about half the speed at which packets may be transmitted and/or processed, and there are a plurality of memory systems in the host, the aforementioned channelization scheme facilitates communication of packets associated with multiple memory systems simultaneously.
[0024] Referring again to FIG. 1, it can be seen that if processing with respect to a particular information communication (here being all packets including a header packet and any subsequent data packets up to, but not including, a subsequent header packet) may require an appreciable amount of time if such processing is withheld until all associated packets are received. For example, in the first example of information communication in channel 120 , wherein header packet H 0 and data packets A 0 , B 0 , C 0 , and D 0 are communicated via bus 100 , 9 cycles transpire before all packets associated with the information communication are received. Although awaiting receipt of all such packets simplifies error processing, allowing processing of particular packets, such as the header packet to set up additional system resources for processing of subsequent data packets, facilitates optimized system performance and/or decreased latencies.
[0025] Directing attention to FIG. 2, a portion of a host system in which an embodiment of the present invention is deployed is shown generally as system portion 200 . The host system of which system portion 200 is a part of may comprise a multi-processor system, such as a Hewlett Packard rx series server system implementing a plurality of Intel ITANIUM processors.
[0026] System portion 200 of the illustrated embodiment includes processor interface 210 disposed between bus 201 , such as may have one or more processors and/or other system resources disposed thereon (not shown), and bus 100 , such as may have memory systems and/or other system resources disposed thereon (not shown). Processor interface 210 of the illustrated embodiment includes processor output data block 241 , processor output address control/processing block 242 , and header/data processing block 243 . Header/data processing 243 of the illustrated embodiment provides processing of packets that are coming into interface 210 via bus 100 , such as to provide information with respect to received header packets to processor output address control/processing 242 and information with respect to received data packets to processor output data 241 . Processor output address control/processing block 242 and processor output data block 241 of the illustrated embodiment preferably cooperate with header/data processing block 243 to output header and data information on bus 201 from information communication received on bus 100 .
[0027] For example, a packet may be processed by header/data processing 243 to determine if the packet includes a bit error through operation of ECC check 222 , as is well known in the art. Header/data processing 243 may also determine if the packet is a header packet or a data packet for providing the packet, or some portion thereof, to an appropriate one of processor output address control/processing 242 and processor output data 241 . For example, if the packet is a header packet, some portion of the packet may be stripped (e.g., from X bits to Y bits), such as to remove the ECC block and/or redundant fields, and the packet information provided to processor output address control/processing 242 for processing as a header packet. Processor output address control/processing 242 may provide various functions, such as header processing 231 requesting bus 201 and manipulating the header information for placing on bus 201 . Additionally, processor output address control/processing 242 may provide queuing of header information in header queue 232 .
[0028] As previously mentioned, to optimize utilization of bus 100 , the bus protocols used therewith may employ channelization techniques, such as the aforementioned time division multiple access techniques. Accordingly, packets associated with N separate channels may be received by interface 210 .
[0029] Packet errors which should be logged may be detected at various stages of processing the aforementioned packets by interface 210 . For example, an error may be detected by ECC check block 222 as a header packet is initially processed by header/data processing 243 , before any associated data packets have been received by interface 210 . Additionally or alternatively, an error may be detected as header information is processed by header processing block 231 , perhaps after one or more associated data packets have been received by interface 210 . Likewise, an error may be detected by ECC check block 222 as a data packet is initially processed by header/data processing 243 , perhaps after processor output address control/processing 242 has completed processing of associated header data and placed the header information on bus 201 .
[0030] According to embodiments of the present invention, header information is logged with respect to captured errors in order to provide an intelligent error log. For example, such header information may be utilized to determine where the packet has come from, where the packet is going, what the packet is, etcetera. However, ensuring header information, particularly the complete header packet information, is available for error capturing and logging typically entails awaiting receipt of not only the header packet but all associated data packets, as it is not known a priori where an error in the information communication is going to occur. From the above discussion it should be readily appreciated that awaiting receipt of all packets of an information communication, particularly when channelization techniques are employed, can result in an inability to achieve optimum system performance and appreciable latencies. Accordingly, embodiments of the invention provide for storage of header information, e.g., complete header packets as received from bus 100 , by interface 210 until processing with respect to a complete information communication (e.g., a header packet and any associated data packets) is complete.
[0031] Referring still to FIG. 2, registers 220 - 221 , associated with bus channels 1 -N, are shown for storing header information. According to one embodiment, control 223 provides header information (e.g., all X bits of a header packet as received from bus 100 ) for each channel of bus 100 to a corresponding one of registers 220 - 221 .
[0032] In operation according to an embodiment of the present invention, a header packet associated with a particular channel of bus 100 is placed in a corresponding one of registers 220 - 221 by control 223 substantially immediately upon receipt of the header packet by interface 210 , thereby overwriting any previous header information held in that particular register. For example, as shown in the flow diagram of FIG. 3A control 233 may analyze each packet received from bus 100 to determine if it is a header packet or a data packet (box 301 ). If the packet is not a header packet, processing may loop back for a determination with respect to a subsequent packet. However, if the packet is a header packet, processing may proceed such that the header packet, or some desired portion thereof, is stored in an appropriate one of registers 220 - 221 (box 302 ).
[0033] Through operation of the flow diagram of FIG. 3A, the header information is held in its corresponding register until such time as a subsequent header packet associated with that particular channel is received by interface 210 . Accordingly, appropriate header information will be held by one of registers 220 - 221 throughout all stages of processing an information communication and, as error logging and processing 224 captures an error, an intelligent log may be made which includes any or all information available from the header packet.
[0034] As can be seen in the embodiment of FIG. 2, irrespective of which point in the processing of a header information or at what point any associated data packets are received by interface 210 , robust header information will be available to error logging and processing 224 when an error is captured. For example, directing attention to FIG. 3B, if an error is detected by ECC check 222 with respect to a header packet as processed by header/data processing 243 , e.g., a bit error is detected, an error signal may be provided to error logging and processing 224 (box 311 ) to retrieve the header packet or desired portions thereof from a corresponding one of registers 220 - 221 (box 312 ), and an intelligent error log entry created (box 313 ). Similarly, if an error is detected by header processing 231 , e.g., the header is determined to have come from an illegal source or is associated with an already completed transaction, an error signal may be provided to error logging and processing 224 (box 311 ) to retrieve the header packet or desired portions thereof from a corresponding one of registers 220 - 221 (box 312 ), and an intelligent error log entry created (box 313 ). Likewise, if an error is detected by ECC check 222 with respect to a data packet as processed by header/data processing 243 , e.g., a bit error is detected, an error signal may be provided to error logging and processing 224 (box 311 ) to retrieve the header packet or desired portions thereof from a corresponding one of registers 220 - 221 (box 312 ), and an intelligent error log entry created (box 313 ). It should be appreciated that the aforementioned intelligent error logs may include such information as the particular type of error detected, such as may be indicated by the particular error signal provided by ECC check 222 and/or header processing 231 , as well as information derived from the header information stored in registers 220 - 221 .
[0035] It should be appreciated that, irrespective of a particular state of a header packet or its associated data packets being processed by interface 210 (e.g., whether the header packet has just been received, the header information is queued for processing, the header information is being processed for placing on bus 201 , or the header information has been fully processed and therefore released from interface 210 ), embodiments of the present invention provide header packet information for error capturing and logging. Moreover, such header packet information is robust, such as including all relevant information from the original header packet, even where a subset of header information is used for processing by interface 210 .
[0036] If implemented in software or Microcode, the elements of the present invention are essentially the code segments to perform tasks as described herein. The program or code segments can be stored in a computer readable medium or transmitted by a computer data signal embodied in a carrier wave, or a signal modulated by a carrier, over a transmission medium. The computer readable medium may include any medium that can store or transfer information. Examples of a computer readable medium include an electronic circuit, a semiconductor memory device, a ROM, a flash memory, an erasable ROM (EROM), a floppy diskette, a compact disk CD-ROM, an optical disk, a hard disk, a fiber optic medium, a radio frequency (RF) link, etc. The computer data signal may include any signal that can propagate over a transmission medium such as electronic network channels, optical fibers, air, electromagnetic, RF links, etc. The code segments may be downloaded via computer networks such as the Internet, Intranet, etc.
[0037] Although embodiments have been described herein with respect to communication protocols implementing channelization techniques, it should be appreciated that the present invention is not limited to use with any particular channelization technique or the use of channelization whatsoever. Likewise, where channelization is employed, embodiments may accommodate any number of such channels, such as by providing a number of registers sufficient for holding desired information associated with each channel. | Disclosed are systems and methods for determining time-outs with respect to a plurality of transactions comprising utilizing a first time-out clock for simultaneously determining time-out states with respect to a first set of transactions of the plurality of transactions, and determining when transactions of the first set of transactions have reached a timed-out state of the time-out states. | 7 |
DESCRIPTION
BACKGROUND OF THE INVENTION
This invention is concerned with sewing machines, more particularly with a lockstitch sewing machine.
Heretofore known lockstitch sewing machines utilize an upper needle having a thread carrying eye located at the tip thereof to carry an upper thread downwardly through a work material to a looptaker, for pickup thereby and concatenation about a lower thread. Since the early days of the sewing machine, the growth of the industry has been predicated upon improvements to this basic method of forming a lockstitch. The instant invention, however, is not concerned with an improvement to the old basic method of generating a lockstitch, but pertains to an entirely new means by which a lockstitch may be accomplished.
SUMMARY OF THE INVENTION
In this invention, the upper thread passes through the sewing machine thread tension and takeup lever as heretofore known. However, thereafter the upper thread is acted upon by deflecting levers in order to position the thread to be accepted by a hook needle carried by a needle looper. The needle looper is best implemented by an outer, work material piercing, needle; which outer needle surrounds an inner hook needle. The needle looper is capable of endwise reciprocation up through a work material from the bottom side thereof, and to expose the inner hook needle portion thereof to permit an upper thread to be deflected therein. The inner hook needle is thereupon retracted into the outer needle in order to prevent escape of the upper thread therefrom, and the needle looper assembly is retracted through the work material to a lowered position. Means are provided to re-extend the inner hook needle from the outer needle when at the lower extremity of travel of the needle looper assembly so as to permit the upper thread retained thereby to be caught by a looptaker and withdrawn from the inner hook needle in order to be cast about a lower thread carrying bobbin for concatenation with the lower thread prior to the upward excursion of the needle looper assembly in the formation of the succeeding lockstitch. The lockstitch sewing machine thus described does not require a needle which must be threaded, using instead the needle looper assembly, which in conjunction with the loop deflecting levers catches an upper thread for each stitch.
DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. The invention itself, however, both as to its organization and method of operation thereof may be best understood by reference to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view of a sewing machine including fragments of a typical work feeding mechanism and illustrating the physical elements necessary to an embodiment of this invention applied thereto;
FIG. 2 is an elevation of the end of the needle latch assembly as it would appear during penetration of a work material;
FIG. 3 is an elevation similar to FIG. 2 showing however the arrangement of parts of the needle latch assembly as they would appear at both the uppermost and lowermost extreme position thereof;
FIG. 4 is an elevation of the needle latch assembly as it would appear after the upper thread had been caught by the needle latch assembly and is being transported to the looptaker;
FIG. 5 is an end elevation of the sewing machine shown in FIG. 1 showing the needle looper assembly in the uppermost position;
FIG. 6 is a cross sectional view of the needle looper assembly shown in the lowermost position and its relation to the looptaker;
FIG. 7 is a perspective view of a portion of the looptaker, needle looper assembly, work material and thread manipulating members indicating the positions thereof at the moment of loop seizure;
FIG. 8 is a plan view of the looptaker and bobbin case supported therein in the process of loop expansion and casting about the bobbin case;
FIG. 9 is a perspective view similar to FIG. 7, shown however after grasping an upper thread and during transit of the needle looper assembly to a lowermost position; and,
FIG. 10 is a plan view of the presser foot, needle looper assembly and thread manipulating members to show the action thereof which directs the upper thread into the hook of the needle looper assembly.
With reference to the drawings, the invention is incorporated in a sewing machine having a frame shown in phantom and including a hollow work supporting bed 10 with a hollow standard 11 rising from one end thereof and terminating at its upper end in a hollow bracket arm 12 that extends laterally over the work supporting bed.
A main shaft 13 is rotatably mounted within the hollow bracket arm 12 and extends longitudinally therethrough. The main shaft 13 has a crank 15 formed in an intermediate portion thereof with a cam surface thereon. A pitman 16 is pivotably mounted in the hollow standard 11 by means of pintal screws 17. At its upper end, the pitman 16 is slotted to provide a cam follower 18 in engagement with the cam surface of the crank 15.
A stitch forming mechanism drive bar 20 is pivotally connected to the bottom of the pitman 16 by means of a pivot screw 21. A rack element 23 and a cam member 24 are connected to the free end of the drive bar 20. The teeth of the rack 23 are in engagement with the teeth of a drive pinion or gear 26 which is connected by means of a set screw 27 to the bottom of a vertical axis looptaker shaft 28 to which a conventional form of looptaker 29 is affixed. Supported within the looptaker 29 against oscillation therewith is a bobbin case 31 which carries internally thereof bobbin 32. Thus, as the main shaft 13 is turned under the urgings of a main drive motor (not shown), the pitman 16 is urged to undergo oscillation by the action of the crank 15 against the slotted cam follower 18 of the pitman, this action causing the drive bar 20 to engage in to and fro motion oscillating the looptaker 29 and by means of cam 24 encouraging lift of the feed dogs (not shown).
At the outer end of the main shaft 13, there is supported a handwheel 38. Adjacent the handwheel 38 there is connected a sprocket 40, which sprocket carries a chain 42 connected to a lower sprocket 44 carried on a lower shaft 45. The lower shaft 45 is journalled in bearings which are carried in extensions 47 depending from the work supporting bed 10. A feed eccentric 49 is supported by the lower shaft 45, the eccentric being encircled by a collar 51 which is connected by a link 52 to the rock arm of a feed rock shaft 54 for imparting feed and return motion to the feed dogs (not shown) alternately with the lifting and falling action imparted by cam 24.
Referring to FIG. 6, on the end of the lower shaft 45 opposite the sprocket 44 there is supported a crank 60, and spaced inwardly thereof a cam disk 62. The crank 60 is connected by way of connecting rod 61 to a lug 64 transverse of and affixed to an upright needle looper assembly 66 by means of screw 65. The needle looper assembly 66 is urged in vertical endwise reciprocation by the crank 60 and connecting rod 61 within bearings provided in appendages 68 affixed to an adjacent extension 47. The needle looper assembly 66 includes a tube 72 which slides within bearings in the appendages 68, the tube having a constricted bore at the upper end to receive an outer needle bar 75 therein. The outer needle bar 75 is fashioned with a hollow interior and at the end thereof tapers to a point 76 at a shallow angle so as to provide ready penetration of a work material (see FIG. 2). Approximately midway of the taper there is formed a scallop 78 for a purpose to be explained below.
Internally of the outer needle bar 75 there is situated a rod-like inner needle bar 80. The inner needle bar 80 extends the length of the outer needle bar 75 and into the tube 72 where it is fastened to a piston 85 by a screw 83, which screw slides in a slot 84 in the tube so as to maintain orientation of the inner needle bar to the outer needle bar. The upper end of the inner needle bar 80 is fashioned with a hook 82, which hook in certain positions of the inner needle bar with respect to the outer needle bar 75 creates a thread carrying eyelet with the scallop 78 in the outer needle bar (see FIG. 4). The lower end of the piston 85 is fashioned into a spindle 86, the bottom end of which is threaded to receive a cup 87. A spring 88 is carried on the spindle 86 between the cup 87 and a cap 89 threadedly attached to the bottom end of the tube 72. Thus, by reference to FIG. 6 it can be seen that the cup 87 urged into engagement with the cam disk 62 by the spring 88 so that the inner needle bar 80 may be raised or lowered and extended from the outer needle bar in accordance with the periphery on the cam disk. The entire needle looper assembly 66 reciprocates endwise through the looptaker 29 adjacent the looptaking beak 30 thereof and upward through a presser foot 56 carried on a presser bar 57. Thus, the needle looper assembly 66 is urged in endwise reciprocation by the crank 60 while simultaneously the inner needle bar 80 thereof partakes of independent motion in syncronism with the outer needle bar under the urgings of the cam disk 62. Referring to FIG. 2 there is shown the position of the inner needle bar 80 with respect to the outer needle bar 75 during its ascent and when the point 76 of the outer needle bar is penetrating the work material supported on the work supporting bed 10 of the sewing machine. In FIG. 3 there is shown the position of the inner needle bar 80 with respect to the outer needle bar 75 when the needle looper assembly 66 is at either extreme of its upper or lower position. As will be explained below, in this position the hook 82 of the inner needle bar 80 is exposed to receive an upper thread in the upper position, or to release the upper thread in the lower position. In FIG. 4 there is shown the position of the inner needle bar 80 with respect to the outer needle bar 75 after an upper thread has been picked up by the hook 82 of the inner needle bar and while the upper thread is being transported through the work material to a lower position for release.
Referring to FIGS. 1 and 5, the end of the main shaft 13 supports a gear and crank combination 90 which is affixed to the main shaft by screw 91. The gear and crank 90 actuates a takeup lever 93 to provide, as is well known in the sewing machine art, thread to the looptaker 29 for enlarging of the loop and passing it around the bobbin case 31 and bobbin 32 and subsequent takeup of the slack thread. The gear and crank combination 90 also drives intermediate gears 96 supported on idler shaft 97 in the head of the sewing machine. An intermediate gear 96 is connected to a gear 100 to which there is adjustably attached two one lobe cams 102 and 104. The cam 102 includes a face cam portion 101 on the gear 100. A thread guide lever 106 is fashioned with an abutment 107 in engagement with one lobe cam 102 and the face cam portion 101. The end of the thread guide lever 106 opposite the abutment 107 is fashioned with a thread guide 109 having an eyelet 110 in one end and attached to the lever 106 by screw 108. Movement of the thread guide lever 106 by the one lobe cam 102 and face cam portion 101 manipulates the eyelet 110 at the end of the lever for a purpose which will be explained below. The thread guide lever 106 pivots on screw 111 carried by the head end of the sewing machine. A biasing spring 112 is carried on a bracket (not shown) affixed to the head end of the sewing machine and is attached to the thread guide lever in a fashion to maintain contact between the abutment 107 thereof and the one lobe cam 102 and face cam portion 101.
A notched lever 114 is pivoted on screw 115 attached to the head end of the sewing machine and is biased by spring 116 connected to a bracket (not shown) so as to maintain the abutment 117 of the notched lever in engagement with the one lobe cam 104. The notched end 118 of the notched lever 114 is arranged adjacent the line of stitching so that it will engage the upper thread extending to the work material and wrap that thread about the inner needle bar 80 into the hook 82 thereof when the needle looper assembly 66 is positioned as shown in FIG. 3 of the drawings in the uppermost position. The cam 102 and the face cam portion 101 will operate upon the thread guide lever 106 to cause the thread guide 109 and eyelet 110 thereof to pivot about the screw 111 initially in a rearwardly direction and when actuated by the face cam portion laterally to the right. This motion is shown in FIG. 10 where the initial position of the eyelet 110 is shown in phantom and the final position thereof is shown in full. This motion will step the upper thread initially to a position behind the hook 82 of the inner needle bar 80 and then to a position laterally to the other side of the inner needle bar. Thereafter the cam 104 will actuate the notched lever 114 to have the notched end 118 thereof sweep the end of the upper thread extending through the throat plate into the hook 82 so that as the hook is retracted to the position shown in FIG. 4 an upper thread will be grasped in the eyelet formed with the scallop 78 of the outer needle. Thereafter, as is shown in FIG. 9, the inner needle bar 80 is withdrawn to the interior of the outer needle bar 75 and the needle looper assembly 66 draws the upper thread down to the looptaking beak 30 of the looptaker 29 (see FIG. 9). In FIG. 1 it will be seen that the needle looper assembly 66 is in the uppermost position with the inner needle bar 80 extended in a thread receiving attitude. The follower end of the inner needle bar 80 is engaged with the cam disk 62 adjacent an abrupt discontinuity thereof, and continued counterclockwise movement of the cam disk, as viewed from the crank 60, will permit the inner needle bar to fall and assume the position shown in FIG. 4. Thereafter the contour of the cam disk 62 is fashioned to synchronize the travel of the inner needle bar 80 with the outer needle bar 75. When the needle looper assembly 66 approaches the lower position of its travel the cam disk 62 is formed so as to reinitiate the relative position of the outer needle bar and inner needle bar illustrated in FIG. 3 to permit the looptaker to seize the loop therefrom. A stop screw 120, supported by bracket 121 affixed to the head of the sewing machine limits the retrograde motion of the thread guide lever 106 as urged by the biasing spring 112. A similar stop screw 123 is also supported by a bracket in order to limit the retrograde movement of the notched lever 114.
In FIG. 7 there is shown a view of the needle looper assembly 66 in the lowermost position with the inner needle bar 80 extended from the outer needle bar 75. When the inner needle bar 80 is elevated by the cam disk 62 to extend out of the outer needle bar 75, the tension on the upper thread is relieved and a loop is thrown which may be picked up by the beak 30 of the looptaker 29, and enlarged about the bobbin case 31 and the bobbin 32 supported therein. In the process of casting the loop about the bobbin case 31, the upper thread is withdrawn from the hook 82 of the inner needle bar 80, as shown in FIG. 8. As the loop is cast about the bobbin case 31, the takeup lever 93 operates as is well known in the sewing machine art, to remove the excess thread from the system. After the upper thread is shed from the needle looper assembly 66, the needle looper assembly may once again rise to an uppermost position to once again draw down an upper thread in preparation for the next succeeding stitch. | A lockstitch sewing machine utilizing a needle looper to extend upwardly through a work material to grasp an upper thread and pull it downwardly through the work material to a looptaker which casts the upper thread about a lower thread in order to form a lockstitch. When the needle looper is in an upper position to catch an upper thread, a hook needle is exposed and thread is deflected into the hook thereof. As the needle looper is retracted to a depressed position the hook needle is moved to a guard position so as to retain the upper thread therein during transit. When the needle looper is at its lower position, the hook is again exposed to release its thread to a looptaker for concatenation with a lower thread. | 3 |
FIELD OF THE INVENTION
The field of the invention relates to gutter systems or the like, and more particularly to debris rejecting and self-cleaning gutter systems.
BACKGROUND
Various means for controlling the dispensation of rain falling on a roof currently exist. When the flow of rain is not properly controlled and directed, erosion of foundation structures may occur, lawn and garden features may be damaged, and rain may run down an exterior wall of the structure, which can damage the structure, perhaps causing leaks into the interior of the structure.
Present systems of gutters are easily clogged by leaves and other debris entering the gutter system, thereby reducing the flow of water, making the gutter less effective. A typical gutter cross-section shape is a rectangular trough design with 90 degree corners, or a designated K-type gutter. Present systems of gutters are difficult to install and are ineffective if they are installed at an incorrect pitch. The pitch of the gutter run is typically less than 1 degree, resulting in the run being nearly level. Over time, debris entering the gutter will collect and buildup in the corners, reducing the capability of the gutter to transport water and may cause the gutter or its supports to fail.
Present systems exist that may be placed over a gutter trough to block debris from entering the gutter system. Systems that block debris from entering the gutter are not very effective, still allowing some debris to enter the gutter, and still have to be cleaned from time to time. Cleaning them is a difficult, time-consuming process that can be dangerous. Cleaning such a debris blocking system requires spending long periods of time perched precariously on a roof or on top of a tall ladder or scaffold while exerting great muscular effort in an awkward position. In some cases, the entire gutter must be disassembled to be cleaned.
Some existing systems have a gap between the gutter and the debris blocking system to allow water to enter the gutter. These systems may only be effective when the momentum energy of the debris is sufficiently high for the trajectory of the debris to go over the gap between the gutter and the gutter-covering device. When the rainfall intensity, or mass flow, is not adequate to convey the debris with enough momentum, then the debris will fall into the gap, entering the gutter. When the rainfall intensity, or mass flow, is too high, the rain has sufficient momentum to continue its trajectory and to overcome the surface tension forces that would keep it flowing along the surface of the gutter-covering device. Thus, instead of entering the gutter, the rain falls beyond the gutter and may cause the same undesirable results as if there was no gutter. Other gutter covers merely trap the unwanted debris when the momentum energy of the debris is not sufficient to wash the debris over the edge, leading to the debris blocking system becoming clogged, impeding the flow of water.
It is desirable in some instances to have an easy to install gutter system that effectively blocks debris from entering the system, but is easy and efficient to clean if the gutter system becomes clogged. It is also desirable in some instances for a gutter system to have an increased accommodation for water flow, so that the gutter system will not overflow and cause water to run back up onto the roof or behind the gutter. It is desirable to have a gutter system be effective over a broad range of rainfall mass flow rates. It is desirable to have a gutter system that is self-cleaning. Such a gutter system would have improved durability and reliability over existing systems.
SUMMARY
The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.
One non-limiting embodiment of the present invention is an improved rain gutter system suitable for receiving a great amount of rain flowing from a roof of a structure and directing the rain to a desired effluence location. The system is designed to receive the rain, to prevent the admittance of debris, and to convey the rain to a collection point, such as a downspout. The gutter system can be adapted to any length of roof. The gutter system is easy to attach to a building or other structure. The gutter system has components to operate in interior and exterior roof corners and the components can be connected to adjacent gutter run components. Some embodiments of the gutter system have structural stiffeners built in. The gutter system is easy to clean in the event that debris or other material does accumulate in the gutter. Some embodiments of the gutter system also provide an auxiliary means of dispensing large amounts of rain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A through 1D illustrate a first embodiment of a gutter system.
FIG. 2A illustrates an embodiment of a gutter system including an interlocking mechanism on the rear of the gutter.
FIG. 2B illustrates an embodiment of a gutter system including an interlocking mechanism on the front of the gutter.
FIG. 3 illustrates another embodiment of a gutter system including a coanda slot that allows water to enter through it.
FIGS. 4A and 4B illustrate another embodiment of a gutter system having a coanda slot, an upper trough, and a lower trough.
FIG. 5 illustrates another embodiment of a gutter system having an endcap with a removable port cap.
FIGS. 6A through 6C illustrate another embodiment of a gutter system having an endcap with a drainpipe.
FIGS. 7A through 7C illustrate another embodiment of a gutter system including a frame for supporting an upper trough.
FIGS. 8A through 8C illustrate another embodiment of a gutter system including chevron shaped holes in a visor and a flange under shingles feature.
FIGS. 9A through 9C illustrate another embodiment of a gutter system including multiple troughs.
FIGS. 10A through 10C illustrate another embodiment of a gutter system including a spiral trough.
DETAILED DESCRIPTION
The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
The described embodiments of the invention provide for a self-cleaning gutter system with integrated debris blockers. While the gutter systems are discussed for use with residential homes, they are by no means so limited. Rather, embodiments of the gutter system may be used in any structure that requires capture and drainage of rainwater.
The following is a description of devices, such as roof gutters, that are able to drain water flowing off of a structure, such as a building. The gutter systems described below feature improved performance in preventing debris from entering and potentially clogging the gutter. In some instances, the device is able to be opened and closed in the event that debris does accumulate inside the device. In some instances, the device is also self-cleaning, by way of a smooth, concave, curved profile on the inside of the gutter run that directs and concentrates water and debris to the lowest point in the gutter profile, thereby allowing the water and debris to flow freely. In some embodiments, the device incorporates a coanda slot along the front of the device, such that water enters the device because of surface tension, and debris falls over the edge of the device onto the ground or a similar surface. The visor, or upper surface, of the gutter might have holes of varying size and shape that allow water to flow into the gutter trough, while preventing debris from entering the gutter trough.
The device may be fabricated from various materials, such as, but not limited to, aluminum, steel, copper, brass, bronze, lead, or another sheet metal; sheet plastic; extruded metal; extruded plastic; a laminated fiber reinforced plastic, such as fiberglass reinforced epoxy, graphite epoxy (Gr/Ep), fiberglass (Fg) Polyester, or any other such material that allows for an appropriate amount of flexibility while having the appropriate structural integrity. The device may be fabricated using various manufacturing processes, including, but not limited to roll forming or progressive roll forming; bending and forming using forms, mandrels, press and other brakes, punches, or dies; compound extrusion of plastics; injection molding using various types of molding; or lamination of fiber reinforced plastic and associated processes and materials, including pre-preg, wet layup, molded layup, vacuum bagging, post-curing, autoclave curing, and other types of manufacturing that may be envisioned.
The device may be attached to a structure in various ways. In one embodiment, perforations in the gutter may be made to allow insertion of a mechanical fastener, such as a screw, nail, staple, or other suitable fastener. A tool appropriate for addressing the mechanical fastener is used such that the mechanical fastener will be secured through the gutter and into the fascia to hold the gutter in the desired position. Each mechanical fastener may be vertically adjustable within the perforations, such that a user may easily adjust the pitch of the gutter run to ensure that water flows in the proper direction towards the downspout. In another embodiment, an external hanger device may be attached to the fascia of the structure to support the gutter.
In a preferred embodiment, a section of gutter run is formed using a single piece of sheet material. The section of gutter run can be any length, up to and including the length of the structure. An upper portion of the material after forming is known as a visor. This portion may also be called a screen, grate, or strainer. A lower portion of the material after forming is known as a trough. The visor and the trough are connected by a straight portion, whereby the gutter is connected to the structure. The visor may have a plurality of holes, or perforations, through it. The holes are of a size, shape, orientation, pattern, gradation, ordering, and spacing that allows rain to pass through the visor while preventing debris from entering the gutter and thereby clogging the trough. Various patterns and combinations of holes may be envisioned. One reason to vary the patterns and combinations of holes may be because a particular type of debris is present on the property, such as oak, pine, tulip, or Bradford pear trees. Other reasons to vary the patterns and combinations of holes can be envisioned. The trough concentrates the flow of rain to the lowest point in the gutter (which may be facilitated, for example, by the smooth, concave shape of the trough) so that any debris that does enter the trough through the holes does not accumulate, but is instead efficiently swept along the run of the gutter to the downspout.
FIGS. 1A-1D show one example of an interlocking roof gutter 100 . The gutter 100 includes a visor 102 with a plurality of holes 112 to capture water that is flowing down the visor 102 . In this particular example, the height of the visor 102 is constant along the gutter run. Other embodiments may include visors where the height of the visor is not constant. In one embodiment, the gutter 100 may be installed such that the top edge 104 of the visor 102 is a constant distance from the roof to prevent the backflow of water between the visor 102 and the structure. In another embodiment, the gutter 100 might incorporate a flange under shingles feature to prevent water from flowing behind the gutter 100 , such as shown in FIGS. 8A-C .
The gutter system 100 of FIGS. 1A-1D includes a trough 106 . The pitch of the bottom of the trough 106 may slope downward along the length of the gutter 100 as the gutter 100 approaches the downspout in order to encourage the flow of water to the downspout. In this embodiment, the depth of the trough 106 increases along the length of the gutter 100 . In this way, the volume capacity of the interior of the trough 106 increases as it approaches the downspout, so that the trough 106 is able to carry increasing amounts of water along its length. As illustrated in FIG. 1D , the increasing depth of the trough 106 causes the bottom edge 110 of the interlocking roof gutter 100 to be farther from the top edge 104 of the visor 102 at the end of the gutter 100 nearer the downspout than it is at the end of the gutter 100 farther from the downspout. Other embodiments may have a trough 106 with a constant cross section as it approaches the downspout. Some embodiments, such as, for example, those described below, may also feature one or more troughs with a slope or taper to increase water capacity as the water moves through the gutter and towards a downspout.
As shown in FIGS. 1C and 1D , the visor 102 falls away from the top edge 104 of the gutter 100 in a constant radius. As the visor 102 falls away from the top edge 104 with a gradually increasing slope, the holes 112 , which may take on any shape as desired or required for aesthetic purposes or to facilitate better water entrapment and exclusion of debris, may become progressively larger. In other embodiments, the visor 102 does not need to fall away from the roof in a constant radius and may fall away from the roof in a changing radius or other manner. Having the visor 102 fall away from the roof with a gradually increasing slope, such as shown in FIG. 1C , or in other embodiments with constant or non-constant radii, will cause the water to fall along the visor 102 with minimal splashing back up onto the roof. Because the visor 102 has a gradually increasing slope, gravity will accelerate the water as it flows down the visor 102 . The increasing rate of water flow and the gradually increasing slope both operate to accelerate the debris, increasing its momentum as it moves along the visor 102 . The increase of momentum in the debris allows for the holes 112 to gradually increase in size because the accelerated debris will pass over the holes 112 and fall away from the structure. However, the larger holes 112 may still capture the water as it accelerates down the slope of the visor 102 . Conversely, near the top of the visor 102 where the water and debris have less momentum, the holes 112 are smaller to prevent debris from entering the gutter 100 , yet still entrain water.
FIG. 2A illustrates another example of a gutter 200 A that includes holes 202 , 204 in the visor 201 and an interlocking mechanism 206 A located on the rear of the device. In this embodiment, the holes 202 closer to the ground are of a larger size than the holes 204 closer to the roof. This serves to allow water to flow freely into the trough 212 due to surface tension, while filtering out the most debris. Holes of a single size and shape are less desirable because they would not be suited for all possible conditions of rainfall intensity, leaf size and shape, the size and shape of other possible debris, wind velocity, and other factors affecting the fall of debris. The holes 202 , 204 may be punched, dimpled, or indented in a manner that promotes the use of the coanda effect to draw water into the holes 202 , 204 and through the visor 201 , falling into the trough 212 . The interaction of the surface tension of the water and the momentum of the rain and debris causes holes 202 , 204 of varying sizes to be desirable. It is possible to envision a different distribution of holes 202 , 204 in the visor 201 . The holes 202 , 204 should be of a size, shape, orientation, pattern, gradation, ordering, and spacing that allows rain to enter the trough 212 while preventing most debris from entering the trough 212 .
The interlocking mechanism 206 A is located on the rear of the gutter 200 A in this embodiment, with the rear being the section that is mounted to the structure. The interlocking mechanism 206 A can be folded flange edges, although other types of interlocking mechanisms can be envisioned. The interlocking mechanism 206 A may also be a closing seam or latching seam with a hem at both seams. Appropriate types of seams for latching or interlocking the gutter 200 A include a grooved seam joint, a cap strip seam, a drive slip joint, and a flat lock seam. In the event that the gutter system 200 A becomes clogged, the user would simply push up on the trough 212 and squeeze the rear of the trough 212 forward to unlatch the interlocking mechanism 206 A. Then the trough 212 may be lowered to empty the debris. One way of lowering the trough 212 is for gravity to act upon the debris in the gutter 200 A, such that the curvature of the front of the gutter 200 A may act as a living hinge and allow it to open and dump its contents. To reclose the gutter 200 A, the user would simply push the trough 212 up while squeezing the rear forward again to engage the interlocking mechanism 200 A. It is possible to envision a gutter 200 A that would have a different type of locking mechanism 206 A, and/or a hinge, for example, if the gutter 200 A is made of a non-flexible material.
FIG. 2B illustrates an embodiment of a gutter 200 B where the interlocking mechanism 206 B is located on the front of the gutter 200 B. In this embodiment, to unlatch the locking mechanism 206 B, the user squeezes the trough 212 such that the front of the trough 212 moves toward the structure, and slightly lifts the front of the trough 212 . This causes internal latching mechanism 208 to separate from external mechanism 210 . When the user lets go, gravity operating on the debris in the trough 212 may cause the curvature of the gutter trough 212 to straighten, allowing the debris to be dumped. Afterwards, the same squeezing and lifting motion may be used to re-engage locking mechanisms 208 and 210 . The mechanisms 206 A and 206 B shown in FIGS. 2A and 2B respectively are only one example of mechanisms that may be used to close and secure the gutter 200 A, 200 B. For example, in some embodiments, other mechanical fasteners, such as screws, folding tabs, or twist tabs may be used instead of the specific mechanisms shown in FIGS. 2A and B.
FIG. 3 illustrates an embodiment of a gutter 300 , which may also include holes in the visor 306 , that allows water to enter through a coanda slot 302 . The visor 306 still has the plurality of holes discussed above. A frame 304 supports the visor 306 of the gutter 300 and provides structural integrity. In times of increased rain flow, water flowing down over the visor 306 of the gutter 300 may not enter the holes, thereby adhering to the visor 306 and entering the gutter trough 308 through the coanda slot 302 . Debris falling onto the gutter 300 will have a momentum that is too high for it to adhere to the visor 306 or will be too large to pass through the coanda slot 302 and will fall away from the building. In the event that debris does enter the gutter trough 308 , the gutter 300 may still be easily opened for cleaning.
Still referring to FIG. 3 , the coanda slot 302 may utilize the coanda effect to help entrain water into the trough 308 . However, the geometry and relative positioning of the coanda slot 302 may also help to entrain water while rejecting debris. In certain embodiments, the coanda slot 302 may comprise an upper curve 310 with an outer slope 312 and an inner slope 314 . The coanda slot 302 may also comprise a lower curve 316 which also has an outer slope 318 and an inner slope 320 . The lower curve 316 may be positioned outward or inward relative to the upper curve 310 . This positioning may influence the fall path of water and/or debris as it moves down the visor 306 and towards the coanda slot 302 . As the water and/or debris move towards the coanda slot, the contour of the upper curve 310 , including the relative slopes of the outer portion 312 and inner portion 314 , will determine the fall path of water and debris as it leaves the surface of the visor 306 . Water, due to the coanda effect, surface tension, or other factors, will tend to adhere more closely to the upper curve 310 and fall closer to the trough 308 . By contrast, debris will not follow the curvature of the upper curve 310 , and may have a fall path that is relatively further from the trough 308 . The lower curve 316 may then be positioned relative to the upper curve 310 such that the fall path of water leads it to contact the inner portion 320 and be directed into the trough 308 . Debris, with a fall path relatively further from the trough 308 , may contact the outer portion 318 of the lower curve 316 and be directed away from the trough 308 . In some embodiments, the upper curve 310 and/or lower curve 316 may be replaced by angles, corners, or creases.
FIGS. 4A and 4B illustrate a cross section of another embodiment of a gutter system 400 . The gutter 400 has an upper trough 402 and a lower trough 404 . The upper trough 402 is an extension of the visor 408 . The cross-section profile of the lower trough 404 of the gutter 400 inversely tapers from smaller to larger size along the run of the gutter 400 to the downspout, thereby causing the lower trough 404 basin to become farther from the roof as it approaches the downspout. This inverse taper profile to the gutter 400 increases the water capacity as it collects more water and moves it towards the downspout. The gutter 400 takes advantage of the coanda effect by utilizing the smoothly curved lower edge 416 of the visor 408 as a coanda surface and locates a coanda slot 406 between the coanda surface and the lower trough 404 . This arrangement provides several effects that promote the flow of water into the gutter 400 while excluding undesirable debris. Water falling onto the visor 408 from the shingles will have a certain velocity caused by the rate of rainfall and the size of the roof Because of viscosity, the water imparts momentum to any debris that may be entrained in the water flow. Initially, water will enter the upper trough 402 via the plurality of smaller holes 410 , but the debris will be predominantly excluded. Gravity will accelerate both the water and the debris. As the water and debris flow along the visor 408 , the slope of the visor 408 becomes more vertical and the velocity of the water and debris increases. Due to the coanda effect, water will enter the upper trough 402 via the perforations 412 , but the debris will have sufficient momentum to continue to fall and will not enter the perforations 412 in the visor 408 or the coanda slot 406 . Instead, the debris will fall off the edge of the gutter 400 away from the structure. The coanda effect is further enhanced by the plurality of perforations 412 having an indented or dimpled shape which provides additional coanda surface to draw water into the upper 402 and lower 404 troughs. The upper edge 414 of the lower trough 404 adjacent to the coanda slot 406 also curves inward and is offset slightly away from the lower edge 416 of the coanda surface. This helps to draw water flowing past the visor 408 into the lower trough 404 because it will fall onto a smooth surface below, guiding the water into the lower trough 404 by the coanda effect. This offset also helps to exclude debris from entering the lower trough 404 .
During low to moderate intensity of rainfall, most water will pass through the plurality of holes 410 , 412 in the visor 408 and collect in the upper trough 402 to flow to the downspout. During high intensity of rainfall, there may be too much water to flow through the plurality of holes 410 , 412 in the visor 408 . In that situation, excess water will enter the lower trough 404 by way of the coanda slot 406 and flow to the downspout. If the intensity of rainfall also causes the upper trough 402 to fill with water passing through the plurality of holes 410 , 412 , the overflowing water will cascade from the upper trough 402 to the lower trough 404 , through the gap between the upper trough 402 and the rear wall of the gutter 418 . In this way, the water will still flow to the downspout.
When the gutter system is installed, gutter run sections are attached to interior and exterior corner sections to fit the roof of the structure. The ends 500 of the gutter runs are plugged with endcaps 502 , illustrated in FIG. 5 , discussed below. The gutters connect to downspouts to carry the water to the ground. The various pieces of the gutter system are attached using joints or couplings. The joints must be made of a material that will allow the gutter to be unlatched for emptying, but will not leak when the gutter is in the closed or latched position. In the particular embodiment shown in FIG. 5 , the endcap 502 includes a removable port cap 504 . Another method of cleaning the gutter is to remove the removable port cap 504 to allow debris to be removed with a tool or flushed out of the trough and into the downspout with water from a water hose. In some embodiments, the endcap could include multiple port caps to flush multiple troughs.
FIGS. 6A to 6C illustrate another example of the end of a gutter run 600 with a plurality of apertures 612 . As shown, these apertures 612 may take on any number of shapes or sizes. An endcap 602 is placed over the end of the gutter run 600 . The endcap 602 includes an opening that allows for a drainpipe 604 to be installed, which passes from the inside of the gutter 600 to the outside of the gutter 600 . The portion of the drainpipe 604 that is on the inside of the gutter 600 bends upward. At the top end of the drainpipe 604 , a ball 606 is located in a housing 608 , which may include features such as a mesh, screen, or mechanisms to block debris from entering and clogging the drainpipe 604 . The ball 606 may be designed such that it will float in water. The portion of the drainpipe 604 that is on the outside of the gutter 600 bends downward. At the bottom end of the drainpipe 604 , there is an opening 610 . The ball 606 acts as a valve, and will float upwardly as the gutter begins to fill with water. In this position, the valve is open, allowing water to drain out of the opening 610 . The opening 610 can be attached to a garden hose or other suitable conduit to convey the water to a safe area for the water to be released. In other embodiments, the ball valve mechanism is not necessary.
FIGS. 7A through 7C show an embodiment of a multi-trough gutter system 800 that is supported structurally by a frame 802 . The upper trough 804 and the lower trough 806 are supported by the internal frame elements 802 at intervals along the length of the gutter run. The frame 802 attaches to the back wall 808 of the gutter 800 . The frame 802 may also extend through the gutter 800 and also function as the fastening mechanism that attaches the gutter 800 to the structure. The frame 802 supports the upper trough 804 continually along the lower surface of the upper trough 804 . The frame 802 also supports the lower trough 806 at or near the lip 810 of the lower trough 806 . In this way, the frame 802 works to resist forces that might cause the lower trough 806 to sag under a heavy load. The particular version of the frame 802 shown in the figures merely illustrates one possible implementation for providing structural integrity to a gutter 800 incorporating an upper trough 804 and a lower trough 806 . It is possible to envision other types of frames 802 being used. It is also possible to envision using a frame 802 in other embodiments of the invention.
FIGS. 8A through 8C illustrate one embodiment of a gutter system 900 incorporating a flange under shingle feature 902 , which may be incorporated with any of the above embodiments to prevent water from flowing behind the gutter. The shingles may be installed on the structure such that the lowest edge of the shingles is not a constant distance from the wall of the structure along the length of the building. In this case, installing the Flange Under Shingles system helps to ensure that the flowing water and debris will enter the gutter system 900 . Flange 902 extends from the back wall 906 of the gutter 900 and fits under the shingles which are adjacent to the gutter 900 . In the particular embodiment of FIGS. 8A through 8C , slot 904 is located where the flange 902 meets the back wall 906 of the gutter 900 . Slot 904 allows water to enter the lower trough 908 . Holes 910 in the visor 903 allow water that flows over the slot 904 to enter the upper trough 912 . A frame (e.g. a bracket, support, or other structure) may be used to maintain the spacing of slot 904 when water is flowing into and over the gutter 900 . In this embodiment, there is no coanda slot. The upper trough 912 extends from the top edge of the visor 903 , as opposed to the embodiment with a coanda slot, wherein the upper trough extends from the bottom edge of the visor.
FIGS. 9A through 9C illustrate an embodiment of a gutter 1000 comprising a visor 1002 with a plurality of holes 1004 to entrain water as it moves down the surface of the visor 1002 . The visor 1002 may slope down towards an upper curvature 1006 that defines the upper boundary of a coanda slot 1008 . A lower curvature 1010 may define the lower boundary of the coanda slot 1008 . The visor 1002 , holes 1004 , coanda slot 1008 and upper and lower curvatures 1006 , 1010 may function similarly to the other embodiments of the gutter described above.
Still referring to FIGS. 9A through 9C , the lower curvature 1010 may extend from the back wall 1005 to form the first trough 1012 at the bottom of the gutter 1000 . Similarly, the upper curvature 1006 may extend inside the gutter 1000 to form the second trough 1014 , and then extend further to form an internal visor 1017 and third trough 1016 . The gutter 1000 with multiple internal troughs 1012 , 1014 , 1016 provides additional water carrying capacity and redundancy compared to gutters with fewer troughs. While three troughs 1012 , 1014 , 1016 are shown, the gutter 1000 may include as many troughs as necessary to provide adequate water capacity for a particular application. As shown, the gutter 1000 may have a first trough 1012 at the bottom of the gutter 1000 fed principally by the coanda slot 1008 . The second trough 1014 and third trough 1016 may receive water entrained in the holes 1004 in the visor 1002 . The internal visor 1017 may have holes similar to the visor 1002 designed to allow water to enter the third trough 1016 but to reject or otherwise discard debris from entering the third trough. The use of multiple troughs 1012 , 1014 , 1016 allows for increased water carrying capacity because additional troughs 1012 , 1014 , 1016 allow for better utilization of the full internal volume of the gutter 1000 without overflow or spillage. Furthermore, multiple troughs 1012 , 1014 , 1016 may also provide redundancy such that if any individual trough becomes clogged or otherwise obstructed, additional troughs are may still be clear and deliver water to a downspout or other water flow path. As shown in FIGS. 9A through 9C , the gutter 1000 with multiple troughs 1012 , 1014 , 1016 may be made by bending or otherwise forming a single sheet of material. In some embodiments, the gutter 1000 may be made of separate pieces bonded, fastened, or otherwise joined together.
FIGS. 10A through 10C provide an illustration of an infinite spiral gutter 1100 . The infinite spiral gutter 1100 may comprise a flange 1102 extending down to an outer visor 1106 which may have a plurality of holes 1004 . The flange 1102 , outer visor 1106 , and/or holes 1104 may function similarly to other embodiments of the gutter system described above. As shown, the infinite spiral gutter 1100 may be attached to a roof or other supporting structure through the flange 1102 . However, in certain embodiments, the infinite spiral gutter 1100 may not include a flange 1102 and may instead be secured to a structure using a frame or mounting fasteners.
Still referring to FIGS. 10A through 10C , the infinite spiral gutter 1100 may be formed from a single sheet of material. For example, a single sheet of metal or other suitable material may initially be flat to form the flange 1102 . The flange 1102 may then transition into the outer visor 1106 with a plurality of holes 1104 . The outer visor 1106 may then transition into the outer coil 1108 and begin to arc down to form the lower trough 1120 . The material may then continue to arc around from the lower trough 1120 in a spiral to form an inner visor 1114 , inner coil 1110 , inner trough 1122 , second inner visor 1116 , center coil 1112 , center trough 1124 , and center visor 1118 . As shown, the infinite spiral gutter 1100 is depicted as having three troughs 1120 , 1122 , 1124 , each having a corresponding visor 1114 , 1116 , 1118 that may include holes similar to the holes 1104 in the outer visor 1106 . However, in some embodiments, the infinite spiral gutter 1100 may have as many troughs between the lower trough 1120 and center trough 1124 formed from any number of coils 1108 , 1110 , 1112 as desired or required for a particular application.
The infinite spiral gutter 1100 may offer a number of advantages over traditional gutters. Similar to the gutter 1000 described in FIGS. 9A through 9C above, the infinite spiral gutter 1100 may have increased water carrying capacity and redundancy because of the multiple troughs 1120 , 1122 , 1124 with multiple visors 1106 , 1114 , 1116 , 1118 to filter out debris. Each successive trough 1120 , 1122 , 1124 may increase the water carrying capacity of the infinite spiral gutter 1100 and provide redundant drainage paths should one or more of the troughs 1120 , 1122 , 1124 become clogged or otherwise obstructed by debris. The infinite spiral gutter 1100 may also provide significant advantages in manufacturing and flexibility. Because the infinite spiral gutter 1100 may, in certain embodiments, be formed from a single sheet of material, many different configurations of the infinite spiral gutter 1100 may be made using the same material stock and processing equipment. For example, the outer diameter, number of coils, and/or spacing between individual coils may be changed or adapted to any particular application. Furthermore, while the infinite spiral gutter 1100 is shown with generally circular coils, alternative embodiments may have oval, square, rectangular, or any other desired shape of coils to adapt the infinite spiral gutter 1100 for fit, compatibility with different structures, and/or aesthetic purposes.
The foregoing is provided for purposes of illustrating, describing, and explaining aspects of the present invention and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Further modifications and adaptation of these embodiments will be apparent to those skilled in the art and may be made without departing from the scope and spirit of the invention. Different arrangements of the components depicted in the drawings or described above, as well as components not shown or described are possible. Similarly, some features are useful and may be employed without reference to other features. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. For example, the physical design of the interlocking roof gutter may differ from that described herein.
Any of the above described components, parts, or embodiments may take on a range of shapes, sizes, or materials as necessary for a particular application of the described invention. The components, parts, or mechanisms of the described invention may be made of any materials selected for the suitability in use, cost, or ease of manufacturing. Materials including, but not limited to aluminum, stainless steel, fiber reinforced plastics, carbon fiber, composites, polycarbonate, polypropylene, other metallic materials, or other polymers may be used to form any of the above described components.
Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below. | An interlocking gutter system with perforations in the visor allows for the maximum amount of water drainage while blocking debris from entering the gutter. The gutter trough has an increasing radius as it approaches the downspout, to increase the capacity for carrying water. In the event that debris does enter the gutter, the interlocking mechanism can be disengaged, thereby allowing the gutter trough to drop away from the visor, dumping accumulated debris with minimal effort. The perforations in the visor can be patterned and sized in order to block the most common debris encountered in that installation. The gutter may allow water to enter the trough via a coanda slot in addition to perforations in the visor. The gutter system may have multiple troughs to further assist in draining a maximum amount of water. In the event of a clog, the system is emptied using an endcap. | 4 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to a method and apparatus for ultrasonically determining the absolute value of intracranial pressure and more specifically relates to a method and apparatus for determining the intracranial pressure using ultrasonic measurements of the velocity of blood flow through an ophthalmic artery.
BACKGROUND OF THE INVENTION
[0002] This invention is an extension and improvement of our previously invented method and apparatus U.S. Pat. No. 5,951,477 for single or single repeatable absolute intracranial pressure (ICP) value measurement and diagnosing of brain pathologies based on such measurements. This document is incorporated by reference in the present application.
[0003] An apparatus for determining the pressure and flow inside the ophthalmic artery is described in U.S. Pat. No. 4,907,595 to Strauss. The apparatus uses a rigid chamber that can be affixed and sealed over the human eye so that it can be pressurized to apply an external pressure against the eyeball. An ultrasonic transducer is also mounted to the chamber and oriented to transmit ultrasonic pulses for a Doppler type measurement of the flow inside the ophthalmic artery (OA). The apparatus operates by enabling an operator to increase the pressure to such a level that the blood flow through the OA ceases. The pressure at which this occurs is then an indication of the pressure inside the OA. Typically, the pressure at which this event occurs is in the range of about 170 mmHg.
[0004] A problem associated with an apparatus as described in the '595 Patent is that the pressure necessary to obtain the desired measurement is so high that it generally exceeds maximum recommended pressures by a significant amount. When such device is then used for an extended time, tissue damage can arise and may result in an increase in the intracranial pressure, ICP, to unacceptable levels.
[0005] Another ultrasonic device for determining changes in intracranial pressure in a patient's skull is described in U.S. Pat. No. 5,117,835 to Mick. Such device involves placing a pair of ultrasonic transducers against the skull and storing received vibration signals. U.S. Pat. No. 4,984,567 to Kageyama et al. describes an apparatus for measuring ICP with an ultrasonic transducer by analyzing the acoustic reflections caused by ultrasonic pulses. Other patents related to ultrasonic measuring of either intracranial pressure or other physiological features are U.S. Pat. No. 4,204,547 to Allocca, U.S. Pat. No. 4,930,513 to Mayo et al., U.S. Pat. No. 5,016,641 to Schwartz, and U.S. Pat. No. 5,040,540 to Sackner.
[0006] None of these prior art teachings provide a clear description for obtaining a non-equivocal indication of the absolute value of intracranial pressure (aICP). The measurements tend to be obscured by noise arising from uncertainties in the measurements and by numerous influential factors, such as arterial blood pressure, cerebrovascular autoregulation state, individuality of anatomy, and patient's physiology and pathophysiology. Such influential factors cannot be eliminated by calibration of the “individual patient—non-invasive ICP meter” system because the non-invasive “golden standard” absolute ICP meter does not exist. Thus, there is a need for the capability to derive a measurement of a person's aICP in a safe, accurate and non-invasive manner that can be implemented with reasonable reliability and without the necessity for calibration.
SUMMARY OF THE INVENTION
[0007] With an apparatus in accordance with the invention, one can derive an indication of the absolute value of pressure inside a skull (intracranial pressure or ICP) in a non-invasive manner. This indication is obtained using an ultrasonic Doppler measuring technique that is applied through the eye of a person and to the ophthalmic artery (OA) in a safe manner.
[0008] This is achieved in accordance with one technique in accordance with the invention, by pressurizing a chamber which is in sealing engagement with a perimeter around an eye, and by using an ultrasonic Doppler measuring device, which is mounted to the chamber, to measure the intracranial and extracranial blood velocities (VI and VE, respectively) of intracranial and extracranial segments of the ophthalmic artery. Velocity parameters representative of or derived from these velocity measurements, VI and VE, are then compared, and the difference between these representative parameters, their difference, ΔV, is identified. ΔV is then used to control the pressure in the chamber. When the pressure in the chamber causes ΔV to approach a desired minimum value close to zero, that pressure becomes an indication of the non-invasively derived intracranial pressure (nICP).
[0009] The technique of the invention can be implemented in a variety of different manners, such as with a manual increase and control over the pressure to be applied to the chamber while monitoring the parameters representative of intracranial and extracranial velocity signals determined with the ultrasonic Doppler device. When these representative parameters appear substantially the same, the applied pressure at which this occurs is then used to determine the intracranial pressure.
[0010] Alternatively, with the ultrasonic Doppler velocity measuring technique of this invention, the ophthalmic artery velocity difference measurement, ΔV, can be used to directly control the pressure in the chamber by applying the signal to a pump. A pressure signal indicative of the pressure in the chamber can be used to store a signal in suitable memory and for display to indicate the nICP.
[0011] A further aspect of the invention enables a measurement of the dynamic characteristics of blood flow velocity in the intracranial and extracranial OA segments of which pulsatility is an example but not an exclusive embodiment.
[0012] It is, therefore, an object of the invention to provide an apparatus for determining the absolute value intracranial pressure (aICP) using a non-invasive ultrasonic technique (nICP). The aICP value (in mmHg or other pressure units) only can be used for traumatic brain injury or other brain pathology treatment decision making. It was impossible to measure the aICP non-invasively until now.
[0013] It is still a further object of the invention to obtain a measurement of the ICP of a patient in a safe and dependable manner.
[0014] Another advantage of the invention is the possibility to measure nICP absolute values in the injured and healthy hemispheres of the brain separately using the ophthalmic arteries of both eyes of the patient.
[0015] Also, another advantage of the invention is the independence of measurement results from many influential factors such as arterial blood pressure, diameter of the OA, cerebrovascular autoregulation state, and hydrodynamic resistances of the ocular and other distant vessels. The invention achieves this advantage by not using the measured absolute values of blood flow velocities in the intracranial and extracranial OA segments (IOA and EOA respectively). Instead, it uses just the comparison of such velocities or associated pulsatility indices or other parameters of dynamic blood flow to find the “balance point”—the point at which a summary blood flow parameter describing IOA hemodynamics is equal to the summary blood flow parameter describing EOA hemodynamics. It is at the balance point that ICP is equal to the extracranially applied pressure inside the pressure chamber. Such comparison is both accurate and not in need of an independent calibration.
[0016] A further advantage of the invention is the ability to make non-invasive absolute ICP value measurements without the necessity to calibrate the “individual patient—non-invasive ICP meter” system. The calibration problem is solved when the proposed method uses the balance of two pressures: ICP and extracranially applied pressure to the human eye and intraorbital tissues. Intracranial and extracranial segments of OA are used as natural “scales” for ICP and extracranial pressure balancing.
[0017] A still further advantage of the proposed invention is the high accuracy of non-invasive absolute ICP measurement which is acceptable for clinical practice.
[0018] These and other advantages and objects of the invention can be understood from the following description of several embodiments in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1A is a schematic and block diagram illustrating an apparatus with a one-dimensional (1D) scanning ultrasonic transducer array in accordance with the invention.
[0020] FIG. 1B-1C are schematic views illustrating cases when a concave two-dimensional (2D) ultrasonic transducer array is used.
[0021] FIG. 2 is a detailed schematic and block diagram view of an apparatus in accordance with the invention.
[0022] FIG. 3 is a plot illustrating the spatial scan of blood flow velocity in the OA by using an ultrasonic transducer array.
[0023] FIG. 4A-4C are perspective views illustrating the mounting of a head frame of the apparatus, in accordance with the invention, to the skull of a patient.
[0024] FIG. 5 is a flow chart for a method of using the apparatus shown in FIG. 1A-1C for measuring the absolute value of intracranial pressure.
[0025] FIG. 6-13 are plots illustrating the steps of adjusting the ultrasonic transducer in order to get Doppler velocity signals from the IOA and EOA simultaneously. The device of the invention is working in scan mode for these tasks.
[0026] FIG. 14 is a view of the software window that shows the procedures of averaging the spectrogram across multiple heart cycles from the IOA and EOA simultaneously. The device of the invention is working in spectral measurement mode for this task.
[0027] FIG. 15 is a view of the software window that shows the procedures for the calculation of aICP according to the measured data and to the method of the invention.
[0028] FIG. 16 is a plot illustrating the results of serial non-invasive aICP measurements of the same healthy volunteer obtained with an apparatus in accordance with the invention.
[0029] FIG. 17 shows the comparison of non-invasive aICP measurement results obtained with a phase contrast MRI apparatus (See Alperin et al., MRI study of cerebral blood flow and CSF flow dynamics in an upright posture: the effect of posture on the intracranial compliance and pressure, Acta Neurochirurgica Supplementum 2005; 95: 177-181; Alperin et al., Relationship between total cerebral blood flow and ICP measured noninvasively with dynamic MRI technique in healthy subjects, Acta Neurochirurgica Supplementum 2005; 95: 191-193) and with apparatus in accordance with the invention. These results also are listed in Table 1 below.
[0030] FIG. 18A-18B show measured typical dependence of the pulsatility index in OA on the measurement depth with an apparatus in accordance with the invention, without and with, respectively, an external pressure applied to the eye.
DETAILED DESCRIPTION OF THE INVENTION
[0031] With an apparatus in accordance with the invention, the ICP inside a person's head can be determined from an observation of the blood velocities inside the OA. This involves an ultrasonic apparatus which senses the response of the blood flow to a pressure “challenge” applied to the tissues around the eye. The pressure challenge is accomplished by a pneumatic or fluid-control device, which can apply a slight pressure to the eye. The pressure is applied to the eye to the necessary level for equilibrating parameters representative of the intracranial and extracranial blood flows in the OA leading to the eye. The possibility of this type of measurement has been demonstrated with the analysis presented in our previous patent U.S. Pat. No. 5,951,477.
[0032] With reference to FIGS. 1 , 2 , and 3 , an apparatus 20 is shown to practice the measurement of the ICP as described above. The head frame 22 of the apparatus is mountable to the head of a person so that an eye engaging inflatable device 28 can apply a slight pressure against the eyelid 23 ( FIGS. 4A-4C ). Suitable braces and positioning bands 24 , 26 are used to hold the head frame 22 in place ( FIGS. 4A-4C ). The inflatable device is formed of a suitable soft material such as rubber to form an inflatable chamber 28 ( FIGS. 4A and 4B ). Chamber 28 is approximately annular in shape so as to enable an ultrasonic transducer 30 to be mounted against an inner flexible membrane 32 and enable a pressurization of the chamber by a pump 34 ( FIGS. 1A-1C ). FIG. 1A shows ultrasonic transducer array 30 which can be a 1D transducer array and can scan electronically the OA in one plane. In FIGS. 1B and 1C , a 2D ultrasonic transducer array 30 is able to perform OA spatial scan in multiple planes. These planes may be parallel or perpendicular to the “boresite” ultrasound beam axis. The distances from the ultrasonic transducer to the internal carotid artery, IOA, and EOA are marked by D, D I and D E respectively ( FIG. 1A-1C ).
[0033] The inner flexible membrane 32 conforms to the shape of the eye 35 as illustrated in FIG. 1A and in such manner as to enable the pressure from the inflation of chamber 28 to provide a slight pressurization of the tissues around the eye. These tissues are contiguous with the tissues in the posterior portion of the eye socket, so the applied pressure is effective there as well. This results in a pressurization of the extracranial ophthalmic artery 36 . The OA originates from the siphon of the internal carotid artery ICA 41 inside the cranium 40 and passes through the optic nerve canal 42 to the eye 35 ( FIGS. 1A-1C ).
[0034] The preferred embodiment of this invention is shown in FIG. 1 and FIG. 2 , and is comprised of an apparatus 20 consisting of: an orbital Doppler velocity meter 1 , a pulse wave spectrogram processing unit 2 , a pressure control unit 3 , and an absolute ICP calculation unit 4 .
[0035] The orbital Doppler velocity meter 1 controls ultrasonic transducer 30 which can be a 1D transducer array ( FIG. 1A ) or a 2D transducer array ( FIGS. 1B and 1C ). This meter has the ability to steer the ultrasound beam relative to the transducer bore site axis. This steering is done electronically within angle ranges from 0 to 8 degrees in one plane for the 1D array embodiment ( FIG. 1A ) and within a solid angle about the transducer bore site for the 2 D array ( FIGS. 1B and 1C ). The orbital Doppler velocity meter 1 can work in two modes:
Scan mode (adjustment) is used to search for Doppler velocity signals from IOA and EOA. In this mode, the scan to locate blood flow in the vicinity of the optical canal is done by pointing the ultrasound beam in a series of different directions and sampling the Doppler signal acquired at multiple depths along the beam (each such direction is called a “look” or “look direction”). The look direction is adjusted electronically. Spectral measurement mode is used when Doppler velocity signals from IOA and EOA have been found and the beam directions (“looks”) and depths associated with, respectively, the intracranial and extracranial ophthalmic arteries, are known. In this mode, the transducers are operated in an alternating (pulse by pulse) fashion. This operation is referred to as “multiplexing” the two beam directions and is done in order to receive Doppler velocity signals from the IOA and EOA separately. These signals are then demodulated and used to derive spectrograms characterizing blood flow at the locations of the IOA and EOA.
[0038] The orbital Doppler velocity meter 1 consists of: transmitter 1 . 1 , receiver 1 . 3 , beam forming circuit 1 . 4 , digital signal processing DSP N-channels 1 . 5 , and units for data processing in scan mode 1 . 6 and spectral mode 1 . 7 ( FIG. 2 ). The beam forming circuit 1 . 4 can be applied for 1D or 2D scan respectively for cases in FIG. 1A and FIG. 1B .
[0039] The transmitter 1 . 1 generates electrical signals to excite ultrasonic transducer array 30 , which can be a 1D or 2D transducer array. Each electrical signal is delayed in beam forming unit 1 . 4 in order to steer the diagram of ultrasonic transducer at required directions (for 1D or 2D scan). The steering angle is set from steering vectors 1 . 62 when apparatus 20 is working in scan mode or from steering vectors 1 . 72 when apparatus 20 is working in spectral mode.
[0040] The Receiver 1 . 3 is put in a low-gain state during transmission of an ultrasonic pulse, and then into a high gain state while listening for echoes. The received signals from each element of ultrasonic transducer array 30 are processed in an N-channel DSP unit 1 . 5 . The number N of DSP channels is equal to the number of elements in the ultrasonic transducer array 30 . In DSP channels 1 . 5 , the received signal is sampled in digitization unit 1 . 52 , and demodulated in demodulation unit 1 . 53 to get a demodulated digital Doppler signal. After demodulation, the signal is decimated with decimation unit 1 . 54 and filtered with clutter filter 1 . 55 . One skilled in the art will appreciate that digitization, demodulation and decimation are applied to echo data in the “RF” domain, typically across one pulse period, while clutter rejection is applied in the “baseband” domain, across multiple pulse periods. Further, clutter rejection can be applied before or after beam forming, if both are linear processes.
[0041] When orbital Doppler velocity meter 1 is working in scan mode, the demodulated and filtered Doppler signal is directed with mode selector 1 . 56 into FFT unit 1 . 57 to calculate the spectrum of this signal. In the next steps, this signal is processed in scan mode processing unit 1 . 6 to reconstruct a spatial image of the Doppler signal intensity distribution in a spatial 3D rendering. In this rendering, the Doppler signal intensity is colored according to signal intensity and plotted based on spatial position. In one embodiment the X-axis is transducer steering angle in degrees while the Y-axis is depth in mm. The color in the image reflects the Doppler signal intensity of blood flow in the eye artery and the spatial location of this artery.
[0042] The scan mode processing unit 1 . 6 consists of: beam forming unit 1 . 61 , steering vectors 1 . 62 , power meter 1 . 63 , Colormap unit 1 . 64 , gain and range control unit 1 . 65 , scan mode image 1 . 66 , and cursor former unit 1 . 67 . With cursor former 1 . 67 , the operator (or the system in an automatic detection mode) is enabled to select and fix two spatial points in the display of the spatial Doppler signal intensity versus spatial position. By placing cursors at the points where Doppler velocity signals indicate blood flow in IOA and EOA, the transducer steering parameters (angle and depth) will be fixed to get Doppler signals only from those selected segments when apparatus 20 is switched in spectral mode. The fixed transducer steering parameters (angle and depth) are then converted into steering vectors 1 . 72 .
[0043] When the orbital Doppler velocity meter 1 is working in spectral mode, the transducer steering vectors 1 . 72 are utilized in a “multiplexed operation”—pulses aimed at the selected segment of the IOA are alternated on a pulse-by-pulse basis with pulses aimed at the selected segment of the EOA. In this mode, the demodulated and filtered Doppler signals from the DSP channels 1 . 5 are directed with mode selector 1 . 56 into spectral mode processing unit 1 . 7 . This unit processes only two Doppler signals from the IOA and EOA in order to get velocity spectrogram image 1 . 77 . The spectral mode processing unit 1 . 7 consists of: beam forming unit 1 . 71 , steering vectors 1 . 72 , FFT calculation unit 1 . 73 , amplitude meter 1 . 74 , Colormap unit 1 . 75 , gain and range control unit 1 . 76 , and velocity spectrogram image unit 1 . 77 .
[0044] FIG. 3 illustrates two embodiments for visualization of blood flow signals in the OA with the orbital Doppler velocity meter operating in scan mode. In one embodiment, the ultrasonic transducer 30 , which can be a 1D or 2D transducer, performs a scan inclusive of the optical canal, based acquiring Doppler data from a series of different directions (“looks”) and depth ranges according to steering vectors 1 . 62 , in order to get a spatial image depicting location of blood flow. Received information regarding the spatial distribution of blood flow can be represented in color maps at different depth frames ( FIG. 3 a ). Each depth frame represents a different distance from the ultrasonic transducer (depth); the color intensity in the depth frame reflects the blood flow signals while the coordinates of the colored spot in the depth frame reflects the transducer steering angle at which the blood flow in the eye artery is detected ( FIGS. 3 a and 3 b ). The example in FIG. 3 b shows that at fixed depth in frame 7 blood flow is detected in the EOA.
[0045] A second embodiment may be used in what may be a simpler technique for simultaneous visualization of blood flow velocity in the IOA and EOA. In this second embodiment, the spatial planes of scanning are made based on rotation of a planar scanning region about the bore site axis of the transducer ( FIG. 3 c ). The rotational method of acquiring the set of scan planes can be implemented by using a 2D transducer array with electronic steering across two spatial angles, or can be implemented with a linear array capable of one scan plane, combined with mechanical rotation of that array. Either method is capable of accomplishing the scan depicted in FIG. 3 c . Whichever method is used, the rotation of scanning planes is performed until blood flow velocity signal is detected from both IOA and EOA simultaneously from different depths ( FIG. 3 d ). Note that this technique may be facilitated by first locating the internal carotid artery and manipulating the transducer until the associated flow signal is on the bore site axis, and then performing the rotational scan. The visual information regarding blood flow spatial distribution may be plotted in a spatial 3D image, or a series of 2D images, but is not restricted to these approaches.
[0046] In the eye, blood flow velocities are typically low and difficult to characterize because of poor signal-to-noise ratio (SNR). This is further complicated because ultrasonic Doppler devices as a rule must use very low power in the eye, which contributes to the low SNR. To overcome this disadvantage, the present invention provides significant improvement in SNR of the ophthalmic artery signal by averaging multiple heart cycles after cross-correlation (time) alignment of the set of spectrograms representative of the multiple heart cycles.
[0047] The pulse wave spectrogram processing unit 2 performs calculation of a coherently averaged full heart cycle blood flow velocity spectrogram and maximum velocity envelope from the set of spectrograms representative of the multiple heart cycles ( FIG. 2 ). After segmentation of the velocity spectrogram derived from a particular vessel location into separate spectrograms, one for each heart cycle, and synchronization of the heart cycles in these separate spectrograms via maximum-correlation of the Doppler shift signals, the coherent averaging in this step can be applied to obtain the maximum velocity envelope by either taking an average of the synchronized envelopes of the individual heart cycle spectrograms, or the envelope of the average of the synchronized spectrograms. This technique may be included to accomplish significant improvement in the accuracy and resolution of the blood flow maximum velocity envelope.
[0048] In order to apply an external pressure on the eyelid, the pressure control unit 3 drives pump 34 and reads data from digital manometer 90 ( FIGS. 1A-1C and 2 ). The absolute ICP calculation unit 4 performs the processing of all measurement data in order to determine the aICP.
[0049] The ultrasonic transducer 30 can be a 1D or 2D array transducer from which an ultrasonic beam can be electronically steered in order to enable the system to direct its ultrasonic acoustic pulses concurrently at both intracranial and extracranial segments 46 , 48 of the ophthalmic artery 36 . Whichever type of transducer, it is helpful that the transducer's central axis, or “bore site”, 44 , is first aligned to the optical canal and directed to view the IOA 46 and internal carotid artery (ICA) 41 ( FIG. 1A ). This alignment is accomplished by positioning an ultrasonic transducer on the eyelid according to known a priori information about human skull geometry. The EOA is then found by electronically adjusting the angle of the transducer scan plane. This results in the ability to electronically steer the transducer beam so as to direct its ultrasonic pulses at the intracranial and extracranial segments 46 , 48 of the ophthalmic artery 36 ( FIGS. 1A-1C ). Concurrent observation of blood flow in the intracranial and extracranial ophthalmic arteries is thereby accomplished. The signal location technique described in this paragraph is part of the preferred embodiment for this invention, but one skilled in the art will appreciate that this is one technique to improve signal quality and ease of acquisition, and that the underlying invention is not restricted to its inclusion.
[0050] In the operation of apparatus 20 , it is desirable that an initial alignment mode be undertaken to assure that the transmitter pulses from the transducer 30 are properly directed at both the intracranial and extracranial segments 46 , 48 of the ophthalmic artery 36 ( FIGS. 1A-1C ). This involves adjustments in the angle phi between the bore site axis 44 of the ultrasonic transducer 30 and the alignment axis 96 of the ophthalmic artery passage 42 ( FIG. 1A ). Such adjustment can be done with the alignment screws 98 . 1 , 98 . 2 and 98 . 3 or with such other suitable frame affixed between the band 26 and the transducer 30 in FIG. 4 .
[0051] As described above, one advantage of the present invention is the independence of measurement results from many influential factors such as arterial blood pressure, diameter of the OA, cerebrovascular autoregulation state, and hydrodynamic resistances of the ocular and other distant vessels. A unique and critical advantage of the invention is the ability to make non-invasive absolute ICP value measurements without the necessity to calibrate the non-invasive ICP meter system. The invention achieves these advantages by not using the measured absolute values of blood flow velocities in the intracranial and extracranial OA segments (IOA and EOA respectively). Instead, it uses just the comparison of such velocities or associated pulsatility indices or other parameters representive of blood flow dynamics, to find the “balance point”—the point at which a summary blood flow parameter describing IOA hemodynamics is equal to the summary blood flow parameter describing EOA hemodynamics. At the balance point, the ICP is determined and is equal to the extracranially applied pressure inside the pressure chamber. Such comparison is accurate and independent of the influential factors noted above since it is always find this balance point regardless of these factors.
[0052] A necessary property of the parameters representative of blood flow dynamics above is that they are independent of different angles at which Doppler blood flow velocities are measured in the IOA and EOA. Therefore when the blood flow pulsation parameters are measured, angle-independent blood flow factors are calculated. In one embodiment, these blood flow pulsation parameters are peak systolic velocity (VS) and end diastolic velocity (VD). Other measurement points of the blood flow envelope within one heart cycle may be used to calculate an angle-independent blood flow factor. The angle-independent blood flow factor in one embodiment is the pulsatility index, which is calculated for measurements in IOA and EOA:
[0000] PI IOA =2*( VS IOA −VD IOA )/( VS IOA +VD IOA ),
[0000] PI EOA =2*( VS EOA −VD EOA )/( VS EOA +VD EOA ),
[0053] One skilled in the art will appreciate that any other index of blood flow velocity pulsation which is not influenced by the OA insonation angle can also be used (e.g., resistivity index, any non-standard index which uses more than two measurement points of the blood flow envelope within one heart pulse, etc.).
[0054] The “balance point” noted above, at which parameters representative of blood flow are equal in the EOA and the IOA, is accomplished when:
[0000] PI IOA =PI EOA ,
[0000] or
[0000] PI IOA /PI EOA =1.
[0055] Pulsatility index is a highly vulnerable metric in that it takes two points out of an entire cardiac cycle of information—velocity envelope values at peak systole and diastole—and constructs an index. Using averaged heart cycle blood flow velocity spectrograms (as described above) greatly reduced the uncertainty associated with each of these two points. Due to the improvement in accuracy and precision of the envelope function from using the averaged heart cycle spectrograms, the calculation of the pulsatility index as used in the ICP determination is in turn of higher accuracy and precision.
[0056] The flow chart of apparatus 20 with reference to FIGS. 1 , 2 , 3 and 4 is shown in FIG. 5 .
[0057] The steps to measure non-invasive intracranial pressure (nICP) are now enumerated. There are two primary aspects to this measurement: scan mode and spectral mode. Scan mode is comprised of steps # 1 - 6 below, and spectral mode is comprised of the remaining steps.
[0058] Step # 1 : Software initialization of scan mode. This mode allows for the operator to align the ultrasonic transducer in the following sequence.
[0059] Step # 2 : Head frame with ultrasonic transducer is placed on patient and acoustic contact between ultrasonic transducer and eyelid is established with coupling gel or acoustically similar material.
[0060] Step # 3 : Transducer is fixed in the head frame according to a priori known angles and positions that align the transducer central axis to the optical canal. This alignment is most successful when the blood flow signal can be observed in the internal carotid artery, ICA. The distance between the ultrasonic transducer to ICA is a priori known to be in range of depth from 65-75 mm ( FIG. 6 ).
[0061] Step # 4 : The steering of the ultrasonic transducer is manipulated in order to visualize the blood flow signal from the IOA. The depth of the IOA signal is between 5 and 6 mm less than the distance from transducer to the ICA ( FIG. 6 ).
[0062] Step # 5 : For a 1D transducer, it is rotated around its axis until the signal from EOA appears. The depth of the EOA is approximately 5 to 7 mm less than the distance from transducer to the IOA. Both signals from the intracranial and extracranial segments of ophthalmic artery (IOA, EOA) must be clearly seen in the software window while in scan mode ( FIGS. 7-13 ). If the 2D array embodiment is utilized, then the manual steering described above can be accomplished electronically.
[0063] Figures FIG. 6-13 show the software windows when the apparatus is working in scan mode (also known as adjustment mode) and the transducer is rotated around its axis:
In FIG. 6 , the transducer rotation angle is 0 degrees at which the velocity Doppler signal from the ICA is seen at depth ˜72 mm and the signal from the IOA is seen at depth ˜50-60 mm, as shown in the left image. In FIGS. 7-8 , the transducer rotation angles are 20 and 40 degrees, respectively, at which the velocity Doppler signals are seen simultaneously from the IOA and EOA in the left image: IOA (depth ˜54 mm) and EOA (depth ˜46 mm).
[0066] In FIGS. 9-10 , the transducer rotation angles are 60 and 120 degrees, respectively, at which the only velocity Doppler signals seen are from the IOA (depth ˜54 mm). The signal from the EOA is weak and unsuitable for measurement.
[0067] In FIGS. 11-12 , the transducer rotation angles are 210 and 230 degrees, respectively, at which the velocity Doppler signals are seen again from the IOA and EOA in left the image: IOA (depth ˜54-60 mm) and EOA (−45-48 mm).
[0068] In FIG. 13 , the transducer rotation angle is 260 degrees at which the velocity Doppler signals are seen only from the IOA (depth ˜54 mm). The signal from the EOA is again weak and unsuitable for measurement.
[0069] In scan mode FIGS. 6-13 , the Doppler echo signals shown are obtained by systematically steering the ultrasound beam in a B-mode style planar region. Note that in the images on the left, the Y-axis is depth in mm, and the X-axis is the transducer steering angle in degrees. The spectral mode signals are shown in the images on the right; the top and bottom right images are Doppler velocity signals from locations designated by markers 2 and 1 respectively (in m/s). The markers are located in the scan mode image on the left.
[0070] In FIGS. 6-13 , it is shown that by turning the ultrasonic transducer around its axis, we always obtain a signal from the IOA. This means that an a priori angle and position of the transducer's positioning is set properly and confirmed empirically (i.e., the transducer central axis is aligned to the optical nerve canal). The signal from the EOA appears only at angles 20-40 degrees and 210-230 degrees. This is consistent with the fact that rotation of the scan plane by 180 degrees will produce the same scan plane.
[0071] Step # 6 : The angles and depths at which selections are made for sampling velocity Doppler signals (spectral mode on the right side of these images) are fixed by manually placing markers in the software window—by pointing and clicking the mouse—when the apparatus is working in scan mode (adjustment).
[0072] After the transducer is positioned to obtain velocity Doppler signals from two different depths and directions (“looks”), the apparatus is put in measurement mode, also referred to as “spectral mode”, in which the transducer is working by alternating its pulsing activity on a pulse-by-pulse basis between two fixed angular steering directions. In the next series of steps # 7 - 14 are the procedures for measuring absolute value of intracranial pressure.
[0073] Step # 7 : A known external pressure on eyelid is applied by inflating pressure chamber 28 by pump 34 ( FIGS. 1A-1C and 2 ). Using manometer 90 , the pressure within chamber 28 is measured and used by the apparatus software to control pump 34 . The measured pressure value is transferred from manometer 90 and stored for each measurement cycle (pressure is varied across measurement cycles).
[0074] Step # 8 : When required pressure is set and stabilized, the software makes Doppler spectral measurements in which the velocity signals are collected and analyzed from the IOA and EOA segment locations.
[0075] Step # 9 : Doppler velocity signals measured in the IOA and EOA segments are demodulated and used to form a spectrogram representative of blood flow at each location.
[0076] Step # 10 : Spectrograms of velocity signals at the IOA and EOA locations are parsed into separate heart cycles, which are synchronized and coherently averaged to form a separate IOA composite heart cycle spectrogram and an EOA composite heart cycle spectrogram ( FIG. 14 ).
[0077] Step # 11 : The peak velocity envelopes for IOA and EOA composite heart cycle spectrograms are calculated ( FIG. 14 ).
[0078] Step # 12 : The parameters representative of velocity signals in the composite heart cycle spectrograms of the IOA and EOA (VS for peak systolic velocity and VD for end diastolic velocity) are calculated from maximum flow velocity envelopes derived from these composite spectrograms.
[0079] Step # 13 : Angle independent factors such as pulsatility indexes are calculated from measured velocity signals separately for IOA and EOA composite spectrograms.
[0080] Step # 14 : The algorithm now repeats measurements of angle independent factors at different pressures applied to the eye by performing steps # 7 - 13 for each different externally applied pressure. The externally applied pressure varies by adjusting the inflation pressure of the chamber placed adjacent to the eye. The external pressure is changed within desired range by increasing it, for example, from 0 mmHg to 30 mmHg in increments such as 5 mmHg. At each fixed pressure, the measured velocity parameters in the IOA and EOA are stored for further processing.
[0081] Step # 15 : When the measurement of velocity parameters in the IOA and EOA is completed, the calculation of aICP is performed. The ICP is the pressure that achieves the “balanced point” where the calculated parameter representative of IOA blood flow is equal to the calculated parameter representative of EOA blood flow ( FIG. 15 ).
[0082] The result of non-invasive absolute ICP value measurements with an apparatus in accordance with the invention is shown in FIG. 16 . Serial non-invasive absolute ICP value measurements have been performed on the same healthy volunteer. The measurements are conducted with 15 minute breaks between two consequent measurements. The conclusion is that the standard deviation (SD=1.7 mmHg) is very low and is interpretable as a physiological variance of aICP combined with the absolute error of non-invasive absolute ICP measurement. The absolute error of ICP measurement is lower than +/−2.0 mmHg ( FIG. 16 ). The error +/−2.0 mmHg is a nominal error of existing invasive absolute ICP meters.
[0083] In FIG. 17 , non-invasive absolute ICP measurement results obtained using phase contrast MRI apparatus (See Alperin et al., MRI study of cerebral blood flow and CSF flow dynamics in an upright posture: the effect of posture on the intracranial compliance and pressure, Acta Neurochirurgica Supplementum 2005; 95: 177-181; Alperin et al., Relationship between total cerebral blood flow and ICP measured noninvasively with dynamic MRI technique in healthy subjects, Acta Neurochirurgica Supplementum 2005; 95: 191-193) are compared with results obtained using an apparatus in accordance with the invention on a group of healthy volunteers. Forty-two healthy volunteers were studied in supine and sitting body positions using a proposed apparatus. Three different ways of transcranial Doppler (TCD) signal analysis were used. These results are also listed in Table 1 below. The good agreement between experimental aICP measurement data using MRI and data using the proposed apparatus is evidence that the proposed method and apparatus are of high accuracy and do not require calibration.
[0000]
TABLE 1
MRI
Vittamed
Mean ICP,
SD,
Mean ICP,
SD,
POSITION
mmHg
mmHg
mmHg
mmHg
SUPINE
9.6
3.6
10.7
3.7
10.6
3.0
10.3
3.6
10.6
3.4
SITTING
4.5
1.8
4.2
3.2
4.8
3.1
4.5
3.5
[0084] FIG. 18 shows the measured typical dependence of the pulsatility index in the IOA and EOA of the ophthalmic artery. The measurements were performed with the apparatus in accordance with the invention on healthy volunteers in a supine body position for which normal aICP is close to 10 mmHg (see Table 1).
[0085] FIG. 18A shows the mean value and standard deviation of measured pulsatility indexes in the IOA and EOA when the external pressure applied in the pressure chamber (Pe) is 0 mmHg. FIG. 18B also shows the same parameters when Pe is 10 mmHg and when Pe≈aICP.
[0086] The experimental results shown in FIG. 18 are evidence that the achievable uncertainty U of aICP measurement by proposed method and apparatus is low enough (U<+/−2.0 mmHg) and acceptable for different clinical applications.
[0087] It should be understood that the foregoing is illustrative and not limiting, and that obvious modifications may be made by those skilled in the art without departing from the spirit of the invention. Accordingly, reference should be made primarily to the accompanying claims, rather than the foregoing specification, to determine the scope of the invention. | A method and apparatus for obtaining the absolute value of intracranial pressure in a non-invasive manner is described by using an ultrasonic Doppler measuring device which detects the intracranial and extracranial blood flow velocities of the intracranial and extracranial segments of the ophthalmic artery. The eye in which the blood flow is monitored is subjected to an external pressure, sufficient to equalize the intracranial and extracranial angle-independent blood flow factors calculated from the intracranial velocity signal and extracranial velocity signal. The absolute value of the intracranial pressure is identified as that external pressure at which such equalization occurs. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 11/263,753, filed Oct. 31, 2005, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to controlling the flow of fluids and gases in a wellbore. More particularly, the present invention relates to a valve for selectively closing a flow path in a single direction.
[0004] 2. Description of the Related Art
[0005] Generally, a completion string may be positioned in a well to produce fluids from one or more formation zones. Completion devices may include casing, tubing, packers, valves, pumps, sand control equipment, and other equipment to control the production of hydrocarbons. During production, fluid flows from a reservoir through perforations and casing openings into the wellbore and up a production tubing to the surface. The reservoir may be at a sufficiently high pressure such that natural flow may occur despite the presence of opposing pressure from the fluid column present in the production tubing. However, over the life of a reservoir, pressure declines may be experienced as the reservoir becomes depleted. When the pressure of the reservoir is insufficient for natural flow, artificial lift systems may be used to enhance production. Various artificial lift mechanisms may include pumps, gas lift mechanisms, and other mechanisms. One type of pump is the electrical submersible pump (ESP).
[0006] An ESP normally has a centrifugal pump with a large number of stages of impellers and diffusers. The pump is driven by a downhole motor, which is typically a large three-phase AC motor. A seal section separates the motor from the pump for equalizing internal pressure of lubricant within the motor to that of the well bore. Often, additional components may be included, such as a gas separator, a sand separator, and a pressure and temperature measuring module. Large ESP assemblies may exceed 100 feet in length.
[0007] The ESP is typically installed by securing it to a string of production tubing and lowering the ESP assembly into the well. The string of production tubing may be made up of sections of pipe, each being about 30 feet in length.
[0008] If the ESP fails, the ESP may need to be removed from the wellbore for repair at the surface. Such repair may take an extended amount of time, e.g., days or weeks. Typically, a conventional check valve is positioned below the ESP to control the flow of fluid in the wellbore while the ESP is being repaired. The check valve generally includes a seat and a ball, whereby the ball moves off the seat when the valve is open to allow formation fluid to move toward the surface of the wellbore and the ball contacts and creates a seal with the seat when the valve is closed to restrict the flow of formation fluid in the wellbore.
[0009] Gas lift is another process used to artificially lift oil or water from wells where there is insufficient reservoir pressure to produce the well. The process involves injecting gas or through the tubing-casing annulus. Injected gas aerates the fluid to make it less dense; the formation pressure is then able to lift the oil column and forces the fluid out of the wellbore. Gas may be injected continuously or intermittently, depending on the producing characteristics of the well and the arrangement of the gas-lift equipment.
[0010] The amount of gas to be injected to maximize oil production varies based on well conditions and geometries. Too much or too little injected gas will result in less than maximum production. Generally, the optimal amount of injected gas is determined by well tests, where the rate of injection is varied and liquid production (oil and perhaps water) is measured.
[0011] Although the gas is recovered from the oil at a later separation stage, the process requires energy to drive a compressor in order to raise the pressure of the gas to a level where it can be re-injected.
[0012] The gas-lift mandrel is a device installed in the tubing string of a gas-lift well onto which or into which a gas-lift valve is fitted. There are two common types of mandrel. In the conventional gas-lift mandrel, the gas-lift valve is installed as the tubing is placed in the well. Thus, to replace or repair the valve, the tubing string must be pulled. In the “sidepocket” mandrel, however, the valve is installed and removed by wireline while the mandrel is still in the well, eliminating the need to pull the tubing to repair or replace the valve.
[0013] Like other valves discussed herein, gas lift valves are typically “one way” valves and rely on a check valve to prevent gas from traveling back into the annulus once it is injected into a tubing string.
[0014] Although the conventional check valve is capable of preventing the flow of fluid in a single direction, there are several problems in using the conventional check valve in this type of arrangement. First, the seat of the check valve has a smaller inner diameter than the bore of the production tubing, thereby restricting the flow of fluid through the production tubing. Second, the ball of the check valve is always in the flow path of the formation fluid exiting the wellbore which results in the erosion of the ball. This erosion may affect the ability of the ball to interact with the seat to close the valve and restrict the flow of fluid in the wellbore.
[0015] Therefore, a need exists in the art for an improved apparatus and method for controlling the flow of fluid and gas in a wellbore.
SUMMARY OF THE INVENTION
[0016] The present invention generally relates to controlling the flow of fluids and gases in a wellbore. In one aspect, a valve for selectively closing a flow path in a first direction is provided. The valve includes a body and a piston surface formable across the flow path in the first direction. The piston surface is formed at an end of a shiftable member annularly disposed in the body. The valve further includes a flapper member, the flapper member closable to seal the flow path when the shiftable member moves from a first position to a second position due to fluid flow acting on the piston surface.
[0017] In another aspect, a valve for selectively closing a flow path through a wellbore in a single direction is provided. The valve includes a housing and a variable piston surface area formable across the flow path in the single direction. The valve also includes a flow tube axially movable within the housing between a first and a second position, wherein the variable piston surface is operatively attached to the flow tube. Further, the valve includes a flapper for closing the flow path through the valve upon movement of the flow tube to the second position.
[0018] In yet another aspect, a method for selectively closing a flow path through a wellbore in a first direction is provided. The method includes positioning a valve in the wellbore, wherein the valve has a body, a formable piston surface at an end of a shiftable member, and a flapper member. The method further includes reducing the flow in the first direction, thereby forming the piston surface. Further, the method includes commencing a flow in a second direction against the piston surface to move the shiftable member away from a position adjacent the flapper member. Additionally, the method includes closing the flapper member to seal the flow path through the wellbore.
[0019] In another embodiment, a valve embodying aspects of the invention is used in a gas lift arrangement to prevent the back flow of oil or gas injected into a tubing string from an annular area while reducing any obstruction of flow through the gas lift apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0021] FIG. 1 is a view illustrating a control valve disposed in a wellbore.
[0022] FIG. 2 is a view illustrating the valve in an open position.
[0023] FIG. 3 is a view illustrating the piston surface formed in a bore of the valve.
[0024] FIG. 4 is a view taken along line 4 - 4 of FIG. 3 to illustrate the piston surface.
[0025] FIG. 5 is a view illustrating the valve in the closed position.
[0026] FIG. 6 is a view illustrating a sidepocket mandrel assembly for use in a gas lift well.
[0027] FIG. 7 is a view taken along line 7 - 7 of FIG. 6 .
DETAILED DESCRIPTION
[0028] FIG. 1 is a view illustrating a control valve 100 disposed in a wellbore 10 . As shown, the control valve 100 is in a lower completion assembly disposed in a string of tubulars 30 inside a casing 25 . An electrical submersible pump 15 may be disposed above the control valve 100 in an upper completion assembly. As illustrated, a polished bore receptacle and seal assembly 40 may be used to interconnect the electrical submersible pump 15 to the valve 100 and a packer arrangement 45 may be used to seal an annulus formed between the valve 100 and the casing 25 . Generally, the valve 100 is used to isolate the lower completion assembly from the upper completion assembly when a mechanism in the upper completion assembly, such as the pump 15 , requires modification or removal from the wellbore 10 .
[0029] The electrical submersible pump 15 serves as an artificial lift mechanism, driving production fluids from the bottom of the wellbore 10 through production tubing 35 to the surface. Although embodiments of the invention are described with reference to an electrical submersible pump, other embodiments contemplate the use of other types of artificial lift mechanisms commonly known by persons of ordinary skill in the art. Further, the valve 100 may be used in conjunction with other types of downhole tools without departing from principles of the present invention.
[0030] FIG. 2 is a view of the valve 100 in an open position. The valve 100 includes a top sub 170 and a bottom sub 175 . The top 170 and bottom 175 subs are configured to be threadedly connected in series with the other downhole tubing. The valve 100 further includes a housing 105 disposed intermediate the top 170 and bottom 175 subs. The housing 105 defines a tubular body that serves as a housing for the valve 100 . Additionally, the valve 100 includes a bore 110 to allow fluid, such as hydrocarbons, to flow through the valve 100 during a production operation.
[0031] The valve 100 includes a piston surface 125 that is formable in the bore 110 of the valve 100 . The piston surface 125 shown in FIG. 2 is in an unformed state. The piston surface 125 is maintained in the unformed state by a fluid force acting on the piston surface 125 created by fluid flow through the bore 110 of the valve 100 in the direction indicated by arrow 115 . The piston surface 125 generally includes three individual members 120 . Each member 120 has an end that is rotationally attached to a flow tube 155 by a pin 195 and each member 120 is biased rotationally inward toward the center of the valve 100 . Additionally, each member 120 is made from a material that is capable of withstanding the downhole environment, such as a metallic material or a composite material. Optionally, the members 120 may be coated with an abrasion resistant material.
[0032] As illustrated in FIG. 2 , the valve 100 also may include a biasing member 130 . In one embodiment, the biasing member 130 defines a spring. The biasing member 130 resides in a chamber 160 defined between the flow tube 155 and the housing 105 . A lower end of the biasing member 130 abuts a spring spacer 165 . An upper end of the biasing member 130 abuts a shoulder 180 formed on the flow tube 155 . The biasing member 130 operates in compression to bias the flow tube 155 in a first position. Movement of the flow tube 155 from the first position to a second position compresses the biasing member 130 against the spring spacer 165 .
[0033] The valve 100 further includes a flapper member 150 configured to seal the bore 110 of the valve 100 . The flapper member 150 is rotationally attached by a pin 190 to a portion of the housing 105 . The flapper member 150 pivots between an open position and a closed position in response to movement of the flow tube 155 . In the open position, a fluid pathway is created through the bore 110 , thereby allowing the flow of fluid through the valve 100 . Conversely, in the closed position, the flapper member 150 blocks the fluid pathway through the bore 110 , thereby preventing the flow of fluid through the valve 100 .
[0034] As shown in FIG. 2 , a lower portion of the flow tube 155 is disposed adjacent the flapper member 150 . The flow tube 155 is movable longitudinally along the bore 110 of the valve 100 in response to a force on the piston surface 125 . Axial movement of the flow tube 155 , in turn, causes the flapper member 150 to pivot between its open and closed positions. In the open position, the flow tube 155 blocks the movement of the flapper member 150 , thereby causing the flapper member 150 to be maintained in the open position. In the closed position, the flow tube 155 allows the flapper 150 to rotate on the pin 190 and move to the closed position. It should also be noted that the flow tube 155 substantially eliminates the potential of contaminants from interfering with the critical workings of the valve 100 .
[0035] FIG. 3 illustrates the piston surface 125 formed in the bore of the valve 100 . To seal the bore 110 , the flow of fluid through the bore 110 of the valve 100 in the direction indicated by the arrow 115 is reduced. As the flow of fluid is reduced, the fluid force holding the piston surface 125 in the unformed state becomes less than the biasing force on the piston surface 125 . At that point, each member 120 of the piston surface 125 rotates around the pin 195 toward the center of the valve 100 to form the piston surface 125 illustrated in FIG. 4 . After the piston surface 125 is formed, the flow of fluid in the direction indicated by arrow 145 is commenced, thereby creating a force on the piston surface 125 . As the force on the piston surface 125 increases, the force eventually becomes stronger than the force created by the biasing member 130 . At that point, the force on the piston surface 125 urges the flow tube 155 longitudinally along the bore 110 of the valve 100 .
[0036] FIG. 5 is a view illustrating the valve 100 in the closed position. After the piston surface 125 is formed, the flow tube 155 moves axially in the valve 100 . This moves the lower end of the flow tube 155 out of its position adjacent the flapper member 150 . This, in turn, allows the flapper member 150 to pivot into its closed position. In this position, the bore 110 of the valve 100 is sealed, thereby preventing fluid communication through the valve 100 . More specifically, flow tube 155 in the closed position no longer blocks the movement of the flapper member 150 , thereby allowing the flapper member 150 to pivot from the open position to the closed position and seal the bore 110 of the valve 100 .
[0037] The flapper member 150 in the closed position closes the flow of fluid through the bore 110 of the valve 100 , therefore no fluid force in the bore 110 acts on the members 120 . To move the flapper member 150 back to the open position, the flow of fluid in the direction indicated by arrow 145 is reduced and the fluid on top of the flapper member 150 is pumped or sucked off the top of the flapper member 150 . At a predetermined point, the biasing member biasing the flapper member 150 is overcome and subsequently the biasing member 130 extends axially to urge the flow tube 155 longitudinally along the bore 110 until a portion of the flow tube 155 is adjacent the flapper member 150 . In this manner, the flapper member 150 is back to the open position, thereby opening the bore 110 of the valve 100 to flow of fluid therethrough, as illustrated in FIG. 2 .
[0038] In one embodiment, the valve 100 may be locked in the open position as shown in FIG. 2 by disposing a tube (not shown) in the bore 110 of valve 100 . The tube is configured to prevent the axial movement of flow tube 155 from the first position to the second position by preventing the formation of the piston surface 125 . Thus, the flapper member 150 will remain in the open position and the valve 100 will be locked in the open position. To lock the valve 100 , the tube is typically pulled into the bore 110 from a position below the valve 100 . In a similar manner, the valve 100 may be unlocked by removing the tube from the bore 110 of the valve 100 .
[0039] In another embodiment, the valve may be used in a gas lift application to prevent the back flow of gas (or production fluid) as gas is injected into a string or stings of production tubing. In one example, gas lift valves are disposed at various locations along the length of an annulus formed between production tubing and well casing. Gas lift valves are well known in the art and are described in U.S. Pat. No. 6,932,581, which is incorporated by reference in its entirety herein. Pressurized gas is introduced into the annulus from the well surface and when some predetermined pressure differential exists between the annulus and the tubing at a certain location, that valve opens and the gas is injected into the tubing string to lighten the oil and facilitate its rise to the surface of the well. The control valve of the invention is used in conjunction with the gas lift valves to prevent a backflow of gas or fluid from the production tubing to the annulus. Typically, the control valve is located adjacent the gas lift valve in the annulus. The valve permits gas to flow into the gas lift valve when it is open. However, when the gas lift valve closes, the control valve, with its closing members restricts the flow of gas or fluid back toward the annulus.
[0040] In gas lift applications, control valves according to the invention may be fixed in a sidepocket mandrel. A conventional sidepocket mandrel has a pocket bore size of about 1.750 inches and the control valve dimensions are designed accordingly. Employing control valves according to the invention permits fluid path dimensions to be maximized. Thanks to the flapper sealing member, no flow restriction or significant pressure drop occurs across the valve, and a more efficient operation of the pump is possible. Moreover, control valves according to the invention prove more reliable because they do not present any erosion related problems like conventional check valves.
[0041] As illustrated in FIG. 6 , in order to allow a larger amount of gas flowing into the tubing and optimizing the fluid flow path, a sidepocket mandrel 200 may be provided with two lateral bores 210 flowing into a main bore 220 which is connected in correspondence of its lower portion to the inside of the tubing string through a slot (not shown). The lateral bores 210 communicate with the main bore 220 through a drilled portion 230 which crosses the entire cross section of the main bore 220 and projects with its ends respectively into both the lateral bores 210 . Each of the two lateral bores 210 in the sidepocket mandrel is provided with a seat 211 a control valve 100 (not shown) can be threadably connected thereto, whereas the main bore 220 is provided with a conventional gas lift valve (not shown). FIG. 7 illustrates a cross section of the sidepocket mandrel assembly in correspondence of the drilled portion 230 .
[0042] A sidepocket mandrel as shown in FIGS. 6-7 is fixed to a tubing string located inside a wellbore and provided with control valves according to the invention in the respective seats 211 . Pressurizing gas in the annulus between the tubing string and the wellbore and opening the gas lift valve at the same time, initiate gas flowing through the mandrel 200 into the tubing so that the control valves 100 are driven in an open condition, wherein the gas is permitted to flow through the mandrel 200 and exercise the necessary pressure to keep the control valves opened. Two different streams of gas are created respectively inside each lateral bore 210 which finally commingle inside the main bore 220 . The gas then flows downwards inside the main bore 220 and finally enters the tubing string. The total amount of gas flowing through the mandrel 200 is directly dependent on the gas lift valve and, because in the opened condition the control valves do not cause any flow restriction, an optimization of the gas flow is obtained. Once the gas flow is either reduced or stopped the control valves close so as to prevent a backflow of gas or fluid from the production tubing to the annulus. The operation of the control valves according to the invention applied in gas lift applications is the same one as previously described in relation with FIGS. 2 to 5 .
[0043] Although a sidepocket mandrel with two lateral bores has been described hereinabove, it is apparent that with regard to the object of the invention the same considerations here apply for a sidepocket mandrel including only one lateral bore.
[0044] Although the invention has been described in part by making detailed reference to specific embodiments, such detail is intended to be and will be understood to be instructional rather than restrictive. For instance, the valve may be used in an injection well for controlling the flow of fluid therein. It should be also noted that while embodiments of the invention disclosed herein are described in connection with a valve, the embodiments described herein may be used with any well completion equipment, such as a packer, a sliding sleeve, a landing nipple, and the like.
[0045] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | The present invention generally relates to controlling the flow of fluids in a wellbore. In one aspect, a valve for selectively closing a flow path through a wellbore in a first direction is provided. The valve includes a body and a piston surface formable across the flow path in the first direction. The piston surface is formed at an end of a shiftable member annularly disposed in the body. The valve further includes a flapper member, the flapper member closable to seal the flow path when the shiftable member moves from a first position to a second position due to fluid flow acting on the piston surface. In another aspect, a valve for selectively closing a flow path through a wellbore in a single direction is provided. In yet another aspect, a method for selectively closing a flow path through a wellbore in a first direction is provided. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to bio measuring meters for determining the presence of an analyte in a biological sample, and more particularly, to a bio measuring meter whose operation is controlled by a code provided by a removably pluggable coding module. The present invention further relates to a coding module pluggable into a bio measuring meter for receiving a sample strip. The coding module defines at least one code, the code ciphering at least one property that is employed in controlling the operation of the meter, for example by controlling the operation of the meter. The invention further relates to a set of coding modules, to a method for producing coding modules, to a bio measuring system, to a bio measuring test set and to a method for operating a bio measuring meter in accordance with the claims.
BACKGROUND OF THE INVENTION
[0002] Bio measuring meters applied for detecting substances contained in blood to be analyzed, such as glucose or cholesterol, use a disposable sample strip. The sample strip has a reaction zone allowing blood to be placed thereon. The operation is controlled by a microprocessor. By execution of various methods, analysis results of the measurement are obtained.
[0003] For processing the sample measurement and the analysing routines the bio measuring meter needs certain parameter values which determine thresholds, time intervals, control numbers and calibration curve attributes.
[0004] Usually it is necessary to calibrate measuring devices in order to compensate for variations from lot to lot of the manufactured sample strip. Various techniques have been suggested for encoding information into the sample strip, as disclosed by U.S. Pat. No. 5,053,199 and references cited therein. This may e.g. be electronically encoded information on a carrier having an optical bar code, a magnetizable film, a perforated strip, a fluorogens or an electrically conductive medium on a foil.
[0005] Each of such known sample strips has to be furnished with an in-formation code, which is an additional manufacturing step and thus an expensive effort for a disposable device.
[0006] Other conventional measuring meters use an additional coding module or code key designed and inserted into a receptacle similar to the slot for the sample strip.
[0007] When performing a measurement, the memory key has to be inserted in the measuring meter before using a new batch of sample strips. Preferably the coding module remains inserted during the measurement or even all the time for the same batch of sample strips.
[0008] Based on the data or the code provided by the coding module the operation method, parameters or algorithms are chosen and a correct measurement result is obtained.
[0009] U.S. Pat. No. 5,366,609 and documents cited therein disclose bio measuring meters which have pluggable ROM coding modules that enable re-configuration of test methods and parameters employed by the meter. Threshold potentials, test times, delay periods and other pertinent test methods and constants may be entered and/or altered.
[0010] The main purpose of the coding module still is to provide information about the type of sample strip. For each new batch of sensor strips, new related information is needed.
[0011] As sample strips are disposable, preferably coding modules are disposable too. Costs for the module are therefore an important factor.
[0012] In a co-pending application, a coding module and bio measuring meter are presented, wherein the code is represented by a parameter value of an electrical component having a determined characteristic, such as a resistor or a capacitor. In comparison with the use of integrated circuits, the use of electrical components reduces the complexity and cost of the design. Thus, some of the drawbacks of the state of the art are overcome. However, the costs due to components and fabrication are still relatively high. Furthermore, electrical components present a risk of being influenced by a contamination of biological samples. Cleaning of such a code key is not easily feasible.
[0013] It is therefore an object of the invention to overcome the drawbacks of the prior art, especially to avoid the usage of memory IC chip technology for storing codes on coding modules, and to provide a coding module, a set of coding modules, a method for producing a coding module, a bio measuring meter with pluggable coding module, a bio measuring system, a bio measuring test set and a method for operating a bio measuring meter, which are not sensible with regard to a pollution caused by a biological sample and which can be produced cost-effectively.
SUMMARY OF THE INVENTION
[0014] In accordance with the present invention, a coding module is presented, which is connectable with a bio measuring meter for receiving a sample strip. The coding module defines at least one code. The code ciphers at least one property that is usable during operation of the meter. The at least one code is represented by at least one figured element.
[0015] According to the present invention, a figured element is an element having an outer structure which is mechanically ascertain-able. The at least one figured element typically can have an identifiable form, shape or surface texture. Preferably, the at least one figured element is arranged at a predefined position of the coding module. These positions define a coding area on the coding module.
[0016] The property usable on operation of the meter can be a set of parameter values that is employed in controlling the operation of the meter, for example by defining an evaluation curve or a parameter value for the choice of a predefined evaluation procedure or an input for a microprocessor routine.
[0017] A coding module being connectable with a bio measuring meter can be brought into measuring contact with the meter once, repeatedly or can remain attached thereto.
[0018] One advantage of using figured elements for encoding information is that the coding module can be integrally formed. No further steps for adding or fixing electric or electronic components are necessary which results in a cost-effective fabrication.
[0019] Whereas in the conventional coding modules, the code is mostly represented by electromagnetic characteristics, and the figured elements according to the present invention have mechanical characteristics which are not influenced by electromagnetic fields or chemical pollution.
[0020] The coding module according to the present invention can be completely free of electronic or electromagnetic components for coding purposes, which leads to a cost reduction by a saving of components and additional fabrication steps. Because of the lack of such components, the module can easily be cleaned. However, electronic or electric contacts may be present for other purposes.
[0021] Preferably, the at least one figured element is able to activate a switch and/or to engage with a switch on a meter. The switch can be activated directly, for example by the figured element closing or interrupting an electrical connection. Alternatively the switch could be activated indirectly, for example electro-magnetically based on e.g. optical, tactile or electric detection of the figured element.
[0022] The coding area of the coding module could also be coated with a second material, for example a conductive layer, thus resulting in an electro-magnetically or optically detectable pattern.
[0023] To allow the engagement with a switch on the bio measuring meter the at least one figured element is preferably formed by a projecting element, for example a protrusion, a tine, a tooth and/or pin, and/or an incising element, for example a cut, a recess and/or a hole. Figured elements of these types can simply be added to a basic form of a coding module but can also easily be formed in a production step when a coding module is integrally made in one piece. Moreover, the coding module can be integrally formed with the sample strip.
[0024] In a preferred embodiment, the at least one code is represented by a number and an arrangement of figured elements, preferably representing a binary code of 1 to 10 digits, more preferably of five digits. Thus the presence or the absence of a certain shaped element can simply be translated to a zero or one in a binary code and thus to one or more numbers. These numbers can for example be used for accessing data from a look up table such as to receive associated parameter values.
[0025] The coding module can have a receptacle able to receive the sample strip. The receptacle can allow a direct electrical coupling between the sample strip and the bio measuring meter. Alternatively the coding module can have an electrical coupling for connecting the sample strip and the bio measuring meter.
[0026] In both alternatives, the samples strip might come into contact with the coding module which leads to the danger of a pollution caused by the biologic sample. The coding represented by at least one figured element is not disturbed by a possible contamination with biologic sample or analyte. In case of a contamination, the function of the coding module is not affected. Furthermore, a one piece coding module can easily be cleaned and sanitized without influencing the coding elements and thus a continued use is allowed.
[0027] According to a further aspect of the invention, there is provided a set of coding modules, particularly of the above described type, with at least two types of coding modules, wherein the coding modules differ in the number, in the shape and/or in the arrangement of their figured elements. Thus, each coding module defines a different code, ciphering parameter values being related to a certain sample strip batch.
[0028] After fabrication of a series of samples strips, the samples strips can be measured and be divided into batches, which batches are associated with certain members of the set of coding modules.
[0029] According to a further aspect of the invention, there is provided a method for producing a coding module or a set of coding modules, preferably of the above described type comprising the step of moulding of a coding module in a mould, wherein the mould is designed to provide at least one figured element.
[0030] The coding module can e.g. be injection moulded. Other processes, e.g. compression moulding, are also possible. The figured elements can be integrally formed or elements can be formed which can be subsequently used to form figured elements, for example a perforation which allows to remove parts of the coding area.
[0031] To fabricate a set of coding modules, the mould can be completely exchanged and the mould can be replaced by a different one featuring different figured elements. Preferably, the mould is modified only on parts.
[0032] For example, only the part of the mould forming the at least one figured element representing the code is replaced by a different part designed to form a further code. After moulding coding modules with a second code, the mould can be modified again. By using this method, it is possible to fabricate a set of coding modules.
[0033] Since for different encodings only parts of the mould have to be exchanged, this method is cost-effective with regard to the investment and preproduction cost.
[0034] Instead of exchanging or modifying the mould to fabricate coding modules with different encodings, it is also possible to fabricate a basic coding module preformed by moulding.
[0035] In a second fabrication step, a code representation is provided by adding, removing and/or changing at least one figured element, wherein the code representation corresponds to a certain type of sample strips.
[0036] This adaptation can be carried out by a mechanical post processing, for example by drilling, cutting or removing at least one prepared part of the coding area.
[0037] According to another aspect of the invention, a bio measuring meter for receiving a sample strip is provided, the bio measuring meter having a receptacle able to accept a pluggable coding module. The bio measuring meter comprises means for receiving information from the coding module defining at least one code. The means comprises means for measuring at least one figured element representing the code.
[0038] The coding module is preferably of the above described type, wherein the code is represented by a number an arrangement of figured elements.
[0039] The bio measuring meter is provided with information about the sample strip batch by the code on the coding module.
[0040] The code can be a simple binary code, defining a code number and being interpreted as one of a variety of sets of parameter values stored in the bio measuring meter. The encoding can be made more complex by using a bigger number of figured elements or by different types of figured elements, such as holes and protrusions.
[0041] The determination of the code based on measuring of the figured elements and the translation of the code into parameter values used during operation is performed by the bio measuring meter. The coding module is only a carrier of the code. The bio measuring meter has the capability of reading the code, decoding and using the information. The parameter values can be derived from the code by a microprocessor routine or can be extracted using a look-up table stored in a memory of the bio measuring meter.
[0042] Preferably the bio measuring meter comprises mechanical, electromagnetic and/or optical means for reading the code, measuring the at least one figured element of the coding module.
[0043] In a preferred embodiment, the bio measuring meter comprises at least one switch, activable by the at least one figured element. More preferably, the bio measuring meter comprising as many switches as positions for figured elements are arranged on the coding module, such that each position of a figured element corresponds to a switch and each figured element interacts with a corresponding switch.
[0044] The bio measuring meter may have different receptacles for the sample strips and the coding module. Alternatively the bio measuring meter may comprise one receptacle able to accept a coding module formed to allow or to provide an electrical connection between the sample strip and the bio measuring meter.
[0045] According to a further aspect of the invention, there is provided a bio measuring system for analysing an analyte, comprising at least one coding module with at least one code, preferably of the above described type and comprising a bio measuring meter, preferably of the above described type, with means for receiving the at least one code from the the coding module. The code ciphers at least one parameter value that is used in controlling the operation of the bio measuring meter, for example in control-ling the execution of an algorithm performed by the meter that enables determination of an analyte concentration value. The at least one code is represented by at least one figured element and the bio measuring meter comprises means for measuring at least one figured element representing the code.
[0046] The bio measuring system can comprise a set of coding modules, each having a different code being associated with a certain batch of sample strips.
[0047] According to a further aspect of the invention, there is provided a bio measuring test set, comprising at least one test strip, and comprising a coding module with at least one code, preferably of the above described type, being associated with the at least one test strip and pluggable into a bio measuring meter. The code ciphers at least one parameter value that is used in controlling the operation of the bio measuring meter when analysing the test strip, for example in controlling the execution of an algorithm performed by the meter that enables determination of an analyte concentration value. The at least one code is represented by at least one figured element.
[0048] Usually, a bio measuring test set comprising one coding module and a plurality of samples strips form a commercial unit which is sold together in one package.
[0049] According to a further aspect of the invention, there is provided a method for operating a bio measuring meter, preferably of the above described type, comprising the steps of (i) inserting a coding module with at least one code into the bio measuring meter; (ii) detecting the at least one code; (iii) determining at least one parameter value used for control-ling operation of the meter; (iv) inserting a sample strip and adding a biologic sample; and (v) analysing the sample on the basis of the at least one parameter value. The detecting of the at least one code is carried out by measuring at least one figured element arranged on the module.
[0050] Although the present invention is presented in the context of a clinical or diagnostic instrument, it has utility in calibration of other medical measurement devices as well.
[0051] The present invention may be more fully understood by referring to the following detailed description of illustrative embodiments thereof and the accompanying drawings thereof.
[0052] The above contents and advantages of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed descriptions and accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] FIG. 1 a is a perspective top view of a first example of a bio measuring meter incorporating the present invention;
[0054] FIG. 1 b is a perspective bottom view of a first example of a bio measuring meter incorporating the present invention;
[0055] FIG. 2 is a schematic representation of a first embodiment of the present invention;
[0056] FIG. 3 a is a top view of a first example of a coding module according to the present invention and corresponding switches of a meter according to the present invention;
[0057] FIG. 3 b is a top view of the example of FIG. 3 a with a coding module inserted in the meter;
[0058] FIG. 4 a is a side view of a switch and a coding module;
[0059] FIG. 4 b is a sectional view of the switch engaged with a figured element from FIG. 3 b along A-A;
[0060] FIG. 4 c is a sectional view of the switch engaged with a figured element from FIG. 3 b along B-B;
[0061] FIGS. 5 a - 5 e are schematic views of different embodiments of figured elements on a coding module according to the present invention;
[0062] FIG. 6 a is a perspective top view of a second example of a bio measuring meter incorporating the present invention with an inserted sample strip and coding module;
[0063] FIG. 6 b is a perspective top view of the example of FIG. 6 a without the sample strip;
[0064] FIG. 6 c is a perspective top view of the example of FIG. 6 a with a removed module;
[0065] FIG. 7 a is a perspective top view of a second example of a coding module according to the present invention and measuring means according to the present invention;
[0066] FIG. 7 b is a perspective bottom view of a second example of a coding module according to the present invention;
[0067] FIG. 8 is a perspective top view of a third example of a bio measuring meter incorporating the present invention; and
[0068] FIGS. 9 a - 9 g are schematic views of different embodiments of figured elements on a sample strip according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0069] Referring to FIG. 1 , a bio measuring meter 100 has a display 111 , an operation button 112 and a receptacle 113 able to receive a disposable sample strip 200 . The sample strip 200 has a reaction zone which contains conductive electrodes. A reactant layer (not shown) is formed in the reaction zone to cover the electrodes. An analyte-containing fluid, for example a drop of blood, can be dripped on a substance entrance 220 .
[0070] The bio measuring meter 100 further has a second receptacle 114 for receiving a coding module 10 , which is inserted into the receptacle 114 of the bio measuring meter 100 .
[0071] When the coding module 10 is plugged into the slot 114 of the bio measuring meter 100 , measuring means of the bio measuring meter 100 get into contact with figured elements 30 a, 30 b, . . . 30 n of the coding module 10 .
[0072] FIG. 1 b is a perspective bottom view of a first example of a bio measuring meter 100 with the inserted coding module 10 .
[0073] FIG. 2 schematically shows a meter 100 with a coding module 10 according to the present invention and with a test strip 200 . The meter 100 comprises standard components such as a microprocessor with a central processing unit, a read-only memory and a random accessible memory, a display, a current measuring unit, an electrode working voltage supply unit and a temperature measuring unit. Those elements are standard in state of the art devices. In addition, the meter comprises a resistance measuring unit 150 which on the one hand is in operative connection with the microprocessor and on the other hand is connected to switches 156 a, 156 b, . . . , 156 n for measuring figured elements 30 a, 30 b, . . . 30 n in the coding module 10 . The arrangement of figured elements 30 a to 30 n ciphers a certain code as will be shown hereinafter. Detection of the figured elements 30 a, 30 b, . . . 30 n is made in a manner known to those skilled in the art, in particular by measuring a current in order to determine whether the switches 156 a, 156 b, . . . , 156 n are open or closed. Analog/digital converters are used to transmit the current values to the micro-processor.
[0074] FIG. 3 a is a top view of a first example of a coding module 10 and measuring means 155 in form of five switches 156 a, 156 b, . . . , 156 e of a meter. The switches 156 a, 156 b, . . . , 156 e are in electrical contact with a common potential at a conductor 157 . Without the coding module 10 being inserted, the switches 156 a, 156 b, . . . , 156 e are in contact with a second conductor 158 . Thus all switches 156 a, 156 b, . . . , 156 e are “closed” able to allow passing a predefined current.
[0075] The coding module 10 in FIG. 3 a has figured elements 30 a, 30 b, . . . , 30 e in the form of cuts 31 , which are arranged in a coding area 32 at certain positions 33 a, . . . , 33 e of the coding module 10 . The number and the arrangement of the cuts represent a five-digit binary code.
[0076] When the coding module 10 is inserted in the bio measuring meter 100 , the figured elements 30 a, 30 b, . . . , 30 e come into contact with the measuring means 155 as shown in FIG. 3 b.
[0077] Each position 33 a, . . . , 33 e of a figured element 30 a, 30 b, . . . , 30 n corresponds to a switch 156 a, 156 b, . . . , 156 e. All switches 156 a, 156 b, . . . , 156 e are opened, i.e. the contact between the conductors 158 and 157 is interrupted, by inserting the coding module 10 except those switches 156 a and 156 d, at which corresponding positions 33 a, 33 d cuts 31 are arranged on the coding module 10 .
[0078] A current is thus flowing through switches 156 a, 156 d. This current can be sensed by measuring the voltage difference across a resistor, not explicitly shown in this Figure, connected in series with the switches.
[0079] FIG. 4 a is a side view of a switch 156 and a coding module 10 , when the coding module is not inserted. The switch 156 is in a closed position, resulting in a current. The current leads to a difference of potential across a resistance 159 connected in series with the switch 156 .
[0080] FIG. 4 b is a sectional view of FIG. 3 along A-A. Switch 156 b is engaged with a figured element 30 b of the coding module 10 . The switch 156 b now is in an open position, and the current is interrupted.
[0081] FIG. 4 c is a sectional view of FIG. 3 along B-B. Switch 156 d of the coding module 10 meets a cut 31 at the position 33 d associated with the switch 156 d. Thus the switch 156 d is in a closed position, when the coding module 10 is inserted.
[0082] The current flowing through switches 156 a - 156 e of the meter 100 is related to the arrangement and the number of the cut 31 . The code represented by the figured elements on the coding module 10 can thus be detected.
[0083] Different embodiments of figured elements on a coding module 10 are shown in FIGS. 5 a to 5 e, for example slots 34 in FIG. 5 a, ribs 35 in FIG. 5 b, holes 36 in FIG. 5 c, dents 37 in FIG. 5 d and bumps 38 in FIG. 5 e.
[0084] The front area 40 of the coding module 10 is tapered to ease the insert and the opening of the switches.
[0085] Referring to FIGS. 6 a to 6 c, in a second example of the present invention, the measuring meter 101 has one receptacle 115 for receiving the sample strip 200 and the coding module 11 .
[0086] The coding module 11 allows an electrical connection between the bio measuring meter 101 and the sample strip 200 . When the coding module 11 is plugged into the bio measuring meter 101 , the sample strip can be inserted in a slot 116 of the same receptacle 115 and electrical contacts 50 on the coding module 11 get in contact with the electrodes of the sample strip 200 .
[0087] FIG. 7 a is a perspective top view of the coding module 11 with a coding area 32 and electrical contacts 50 and measuring means 155 . When the coding module 11 is inserted in the measuring meter, the coding area 32 with the figured elements 30 a, 30 b, . . . , 30 n engages with the switches 156 a, 156 b, . . . , 156 n, whereas the electrical contacts 50 get in contact with electrode contacts 160 .
[0088] FIG. 7 b is a perspective bottom view of the coding module 11 with electrical contacts 50 .
[0089] When the coding module 11 and the sample strip 200 are inserted in the measuring meter 101 , the contacts 50 on the coding module 11 get in electrical contact with the electrodes of the sample strip. In a similar manner, contacts 160 of the meter 101 are brought into electrical contact with the contacts 50 of the coding module 11 and consequently with the electrodes of the sensor strip 200 .
[0090] This embodiment makes sure that the meter can not be operated without a module 11 properly inserted.
[0091] Alternatively, the electrical contact between the electrodes on the sample strip and the electrode contacts 161 in the meter 102 can be made without conductive means on the coding modules 12 , as shown in FIG. 8 . The coding module 12 comprises a recess 60 which allows the electrode contacts 161 of the meter 102 to get in electrical connection with the electrodes of the sample strip, when the coding module 12 is inserted in the meter 102 .
[0092] Different embodiments of figured elements integrally formed with the sample strip 200 , i.e. the figured elements 91 ˜ 97 are directly mounted on the sample strip 200 , are shown in FIGS. 9 a ˜ 9 g. Each time while the sample strip 200 is inserted, the states of the switches are switched corresponding to the figured elements 91 ˜ 97 and the code represented by the figured elements on the sample strip 200 can thus be detected.
[0093] While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention needs not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures. | A bio-measuring meter is provided. The bio-measuring meter includes a receptacle receiving a sample strip for the bio-measuring meter; and a figured piece identifying device comprising plural switches for receiving a figured piece, wherein at least one of the plural switches is switched by the figured piece to generate a current signal, and a datum of the sample strip is adjusted by a predefined respective parameter for the current signal. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional applications No. 60/389,845 filed Jun. 19, 2002 and No. 60/390,047 filed Jun. 19, 2002.
This is a continuation application based on application Ser. No. 10/600,804, filed Jun. 19, 2003, now U.S. Pat. No. 7,027,673, the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to an apparatus and method for facilitating the processing of optical signals from single mode optical fibers by integrated circuits.
BACKGROUND OF THE INVENTION
Optical fibers have been widely used for the propagation of optical signals, especially to provide high speed communications links. Optical links using fiber optics have many advantages compared to electrical links: large bandwidth, high noise immunity, reduced power dissipation and minimal crosstalk. Optical signals carried by optical fibers are processed by a wide variety of optical and optoelectronic devices, including integrated circuits. Optical communications signals in optical fibers are typically in the 1.3 μm and 1.55 μm infrared wavelength bands. Optoelectronic integrated circuits made of silicon are highly desirable since they can be fabricated at low cost in the same foundries used to make VLSI integrated circuits. The optical properties of silicon are well suited for the transmission of optical signals, due to its transparency in the infrared wavelength bands of 1.3 μm and 1.55 μm and its high refractive index. As a result, low loss planar silicon optical waveguides have been successfully built in silicon integrated circuits.
Optical signals traveling in optical fiber frequently need to be coupled to optoelectronic circuits and this can be done through a variety of known techniques and devices. There are many advantages to directly coupling optical signals on fiber with integrated optoelectronic silicon based circuits. The flat end of an optical fiber can be directly connected to the edge of a silicon integrated circuit, so the optical signal can be coupled to a flat end of a planar waveguide. An optical signal in a fiber can be coupled to a planar waveguide through the top surface of an integrated circuit using a grating coupler. The efficiency of such fiber to chip connections depends on many factors, including the number and types of optical modes in the fiber and in the integrated waveguide. Once an optical signal is on a chip, it can be processed either as an optical signal or converted to an electronic signal for further processing.
An optical beam traveling in a single mode fiber (SMF) with circular cross section will typically have two optical modes, with one mode polarized in the x direction and a second mode polarized in the y direction. These two orthogonal polarizations have approximately the same propagation constant and approximately the same group velocity. Some refer to these two modes as a single mode with two polarization components. Within this discussion of the present invention, the two orthogonal polarizations are referred to as two modes.
Similarly, two orthogonal polarization modes are preset in standard forms of polarization maintaining fibers. These two modes have sufficiently different phase and group velocities to prevent light from coupling back and forth between the two modes. However, the differences are slight enough that they can usually be treated in a similar manner to SMF, when used as an input to polarization splitting elements.
In theory and under ideal conditions, there is no exchange of power between the orthogonal polarizations. If an optical signal is directed into only one polarization, then all the power should remain in that polarization. But in actual practice, imperfections or strains in the fiber cause random power transfer between the two polarizations. The total power is thus divided between the two polarizations, and this may not be a problem in some applications, but in many situations, this can be a major problem. In some cases, there can be a great deal of fluctuation and power transfer between the two polarizations. Such random fluctuations could cause the power delivered on one polarization, to be close to zero, which would result in some loss of signal, if only that polarization is being received.
Single mode optical fiber with a circular cross section has two optical modes, although due to the rotational invariance of a single mode fiber, one mode is difficult to describe without referencing the presence of the other. Planar waveguides have a different type of modal configuration, where there are two primary types of modes: the transverse electric (TE) and the transverse magnetic (TM), which describe which field of the mode is oriented purely transversely to the direction of propagation. This is strictly true only for 2 dimensional ideal waveguides, however this naming convention is also used for real world three dimensional waveguides, which are only approximately TE or TM. Future references herein will make the common assumption that quasi-TE or quasi-TM modes are understood as TE or TM modes.
It is difficult to connect an optical signal from an optical fiber to a planar waveguide due to differences in: cross sectional geometry, polarization characteristics and the number of optical modes. An SMF optical fiber has a circular cross section with a core diameter of less than ten microns. A nanophotonic planar waveguide can be substantially smaller, and as a result, contain modes that vary substantially in cross-sectional geometry. An SMF fiber will typically have two polarizations with essentially the same phase and group velocities. The polarizations in a planar waveguide can have very different phase and group velocities, or the planar waveguide could support only a single polarization mode. The number of optical modes in an SMF fiber is two when operated at the appropriate wavelength. A typical planar waveguide can have many optical modes within it, or it could have only one, depending on the design.
Waveguides are designed for use over a particular wavelength range, so a single mode waveguide at one wavelength very often becomes multimodal at substantially shorter wavelengths. When one skilled in the art refers to waveguide operation, it is commonly understood that a particular wavelength range is being referenced with respect to single or multimode operation.
The design process for optical paths comprises construction of maskworks. Maskworks include shapes, layout, data structures, netlists, and alignment marks and other elements of the design which are typically stored as digital data on a computer system. In addition, these electronic representations of the designs are transferred to a set of many physical masks which are used during the fabrication of the components. These many masks are included in the definition of maskworks.
As a result of the many differences in characteristics between optical fibers and planar waveguides, it has been difficult to connect optical signals from one to the other.
SUMMARY OF THE INVENTION
One embodiment of the present invention is an apparatus and method for splitting a received optical signal into its orthogonal polarizations and sending the two polarizations on separate dual integrated single mode waveguides to other systems on chip for further signal processing. The present invention provides an apparatus and method for facilitating the processing of optical signals in planar waveguides received from optical fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an apparatus, according to one embodiment of the present invention.
FIG. 2 is a block diagram of an apparatus, according to an alternate embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 is a block diagram of an apparatus, according to one embodiment of the present invention. Optical signal 101 is input to polarization splitting element 102 . Polarization splitting element 102 splits the received optical signal into two orthogonal polarizations or modes which are sent to output ports as output signals 103 and 113 .
Output signal 103 is sent to the input of waveguide 104 . The optical signal received by the waveguide 104 propagates through it and appears as output signal 105 . Output signal 105 is input to optoelectronic signal processing system 106 , which processes the received signal and generates output 107 .
Output signal 113 is sent to the input of waveguide 114 . The optical signal received by the waveguide 114 propagates through it and appears as output signal 115 . Output signal 115 is input to optoelectronic signal processing system 116 , which processes the received signal and generates output 117 .
Waveguides 104 and 114 are fabricated as identical waveguides within the limitations of the particular semiconductor processing technology used to make them. The two waveguides are of the same length, width and height and made of the same materials, during the same semiconductor processing steps. To minimize differences in the waveguides due to local variations in an integrated circuit, the waveguides 104 and 114 can be fabricated in close proximity to each other on the same integrated circuit. In an exemplary embodiment, the waveguides 104 and 114 are no more than five microns apart. Just as matched transistors on an integrated circuit have to be built in close proximity to each other, the waveguides 104 and 114 have to be fabricated close together in order to be considered a matched pair of waveguides.
In one embodiment, the polarization splitting element and the two waveguides are disposed on the same integrated circuit. In an alternate embodiment, the two waveguides are disposed on the same integrated circuit.
If we consider waveguides 104 and 114 as identical waveguides, then their operating characteristics would be identical. Two optical modes propagated separately through the two waveguides will encounter the same optical environment, and any change in the two signals due to the waveguides will be the same. Optoelectronic signal processing systems 106 and 116 are also designed to be identical in operation, and have the same impact on the two separate optical modes. Systems 106 and 116 can be any of a general type of signal processing systems, which can process signals optically, electronically or optoelectronically. The two identical signal processing systems can be any one of the following types of devices, such as: photodetectors, filters, modulators, demodulators, amplifiers, pulse shapers, multiplexers, demultiplexers, etc., and other kinds of signal processors. The two identical signal processing systems can be output devices, such as chip to fiber couplers. In an alternate embodiment, the two systems 106 and 116 can be replaced by one signal processing system with two input ports and one output port.
The outputs of the two signal processing systems can be combined together to generate a single output signal.
Thus, the two modes can travel down paths, which are very similar before independently reaching the signal processing system, and the sum of the effects of the identical waveguides can be expected to produce a nearly polarization independent effect.
A matched pair of optical waveguides can have two basic forms. In the first form, they are exactly identical copies of each other, placed along the same orientation, in proximity to each other. The second form is where the two copies are mirror images of each other, along some line in plane with the substrate, and the two copies are in proximity to each other.
A particularly advantageous aspect of the present invention is that splitting the optical input signal into its two orthogonal polarizations and processing the two polarizations in an identical manner enables the two planar waveguides operating together to receive an optical signal without being adversely affected by the polarization characteristics of the optical waveguide.
When waveguides are fabricated, there are two main sources of fabrication error: film thickness and etch process variation. Both of these two effects are dependent on the distance between two structures that are desired to be identical. The proper distance is best quantified with a number called the autocorrelation length of the variable. The autocorrelation length is a distance over which one thickness, for example, is known to be correlated to another, and beyond this distance, the relative thicknesses become increasingly non-deterministic. This autocorrelation function is well known to those skilled in the art, and can also be applied to the variations in process bias that create asymmetries between waveguides or optical circuits. A particularly relevant way to express the effects of a combination of effects, each with their own autocorrelation length is to combine them as a number representing the autocorrelation length of the phase of the optical signal.
FIG. 2 is a block diagram of an apparatus, according to one embodiment of the present invention. Optical signal 201 is input to polarization splitting element 202 . Polarization splitting element 202 splits the received optical signal into two orthogonal polarizations or modes which are sent to output ports as output signals 203 and 213 .
Output signal 203 is sent to the input of waveguide 204 . The optical signal received by the waveguide 204 propagates through it and appears as output signal 205 . Output signal 205 is input to photodetector 206 , which processes the received signal and generates electrical output signal 207 .
Output signal 213 is sent to the input of waveguide 214 . The optical signal received by the waveguide 214 propagates through it and appears as output signal 215 . Output signal 215 is input to photodetector 216 , which processes the received signal and generates electrical output signal 217 .
Electrical output signals 207 and 217 can be combined together by summing circuit 208 to generate electrical output signal 209 . In an alternate embodiment, the summing circuit 208 and the two photodetectors 206 and 216 can be replaced by one photodetector with two input ports and one output port.
A particularly advantageous aspect of the present invention is the generation of an electrical output signal which corresponds to the total power of the two polarizations of the optical input signals, regardless of how the power is randomly transferred between the two polarizations.
Although the present invention has been described in detail, it should be understood that various changes, substitutions and alterations can be made without departing from the spirit and scope of the invention. | An apparatus and method for splitting a received optical signal into its orthogonal polarizations and sending the two polarizations on separate dual integrated waveguides to other systems on chip for further signal processing. The present invention provides an apparatus and method for facilitating the processing of optical signals in planar waveguides received from optical fibers. | 6 |
[0001] This application claims the benefit of application number Ser. No. 61/546,309, filed Oct. 12, 2011, the entire content of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention relates to imaging devices and, more particularly, to ultrasound imaging devices.
BACKGROUND
[0003] High-frequency ultrasound (HFUS) has been used to generate high-resolution (<100 μan) images in medical applications such as endoscopy, intravascular imaging, ophthalmology, and dermatology. The production of HFUS transducers, however, has proven to be difficult using conventional design and manufacturing techniques. Thin-film PVDF and capacitive transducers (CMUT) have circumvented the difficulties in dicing piezoceramics on the micron scale, however the electrical connections required still make these devices susceptible to excessive noise due to crosstalk, RF interference, and small capacitance. These factors severely limit image quality.
SUMMARY
[0004] Devices that optically generate and detect ultrasound circumvent the problems intrinsic to small-scale piezoelectric transducers by requiring no electrical cabling or interconnections. An etalon in as an optical device containing parallel, partially-reflective mirrors. Thin-film etalons are good candidates for optical ultrasound sensor arrays and exhibit the high sensitivity and large bandwidth required for high-resolution imaging. They are also relatively easy to manufacture using nanofabrication techniques. These devices operate by subjecting a small and compressible Fabry-Pérot interferometer to high-frequency ultrasound (HFUS) which in turn modulates the optical cavity thickness. This change in thickness alters the optical path length thereby resulting in a shift in the resonance wavelength. If the probe beam's wavelength is tuned on either edge of the resonance, a corresponding change in the beam's reflected intensity occurs and can be captured using a photo detector. A distinct advantage of etalon sensors is that the sensitivity does not decrease as the active area is decreased. Furthermore the active area of the sensing element is merely dependent on the spot size of the probe beam. The size of the element can therefore be easily reduced to a spot of diameter less than 100 μm by using a focusing lens. This generates a point source-like detector which provides for a wide acceptance angle.
[0005] HFUS can also be generated via the photoacoustic effect—the conversion of optical energy into a thermoelastic wave. While the most common method of photoacoustic excitation in medical imaging is the direct irradiation of tissue, photoabsorptive thin films can be used as photoacoustic targets for use in pulse-echo mode. Moreover, the simple nature of these films allows them to be integrated into etalon structures so as to provide an all-optical transmit/receive ultrasound sensor. A transducer may be created by transforming one of the etalon mirrors into a periodic gold nanostructure. When exposed to a short laser pulse at the structure's plasmon resonance frequency, a thermoelestic wave is generated. By designing the dimensions of the nanostructure appropriately, this resonance frequency occurs sufficiently distal to that of the etalon structure thereby allowing dual-mode functionality with the use of two optical sources. However, this structure is difficult to fabricate and unfortunately has a low damage threshold which makes long-term use unviable. A photoabsorptive black polydimethylsiloxane (PDMS) layer may be introduced on top of an unmodified etalon, however this configuration introduces two significant disadvantages: (1) it requires the transmitting and sensing elements to be in different locations which was shown to reduce bandwidth and hinder image reconstruction, and (2) deposition of the transmitting layer on top of the etalon introduces acoustic attenuation and decreases the sensor's bandwidth by effectively making the device thicker.
[0006] An all-optical ultrasound transducer is described herein that integrates an optically-absorbing polyimide thin-film into an etalon sensor. This optical technique provides for very small ultrasound transducers. Transmission and reception of the ultrasound is based upon optical interfaces. A laser is delivered to the device optically, which is absorbed and causes the device to emit ultrasound. A second layer acts as a resonator and is sensitive to pressure of the ultrasound and therefore provides a way to detect the ultrasound echoes. The device forms a transmitter receiver for ultrasound while the interface to the outside world is through optical signals and not electronic signals.
[0007] One advantage of opto-acoustic technology that is based on optic signaling is that the element described herein can be made very small depending upon the optics. For example, the device could focus down to 10 micron, so the effective area of a transducer in accordance with the techniques herein could be 10 micron in this example. The opto-acoustic technology may be applied for miniaturized imaging probes, as one example, including ultrasound imaging probes. Example applications include intravascular imaging, intracardiac or any image guided interventions, such as laparoscopic surgeries, where visual feedback is needed. In these applications, imaging probes in accordance with the techniques described herein may be less invasive than conventional techniques because of the reduced size of the transducers. Moreover, more intense light rays may be utilized so as to provide improved imaging sensitivity. The number of imaging elements may also be increased due to the reduced size, which may aid in forming higher quality of images.
[0008] The optical and acoustic properties of the device as well as the imaging capabilities of the device are described herein. An example device design for high resolution imaging applications is described. Because the opto-acoustic transduction mechanisms rely on light delivery, the coupling of a 2-D transmit/receive array with optical fibers provides a compact and flexible device well suited for endoscopic and intravascular ultrasound (IVUS).
[0009] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1 is a block diagram illustrating an example optical ultrasound transducer, in accordance with one or more aspects of the present disclosure.
[0011] FIG. 2 is a block diagram illustrating an example optical ultrasound transducer, in accordance with one or more aspects of the present disclosure.
[0012] FIG. 3 is a block diagram illustrating an example optical ultrasound transducer, in accordance with one or more aspects of the present disclosure.
[0013] FIG. 4 is a block diagram illustrating an example optical ultrasound transducer, in accordance with one or more aspects of the present disclosure.
[0014] FIG. 5 is a block diagram illustrating an example optical ultrasound transducer, in accordance with one or more aspects of the present disclosure.
[0015] FIG. 6 is a block diagram illustrating an example layered microstructure and operating principle of an all-optical, thin-film, high-frequency ultrasound transducer, in accordance with one or more aspects of the present disclosure.
[0016] FIG. 7 is a graphical diagram showing an example resonance profile of an etalon sensor when optically tested, in accordance with one or more aspects of the present disclosure.
[0017] FIGS. 8A and 8B are graphical diagrams showing example pulse-echoes from an optical ultrasound transducer, in accordance with one or more aspects of the present disclosure.
[0018] FIGS. 9A and 9B are graphical diagrams showing a recorded waveform and associated frequency response of an optical ultrasound transducer, in accordance with one or more aspects of the present disclosure.
[0019] FIGS. 10A-10C are graphical diagrams showing etalon detection of a polyimide pulse-echo in an optical ultrasound transducer, in accordance with one or more aspects of the present disclosure.
[0020] FIG. 11A and 11B are a block diagram and associated graphical diagram illustrating an example 1-D synthetic aperture scanning system, in accordance with one or more aspects of the present disclosure.
[0021] FIG. 12 is a block diagram illustrating an example configuration of an optical ultrasound transducer, in accordance with one or more aspects of the present disclosure.
DETAILED DESCRIPTION
[0022] FIG. 1 is a block diagram illustrating an example optical ultrasound transducer, in accordance with one or more aspects of the present disclosure. In the example shown in FIG. 1 , an ultrasound transducer includes single mode fiber optic (SMF) 1 , coated with high optical absorption thermoelastic material layer 2 (hereinafter “PI layer 2 ”), typically 1-2 μm in width. In other examples, SMF 1 may instead be a multimode fiber optic (MMF). In the example of FIG. 1 , SMF 1 is also coated with a first reflecting surface, layer 3 a, a transparent polymer, layer 4 , and a second reflecting surface, layer 3 b. A laser pulse (e.g., of UV light) at a wavelength within the absorbing range of PI layer 2 (e.g. 355 nm) is delivered through SMF 1 and is absorbed by PI layer 2 . PI layer 2 acts as a transmitter that absorbs light at specific wavelengths in order to generate an acoustic tone. PI layer 2 is transparent to other wavelengths, such that light can propagate through PI layer 2 and probe the detector, which comprises layers 3 a, 4 , and 3 b. For example, PI layer 2 may comprise a material that has very high absorption in the ultra-violet (UV) light range and very good transmission characteristics in the infra-red light range. PI layer 2 may be a polymer or a mixture of a dye and a polymer that has high optical absorption at a specified range (absorption range) and high optical transmission at a different wavelength range (transmission range). As an example, PI can stand for Polylmide polymer. In this case the absorption range would include 200 nm<λ<400 nm, and the transmission range would include 600 nm<λ<2000 nm.
[0023] In the detector (i.e., layers 3 a, 4 , 3 b ), light transmits back and forth between the two mirrors of layer 3 a and 3 b, and any pressure applied to one of the mirrors creates change in the directivity. The pulse absorption thereby generates ultrasound waves by the thermoelastic mechanism. A second laser (e.g., one having a continuous wavelength at 1550 nm) is delivered through SMF 1 and is used to probe the etalon structure of layers 3 a, 4 , 3 b. Layer 4 is a compressible polymer layer which acts as a spacer between the two reflecting surfaces 3 a and 3 b. Because layer 4 is compressible, it is responsive to acoustic pressure and the distance between the two reflecting mirrors (i.e., layers 3 a, 3 b ) is modified by the acoustic wave. The etalon structure of layers 3 a, 4 , 3 b allows a specific wavelength or a specific wavelength range to penetrate into the space between the mirrors and resonate back. A resonance shift occurs in response to compression of layer 4 . This change in the distance is probed by the continuous wavelength laser. The reflection of the second laser is measured by a photodetector (PD). The PD output is converted from current to voltage and then sampled by an analog-to-digital converter (A/D). The digital signal received from the A/D converter corresponds to the acoustic pressure at the active area of the device (i.e., the tip of SMF 1 ).
[0024] FIG. 2 is a block diagram illustrating another example optical ultrasound transducer, in accordance with one or more aspects of the present disclosure. In the example of FIG. 2 , SMF 1 is coated with a first reflecting surface, layer 3 a, PI layer 2 , and a second reflecting surface, layer 3 b. PI layer 2 may typically be, in this example, 5-10 μm in width. Layer 3 a may be a wavelength-selective mirror coating design to transmit short waves (including uv) and reflect long waves (including near infra-red 1550 nm). As shown, PI layer 2 is formed between layers 3 a and 3 b and operates both as a compressible spacer (receiver) and a pulse converter (transmitter). PI layer 2 is selected to have very good transmission. That is, PI layer 2 may be relatively transparent in the near infra-red (NIR), allowing it to act as the spacer between the mirrors of layers 3 a, 3 b, but at the same time it may have good absorption for UV light and thereby operate as a pulse converter to convert the UV light to ultrasound as in the configuration of FIG. 1 .
[0025] In the example of FIG. 2 , a laser pulse at a wavelength within the absorbing range of PI layer 2 (e.g. 355 nm) is delivered through SMF 1 and is absorbed by PI layer 2 . In this example, layer 3 a is transparent to UV such that the UV pulse is transmitted into PI layer 2 and absorbed to generate the ultrasound. The pulse absorption generates ultrasound waves by the thermoelastic mechanism. A second laser, such as a continuous wave (CW) laser at 1550 nm, is delivered through SMF 1 , and is used to probe the etalon structure of layers 3 a , 2 , 3 b. The reflection of the CW laser is measured by a PD. The PD output is converted from current to voltage and then sampled by an A/D converter. The digital signal corresponds to the acoustic pressure at the active area of the device (i.e., the tip of SMF 1 ).
[0026] FIG. 3 is a block diagram illustrating an example optical ultrasound transducer, in accordance with one or more aspects of the present disclosure. As shown, SMF 1 is coated with PI layer 2 and a first reflecting surface, layer 3 a. As shown in FIG. 3 , a layer of transparent polymer, layer 4 b, is then coated on layer 3 a. Layer 4 b is then patterned to remove material not in front of the SMF core of SMF 1 . A second polymer layer, layer 4 a, is then applied to fill the space of the removed material. A second reflecting surface, layer 3 b , is then coated on to form the detector. The optical refraction index of layer 4 b is higher than the refraction index of layer 4 a. This reduces any lateral divergence of the light from the detector as the light emerges from the optical fiber, SMF 1 , thereby reducing any loss of energy from the resonator. As a result, the device may achieve higher quality factor (Q-factor) of its optical resonance and therefore higher acoustic sensitivity. In a sense, layers 4 a , 4 b operate to extend the fiber cladding and fiber core of SMF 1 , correspondingly, into the etalon structure of layers 3 a, 4 a, 4 b, and 3 b, so as to confine the light within the detector.
[0027] In the example of FIG. 3 , a laser pulse at a wavelength within the absorbing range of PI layer 2 (e.g. 355 nm) is delivered through SMF 1 and is absorbed by PI layer 2 . The pulse absorption generates ultrasound waves by the thermoelastic mechanism. A second laser (CW at 1550 nm) is delivered through SMF 1 and is used to probe the etalon structure of layers 3 a , 4 a, 4 b, 3 b. The reflection of the CW laser is measured by the PD. The PD output is converted from current to voltage and then sampled by the A/D converter. The digital signal corresponds to the acoustic pressure at the active area of the device.
[0028] The construction of FIG. 3 may similarly be applied to the device of FIG. 2 . In this case, PI layer 2 , disposed between layers 3 a, 3 b, may be formed to have two parts having different refraction indices so as to extend the fiber cladding and core into the etalon structure.
[0029] FIG. 4 is a block diagram illustrating an example optical ultrasound transducer, in accordance with one or more aspects of the present disclosure. As shown, a bundle of single mode fibers or multimode fibers (i.e., a group of two or more of SMF 1 ) are each coated with a PI layer 2 . In the example of FIG. 4 , PI layer 2 may typically be 1-2 μm in width. Each of SMF 1 may also be coated with a first reflecting surface, layer 3 a, a layer of transparent polymer, layer 4 , and a second reflecting surface, layer 3 b. In this way, an ultrasound transducer having multiple imaging elements may be formed from the example embodiment of FIG. 1 . Although not shown, the example embodiment of FIG. 2 may be arranged in a similar manner to form an ultrasound transducer of multiple elements.
[0030] FIG. 5 is a block diagram illustrating an example optical ultrasound transducer, in accordance with one or more aspects of the present disclosure. In this example, each fiber in a bundle of single mode fibers or multimode fibers 1 is coated with PI layer 2 , typically 1-2 μm in width, and a first reflecting surface, layer 3 a. A layer of transparent polymer, layer 4 b , is then coated on the surface of layer 3 a. Layer is then patterned to remove material not in front of the core of each of SMF 1 . A second polymer layer, layer 4 a, is then applied to fill the space. A second reflecting surface, layer 3 b, is then coated on. The optical refraction index of layer 4 b is higher than the refraction index of layer 4 a, thereby extending each of SMF or MMF 1 into the detector. In this way, an ultrasound transducer having multiple imaging elements may be formed from the example embodiment of FIG. 3 .
[0031] In this way, as shown in FIGS. 1-5 , the UV pulse for HFUS generation may be integrated into the optical assembly used for etalon detection. These pulses are directed through the same lens used to focus the NIR beam, which allows the transmitting and sensing elements to be precisely in the same location. The resonance wavelength may be prerecorded at each detector site so as to compensate for the change in etalon thickness encountered during beam scanning This facilitates acquisition of the maximal signal available at each detection site. Coupling the UV light to a multi-mode optical fiber provides a fiber optic HFUS imager. In some examples, an optical ultrasound transducer, in accordance with one or more aspects of the present disclosure, may be used in combination with other optical imaging methods. For instance, an optical ultrasound transducer as exampled in one of FIGS. 1-5 may be used with photoacoustic imaging, optical imaging (i.e., endoscopy), fluorescence imaging, optical coherence tomography (OCT), or other optical imaging methods. Such a combination is possible due to the limited absorption ranges of the optical ultrasound transducer. That is, the optical ultrasound transducer as described in the present disclosure may be used in connection with a third light source or more light sources. The third light source may provide light at a third wavelength, within the transmission range of PI layer 2 , used for other optical imaging methods. In some examples, the third light source may be white light, or other broadband illumination sources.
[0032] FIG. 6 is a block diagram illustrating an example layered microstructure and operating principle of an all-optical, thin-film, high-frequency ultrasound transducer, in accordance with one or more aspects of the present disclosure. In this example, a polyimide adhesion promoter is spin-coated onto a glass substrate having a 25 mm diameter and 3 mm thickness. A layer of polyimide precursor is spin-coated onto the substrate. The polyimide precursor has a thickness of approximately 2.5 μm. The sample may be heated to 250° C. at a rate of 10° C./min and then cured (e.g., for 90 minutes) in nitrogen. After gradually cooling to room temperature, a first etalon mirror, e.g., a 3/30/3 nm Ti/Au/Ti film, is deposited on top of the polyimide film using electron-beam evaporation. A 10 μm layer of photoresist is then spin-coated, cured, and exposed to UV light for cross-linkage. A second etalon mirror, identical to the first, is then deposited. Additionally, 1.5 μm of photoresist may be added to provide a layer of protection. In operation, pulsed UV is absorbed by the polyimide layer which launches an acoustic wave. The etalon, which operates at NIR wavelengths, detects the echo.
[0033] In operation, the example device of FIG. 6 may produce an optically-generated acoustic pulse having an amplitude of 4.3 MPa and a −3 dB bandwidth of 29 MHz centered at 27 MHz. The etalon sensor may achieve a Noise-equivalent Pressure of 1.3 Pa/√{square root over (Hz)}. When used in pulse-echo mode, the −6 dB upper cutoff frequency of the device's transmit/receive response may reach 47 MHz. A 1-D synthetic aperture can be created, and imaging results may reach an upper limit of 100 μm and 40 μm on the lateral and axial resolution, respectively.
[0034] With the incorporation of fiber optics and 2-D beam scanning, aspects of the present disclosure may be applied, for example, in endoscopic and intravascular ultrasound. For instance, a transmitting film may be used that is (1) easy to fabricate, (2) of a high damage threshold, and (3) sufficiently transparent to wavelengths used for etalon sensing. This would allow the sensing and transmitting elements to be in the same location and would allow the transmitting film to be placed underneath the etalon. In one example, a polyimide precursor PI-2555, a material known for its resistance to high temperatures and characteristic optical absorption in the UV spectrum, may be used for PI layer 2 in FIGS. 1-5 .
[0035] FIG. 7 is a graphical diagram showing an example resonance profile of the etalon sensor of FIG. 6 when optically tested, in accordance with one or more aspects of the present disclosure. A fiber-connectorized output of a NIR wavelength-tunable CW laser may be routed to a fiber optic collimator with a polarization maintaining fiber. An optical circulator can be implemented using a polarizing beam-splitter and quarter-wave plate. Following the wave plate, the 3 mW beam may be focused onto the etalon with a spot size of 26 μm in diameter. The beam may then be reflected back through the circulator and detected using a DC IR power meter (e.g., a Thorlabs PM100). The NIR laser wavelength can then be swept throughout its tunable range (1508-1640 nm), and the analog output of the power meter may be digitally acquired at each wavelength. The Q-factor and Finesse may achieve 453 and 23, respectively.
[0036] The acoustic performance of the sensing and transmitting elements were next verified independently. The IR power meter may be replaced with a high-speed InGaAs photodetector. After tuning the wavelength of the CW NIR beam for maximum sensitivity, a 25 MHz ultrasound probe may be driven by a Pulsar/Receiver unit and focused onto the etalon structure in water.
[0037] FIGS. 8A and 8B are graphical diagrams showing example pulse-echoes from an optical ultrasound transducer in accordance with one or more aspects of the present disclosure. FIG. 8A shows a pulse-echo of a 25 MHz transducer using an etalon structure as a reflecting target. FIG. 8B shows etalon detection of a 25 MHz pulse with an inset zoomed in on noise preceding the pulse. In FIG. 8A can be found the pulse-echo off of the etalon as detected by the probe, bandpass filtered from 2.5 to 50 MHz. Signals may be sampled at 250 MHz with an 8-bit digitizer (e.g., NI PXI-5114). FIG. 8B shows the same pulse as may be detected by the etalon, amplified by 30 dB and band-pass filtered from 2.5 to 50 MHz. The maximum pressure generated by the probe may be measured to be 1.13 MPa using a calibrated hydrophone (e.g., Onda HGL-0085). Based on a maximum amplitude (31.2 mV), and the RMS value of the noise prior to the main pulse (0.26 mV), the Noise-equivalent Pressure (NEP) would then be 8.9 kPa or 1.3 Pa/√{square root over (Hz)}. Dividing the square of the maximum pressure by the square of the NEP results in a signal-to-noise ratio of 127.
[0038] A 5 ns 4 mJ 355 nm pulse from a ND:YAG laser may be directed towards the device at an incident angle of roughly 60 degrees. The area of illumination may be elliptical with a major diameter of 3.3 mm and minor diameter of 2.3 mm, yielding a fluence of 67 mJ/cm2. The bandwidth and amplitude of the acoustic signal generated by the polyimide film can then be measured using the hydrophone from a distance of 1.6 mm.
[0039] FIGS. 9A and 9B are graphical diagrams showing a recorded waveform and associated frequency response of an optical ultrasound transducer, in accordance with one or more aspects of the present disclosure. In the examples of FIGS. 9A , 9 B, the waveform may be averaged 16 times. In particular, FIG. 9A shows the signal generated by polyimide film with 355 nm pulse as measured using a calibrated hydrophone, averaged 16 times. FIG. 9 b shows uncorrected and corrected power spectrums of the waveform. The power spectrum of the waveform may be corrected by dividing it by the square of the sensitivity spectrum (original units of V/Pa) provided with the calibrated hydrophone (up to 60 MHz). Based on the corrected spectrum, the center frequency and peak response occurred at 27 MHz with a −3 dB bandwidth of 29 MHz. The mean sensitivity across the −3 dB bandwidth (56 nV/Pa) may be used to convert the vertical scale of the waveform from volts to pascal, thereby indicating a maximum generated pressure of 4.3 MPa.
[0040] FIGS. 10A-10C are graphical diagrams showing etalon detection of a polyimide pulse-echo in an optical ultrasound transducer, in accordance with one or more aspects of the present disclosure. The example device of FIG. 6 may be configured to operate in transmit/receive mode. In order to do so, the hydrophone may first be removed, and the signal detected by the etalon with no target may then be recorded. In particular, FIG. 10A shows a heat signal generated by a UV pulse with no target present. FIG. 10A shows the signal created by the heating of the etalon with the UV pulse. Its time course is on the order of 100 μs. Thus it is separable from the signals of interest by use of filtering. A glass slide may be placed 2.7 mm away from the device, and the pulse emitted by the polyimide film may be reflected off of the slide and detected by the etalon. FIG. 10B shows pulse-echo off of a glass-slide, high-pass filtered at 4 MHz. FIG. 10C illustrates the power spectrum of the pulse-echo. A high-pass filter with a cutoff frequency of 4 MHz may be used to filter out the heat signal. FIG. 10C shows, as one example, the upper cutoff frequency of the transmit/receive response falling below −6 dB at 47 MHz.
[0041] FIG. 11A and 11B are a block diagram and associated graphical diagram illustrating an example 1-D synthetic aperture scanning system, in accordance with one or more aspects of the present disclosure. FIG. 11A illustrates an experimental setup for the 1-D synthetic aperture scanning The imaging capabilities of the all-optical transducer may be tested by placing a wire of 250 μm in diameter approximately 2 mm away from the device. The optical assembly can then be translated perpendicular to the wire's axis in order to create a 1-D synthetic imaging aperture. The IR beam may be scanned across a 1.4 mm line using a step size of 10 μm resulting in a 142 sensor array. Signals may again be sampled at 250 MHz, and 16 waveforms acquired and averaged at each location. After band-pass filtering the signals from 20 to 50 MHz, image reconstruction may be performed using a basic beam-forming algorithm. FIG. 11B shows the result, which indicates an upper limit on the −6 dB resolution, approximately 40 μm in the axial dimension and 100 μm in the lateral dimension. In general, even better image quality and higher resolution may be achieved by upgrading to a 2-D aperture.
[0042] As such, the constructed model demonstrated the functionality of an all-optical high-frequency ultrasound transducer. An optically-absorbing polyimide thin-film generated a 4.3 MPa signal, and the etalon sensor exhibited an NEP of 1.3 Pa/√{square root over (Hz)}. The −6 dB transmit/receive response reached 47 MHz, and lateral and axial resolutions of 100 μm and 40 μm, respectively, were achieved using a 1-D synthetic aperture.
[0043] FIG. 12 is a block diagram illustrating an example configuration of an optical ultrasound transducer, in accordance with one or more aspects of the present disclosure. The optical ultrasound transducer, as described, may be combined with other optical components to achieve line of sight in different directions. As seen in the example of FIG. 12 , a prism may be placed between the SMF (e.g., SMF 1 of FIGS. 1-5 ) and the etalon structure, in order to achieve a right-angle light of sight. In other examples, the fiber itself (e.g., SMF 1 of FIGS. 1-5 ) may be polished in differing degrees (e.g., a 45 degree angle), in order to achieve various viewing angles. In this way, the optical ultrasound transducer may be utilized in implementations involving side-viewing imaging devices.
[0044] The device described herein may be incorporated into a forward-viewing IVUS imager for evaluating Chronic Total Occlusion (CTO). The forward-viewing IVUS may operate at frequencies beyond 50 MHz, for example, and provide a sufficiently high resolution (30-200 μm) while retaining an adequate penetration depth (2-10 mm). While a few groups have successfully developed CMUT-based forward-viewing IVUS, a frequency response above 35 MHz has yet to be demonstrated. The results described herein indicate that bandwidth of the device could easily be increased beyond 50 MHz by reducing the 10 μm photoresist layer to 5 μm, for example. In addition, the techniques described herein may allow simple and low-cost fabrication of a transmit/receive etalon relative to CMUT arrays. Moreover, the device described herein need not require electrical connections because of its use of light delivery. The coupling of the device to an optical fiber bundle provides a flexible, compact, and robust design, which may have particular applicability for IVUS.
[0045] Various embodiments of the invention have been described. These and other embodiments are within the scope of the following claims. | In general, this disclosure describes various optical ultrasound transducers and methods of producing such. As one example, an optical ultrasound transducer comprises an optical fiber and a polymer layer formed on the optical fiber to receive light from the optical fiber. The polymer layer may absorb light of a first wavelength and be substantially transparent to light of a second wavelength. In response to the light of the first wavelength, the polymer layer may generate an acoustic tone. The optical ultrasound transducer may further include an optical detector formed on the polymer layer, the optical detector comprising an etalon structure having a first mirror layer and a second mirror layer separated by a compressible layer, wherein the compressible layer resonates in response to the light of the second wavelength passing through the polymer layer and is compressible in response to acoustic pressure from echoes of the acoustic tone. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a sighting device for an archery bow. More particularly, the invention is directed to a bow sight with a dual sighting arrangement that has both a front and rear sight. The front and rear sights are mounted and affixed to a frame coupled to a bow or bow riser, and are operable to improve bow shooting whether in an elevated stand or on the ground.
Bow sights are utilized to improve the trajectory of arrows fired at a target by an archer. More specifically, it is desired, as in target shooting, to provide as tight a cluster or pattern of arrows in a target as possible. This compact cluster of arrows is indicative of an accurately sighted bow, as well as an able archer. Various devices and bow sights are utilized to improve the accuracy of the archer, including the following: front sights; rear sights; string-mounted devices, bow rider-mounted devices; notched sights; elevation pins, bow riser angular or rotational indicators; and, combinations of the above, as examples. These devices have a singular purpose, to improve the accuracy of the archer. Many of these devices are sold for elevated stand shooting in which the archer is in a tree and is hunting deer on the ground below the tree. One such bow sight has a front pendulum sight in front of the bow, which pivots as the bow is tilted.
Range finders for a bow frequently use at least one adjustably mounted elevation pin in a bracket to provide the archer with reference means for targeting position or distance. U.S. Pat. No. 4,580,349-Webb et al., illustrates a range finder utilized in cooperation with a string-mounted sight for sighting the bow on a target. Target alignment is accomplished through the string-mounted sight aligned with a projecting pendulum member, and one of several preset range pins, which range pin is selected is based upon the position of the pendulum member relative to vernier marks indicative of the range of the sighted target.
Screw thread adjustments may provide bow sight adjustment about the vertical and lateral axes of the bow, as shown in U.S. Pat. No. 4,142,297-Altier, as well as for basic technique adjustments about the vertical, lateral and longitudinal axes. This sighting arrangement utilizes the same structure for both rough and fine adjustments. However, these adjustments are fixed position adjustments, which require manual adjustment of the total apparatus to accommodate varying conditions. The apparatus includes a windage and/or elevation adjustment.
A dual sight apparatus, that is front and rear sight, is disclosed in U.S. Pat. No. 4,685,217 to Shader. The sight utilizes a vertical sight, which appears as a taut string or wire in the vertical direction, as well as the wind or elevation pins located at the front of the bow. This arrangement provides an added fixed reference point for the archer.
A bow sight pivotable about a fixed point attached to the bow is illustrated in U.S. Pat. No. 3,013,336 to Pennington. This device includes a wind adjustment means extending perpendicular to the pivoting sight, which is horizontally maintained by a counterweight. A scale provides an indication of the degree of inclination from the horizontal. However, the windage device is fixed to the general line-of-sight arm and therefore moves with this arm as it pivots during use of the archery bow.
Other bow sights provide pivotable members to pivot the sight for adjustment to changes in the vertical orientation of the bow, or to adjust for changes of elevation of the line of sight. U.S. Pat. No. 4,616,422 and U.S. Pat. No. 4,120,096 illustrate various alternative bow sight apparatus for aiming and firing a bow from an elevated position.
It is desirable to utilize a fixed bow sight to provide a continuous frame of reference and a variable sight to adjust to changes in the angle of inclination of the bow. Further, it is desirable to be apprised of bow rotation out of a plane normal to the ground as the rotation will displace front and rear sight alignment, thereby effectively altering the sight adjustment and varying the accuracy of the archer utilizing the sighting device.
The present invention provides a front sight with multiple fixed reference points, which can be preset for given distances, and a rear sight that is pivotal about a horizontal axis to maintain the rear sight in a generally horizontal position even though the bow is tilted from a true vertical position at the time of shooting. The pivotal rear sight is also indicative of bow rotation out of a plane vertical to the ground, as its pivoting is inhibited by such rotation.
SUMMARY OF THE INVENTION
The present invention provides a bow sight encompassing both a pivoting rear sight arrangement that compensates for variations in the elevation for line-of-sight firing and adjustable wind or elevation pins. Preferably, the pins and rear sight are affixed to a common support arm.
The pivotable rear sight is mounted on a pendulum, which pivots to remain vertical as the bow is tilted from a true vertical to assure the rear sight remains constant with eye elevation or the horizon. The front sight may be selected from a plurality of elevation pins which have been previously adjusted and set for a fixed distance, and is alignable with the rear sight for focusing on a target. The pivotable rear sight is particularly adaptable to changes in the angle of the bow riser elevation relative to the ground. That is, if the archer is shooting from an elevated position, the rear sight will pivot to retain its orientation to the horizon and then the archer may focus on a target with any of the fixed elevation or windage pins.
The bow sight assembly has a mounting bracket for the support or sight bar with three adjustment grooves or slots to accommodate the sight bar at a comfortable position for the archer. The front sight elevation pins include a bead or ball projecting from their end as a focal point, and are fitted in the slotted wind pin bracket at the forward end of the sight bar. The rear sight is positioned at the rear end of the sight bar, and projects therefrom on a mounting rod or axle generally parallel to the ground for pivotable rotation thereon. This rear sight is pivotable on the axle in response to gravitational forces as the center of mass of the rear sight is below the axis of the mounting axle.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Figures of the drawing, like reference numerals identify like components, and in the drawing:
FIG. 1 is an oblique view of a single-piece sight bar and wind pin bracket;
FIG. 2 is an oblique view of a sight bar and wind pin bracket as assembled separate elements;
FIG. 3 is an oblique view of an alternative embodiment of a slotted wind pin bracket;
FIG. 4 is an oblique view of a slotted mounting bracket;
FIG. 5 is an enlarged, oblique view of a pivotable rear sight;
FIG. 6 is an enlarged, oblique view of an alternative embodiment of a pivotable rear sight;
FIG. 7 is a sectional view of the rear sight in FIG. 6 taken along the lines 7--7;
FIG. 8 is an enlarged, oblique view of a windage pin and pin collar;
FIG. 9 is an oblique view of the dual sight assembly mounted on a bow riser;
FIG. 10 is a line-of-sight projection from an archer through the elevation pins and rear sight in the horizontal plane;
FIG. 11 illustrates line-of-sight projections from a position lower than and higher than a horizontal line of sight as in FIG. 13; and
FIG. 12 illustrates the line of travel of an arrow at various sight lines and various distances.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a bow sight assembly for an archery bow. Present bow sights include means to accommodate shooting from an elevated perch or a ground location. These bow sights are utilized to improve the accuracy of the archer and to provide a tighter arrow cluster at the target when utilized for target shooting. Heretofore, conventional bow-sight apparatus included eyepieces or peep-sights located on the bow string; fixed-mounted line-of sight apparatus attached to the bow arc; rotatable sight apparatus to provide a steady bow sight in the case of bow variance from a vertical position, that is, vertical to the ground; and, various wind pin or elevation pin arrangements projecting from the sight apparatus.
To improve the accuracy of an arrow fired from an archery bow, a bow sight should be usable to shoot arrows from a horizontal position or from an elevated position as in a tree, and at varying distances. The bow sight arrangement, including dual-sight structures, should be operable in low-light conditions and provide a clear view through the sight apparatus to the target. In addition, the sighting apparatus will indicate to the archer any twisting of the bow hand, which would misalign the bow and consequently the target.
The present invention provides a bow sight to improve the accuracy of an archer whether on the ground or in an elevated stand and at varying distances from a target. It is adaptable to firing an arrow at or from an elevated perch, as well as being usable in low-light conditions and as an indicator of any twist in the bow alignment. The present bow sight is mountable on an archery bow and adaptable to be initially sighted or zeroed at varying distances, and to accommodate variations in shooting elevation; that is, the archer may be in a elevated perch or firing at an elevated target. The sight apparatus has a self-adjusting or aligning rear sight cooperating with front-sight, fixed elevation or windage pins, which front and rear sights are preferably affixed to a common arm. As will be explained, the preferred rear sight includes a pendulum that swings to remain at a true vertical position as the bow is tilted through various angles, and the preferred sight is a horizontal notch on top of the pendulum, which remains in a horizontal plane as the bow is tilted through various angles. Therefore, the relative relationship between the self-adjusting rear sight and the previously-set or fixed front sights, that is the windage pins, is essentially constant. The windage pins and rear sight are readily utilized from any position or in any light condition without further adjustment of the sighting device. The apparatus includes a mounting brace or yoke securable on a bow and operable to retain the sight bar with the front and rear sights. The sight bar is movable to any of the brace slots as a vertical adjustment and is longitudinally adjustable in the slot to thus provide the most comfortable and accurate position for the archer. During the initial adjustment or focusing of the sight bar and front and rear sights, the archer may fix the windage pins for fixed distances, which are vertically adjustable in slots to fixed positions to fix a target range or distance. Thereafter, the relative relationship between the rear sight and front sight will be maintained as the rear sight pivots on its axis to maintain its alignment for sighting by the archer and for alignment with any one of the elevation or windage pins. The structure and operation of the sighting mechanism will be further discussed below.
Sight bar 10 and wind pin bracket 12 are noted in FIG. 1 as a single member. Bar 10 has wall 14, as well as a plurality of locating or mounting through-passages 16 with tapered or chamfered ends 18 at inner side 20 and outer side 22 of bar 10. Through-bore 24 for rear sight mounting is provided at the back or rear end 26 of sight bar 10. Wind pin bracket 12 is mounted and secured at front end 27 of sight bar 10, and includes parallel slots 28, 30 and 32 for adjustable sight pins 34, 36 and 38, respectively, as noted in FIG. 9. It is appreciated that wind pin bracket 12 may be a separate element and joined to sight bar 10 at bar end 11 by securing means 13, such as socket screws, as shown in FIG. 2. In an alternative embodiment, wind bracket 12 is illustrated in FIG. 3 with curved outer surfaces and arced slots 28a, 30a and 32a for receiving pins 34, 36 and 38, respectively. The forms of the wind pin bracket 12 are merely exemplary and not a limitation.
A mounting brace or yoke 40 may be mounted on the arc of the bow 92, as illustrated in FIG. 9 by means known in the art. In FIG. 4, mounting brace or yoke 40 has an outer face 42 and an inner face 44. Parallel ribs 46 extend from inner face 44 to provide slots 48, 50 and 52 therebetween. As illustrated in FIG. 4, a plurality of through-bores 54, 56, 58, 60, 62 and 64 extend, respectively, through slots 48, 50 and 52 in pairs, which bores are alignable with sight bar passages 16 to receive securing means, such as screws or rivets, to retain sight bar 10 in brace 40.
A preferred embodiment of the rear pivotable sight 66 is illustrated in FIGS. 5 and 9. In FIG. 5, rear sight 66 is shown, in an enlarged view, mounted on mounting axle 68 at first end 65, which axle 68 extends through passage 24 in sight bar 10, and is secured at second end 69 in sight bar 10 by front and rear mounting axle lock nuts 70 and 72. In FIG. 5, rear sight 66 has a cross bore 74, shown in dashed outline, to receive axle 68 at first end 65, which cross bore 74 is positioned in the body of rear sight 66 at a point vertically above the center of gravity, c.g., of rear sight 66. Thus, the lower portion 76 of rear sight 66 will pivot on axle 68 in response to gravity to maintain a lower orientation on axle 68 than the sight slot 78 of rear sight 66.
In an alternative embodiment, rear sight 67 is illustrated in FIGS. 6 and 7 in a generally spherical shape, and has a cross bore 77 with a diametrical axis 75 extending therethrough. A circumferential groove 80 is provided in outer surface 82 of sphere 67 and is generally perpendicular to diameter 75. When rear sight 67 is mounted on axle 68, the bottom of groove 80 will maintain its orientation relative to pins 34, 36 and 38. The rear sights 66 or 67 are generally mounted in proximity to the bow string (not shown) and the wind pins are generally forward of the bow riser 92.
An exemplary sight or windage pin 85 is illustrated in FIG. 8, which sight pin 85 is mountable in pin collar 86 through through-bore 88. Pin collar 86 and sight pin 85 are thereafter mounted and secured in wind pin bracket 12 at a fixed position by first and second pin collar lock nuts 90 and 91 at the bracket front face and rear face, respectively. The wind pins 34, 36 and 38 can thus be seen to be adjustable in slots 28, 30 and 32, respectively by merely loosening their respective collars and lock nuts. Sight pin 85 includes a sight bead 87 for alignment with slot 78 of rear sight 66 for more accurately sighting a target and aiming an arrow.
The mounting brace or yoke 40 is secured to an archery bow or riser 92, as illustrated in FIG. 9, by means known in the art, such as screws, bolts, rivets or other means. Thereafter, mounting or sight bar 10 is mounted and secured in brace 40 in one of slots 48, 50 or 52 by securing means, such as, bolts or rivets, extending through passages 16 and one of the pairs of passages 54 to 64 in the slots 48, 50 or 52. Thus, the sight bar is adjustable and secured in a slot at a position comfortable to the user for sighting along the sight bar through rear sight 24 and wind pins 34, 36, or 38, as shown in FIGS. 10-12.
Windage pins 85 are generally utilized to set the range or distance of the bow and these pins are accordingly sighted and adjusted prior to use. Illustrative of this arrangement is the sighting configuration noted in FIG. 12. The horizontal plane is generally along the line of sight and a measured distance is provided between the archer and the measured distance-targets noted by the letter X at the terminus of arcs a, b and c. As noted in FIG. 12, the arrows are not propelled on a straight line, but, generally follow a parabolic arc through the air. Thus, the archer predetermines the distance ranges for accuracy to a target, and adjusts the wind pins for sighting with the rear sight based upon the horizontal distance between the archer and the target point. Therefore, the wind pins 34, 36 and 38 are each adjusted to accommodate various target distances, as shown in FIG. 12. The wind pins are secured in wind pin bracket 12 by pin collars and lock nuts 86 and 90.
As illustrated in FIGS. 10 and 11, the archer may sight through slot 78 in rear sight 66 along any of the sight pins 34, 36 or 38 at their respective beads 87. As the angle of the bow changes relative to the horizontal plane noted in FIGS. 10 and 11, the position of rear sight 78 remains relatively constant. That is, the rear sight means includes a pendulum means that pivots on a horizontal axis to maintain a true vertical position irrespective of the degree of tilt of the bow to a true vertical position. The sight notch is horizontally disposed on the top of the pendulum, and remains horizontal as the bow is tilted. Thus, the rear sight 66, because it is a pendulum rotatable on a horizontal axis, is perpendicular to the horizontal line of sight. The center of gravity of this rear sight 66 is below its cross bore 74, through which axle 68 extends, thus allowing the rear sight 66 to pivot and maintain its perpendicular orientation relative to the horizontal plane. Therefore, as the angle of the bow changes in a plane perpendicular to the ground, the rear sight, which is preferably a notch cut in the top edge of the pendulum, remains horizontal as the bow is tilted relative to the pendulum, with the result that the archer maintains a consistent line of sight through the sighting assembly. As rear sight 66 is positioned away from the immediate vicinity of the archer's eye, it affords him a better opportunity to sight along slot 78, which separation was not previously available with the sights mounted on bow strings. Further, rotation of rear sight 66 or the lack of rotation about the axle 68 affords the archer an indication that the bow may not be perpendicular to the plane of the ground or is otherwise inclined or twisted relative to the archer's hand, which can negatively affect the alignment of the bow and consequently the accuracy of the arrow. The particular shape of the pendulum or pivotal rear sight means may be changed from that illustrated and other sights beside a notch may be mounted on the pendulum and still fall within the purview of the invention.
In the alternative embodiment in FIGS. 6 and 7, rear sight 67 is operable to consistently provide a rear sight notch along the edge of groove 80. Sight 67 can thus be aligned with any of windage pins 34, 36, or 38 as the angle of elevation changes or varies.
While only specific embodiments of the invention have been described and shown, it is apparent that various alterations and modifications can be made therein. It is, therefore, the intention in the appended claims to cover all such alterations and alterations as may fall within the scope and spirit of the invention. | An archery bow sight apparatus having a sight bar with at least one front sight that is adjustable to a fixed position relative to the sight bar, and a rear sight that is independently pivotal to maintain a vertical alignment with the ground, which combination of fixed and pivotal sights provide an archer with an improved sight means for greater accuracy in clustering his arrows in a target. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation application of U.S. application Ser. No. 12/292,605 filed on Nov. 21, 2008, which is a Continuation application of U.S. application Ser. No. 11/580,010 filed on Oct. 13, 2006. Priority is claimed based on U.S. application Ser. No. 12/292,605 filed on Nov. 21, 2008, which claims the priority of U.S. application Ser. No. 11/580,010 filed on Oct. 13, 2006, which claims priority to Japanese application 2005-312619 filed on Oct. 27, 2005, all of which is hereby incorporated by reference into this application.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to liquid crystal display devices and, more specifically, to a technology working effectively when a liquid crystal display panel is fixed to a backlight unit including a light guide plate, an optical sheet group, and others.
[0003] A color TFT (Thin Film Transistor) module including a small-sized liquid crystal display panel with subpixels of about 240×320×3 is widely used as a display section of portable equipment, e.g., mobile phone.
[0004] Such a liquid crystal display module generally includes a liquid crystal display panel, and a backlight unit that exposes the liquid crystal display panel to light. When the liquid crystal display module is used as a display section as portable equipment such as mobile phone, the backlight unit is configured by a resin-molded frame (hereinafter, referred to as mold), an optical sheet group, a light guide plate, a reflective sheet, and a light source. The optical sheet group and the light guide plate are disposed inside of the mold, and the reflective sheet is disposed below the light guide plate. The light source is disposed on the side surface of the light guide plate, and is exemplified by a white light-emitting diode.
[0005] FIGS. 8A to 8B are both a diagram for illustrating a liquid crystal display module of a previous type for use for mobile phones. Specifically, FIG. 8A is a plan view (viewed from the side of a liquid crystal display panel, from the front surface side, or from the side of a viewer), and FIG. 8B is a side view.
[0006] The liquid crystal display panel is configured by a pair of glass substrates ( 5 , 6 ), an upper polarizer 7 , and a lower polarizer (not shown). The glass substrates are facing each other with a liquid crystal layer sandwiched therebetween, and the upper polarizer is affixed to these glass substrates. The glass substrate 6 carries thereon a semiconductor chip 12 . Such a liquid crystal display panel is disposed in a mold 1 .
[0007] With the liquid crystal display module of FIGS. 8A and 8B , for implementation of size and profile reduction, a flexible printed circuit (hereinafter, referred to as FPC) 11 is bent and directed to the rear surface side of the backlight unit, and then fixed thereto. The FPC 11 is equipped with electronic components such as resistance and capacitor, and a white light-emitting diode serving as a light source. Note here that, in FIGS. 8A and 8B , a reference numeral 40 denotes a clearance between the liquid crystal display panel and the mold 1 .
SUMMARY OF THE INVENTION
[0008] In the liquid crystal display module of FIGS. 8A and 8B , the liquid crystal display panel is fixed to the frame-shaped resin mold 1 by a double-faced tape 10 . FIGS. 9A and 9B each show the displacement position of the double-faced tape 10 .
[0009] Using the double-faced tape 10 for fixing use requires, however, some level of area good for effective bonding. Also required is flatness for the bonding surface of the frame-shaped resin mold 1 , or there is a problem of poor repairability (recyclability).
[0010] In the configuration that the FPC 11 connected to a terminal portion of the liquid crystal display panel is bent and directed to the rear surface of the backlight unit, a double-faced tape 31 is used to press down the FPC 11 not to arise from the surface or bulge due to the bending repulsion (hereinafter, referred to as spring back force).
[0011] For the FPC 11 not to arise from the surface or bulge, there needs to put some thought into displacement position of the double-faced tape 31 , and increases the area for taping. When the fixing force is not yet enough, a metal plate or others have to be used to cover over the FPC 11 . This is the cause of preventing the liquid crystal display module from being reduced in size and profile.
[0012] The invention is proposed to solve such problems observed in the previous technology, and advantages of the invention are to provide the technology of implementing the size and profile reduction with ease for a liquid crystal display device.
[0013] These and other advantages and new features of the invention will become apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
[0014] The typical main disclosure of the invention is summarized as below.
[0015] 1. A liquid crystal display device that includes: a liquid crystal display panel; a backlight unit disposed on the rear surface side of the liquid crystal display panel; and a flexible printed circuit whose end is connected to a terminal portion of the liquid crystal display panel. In the device, the backlight unit includes a frame-shaped mold, the liquid crystal display device includes at least a fixing member for use for fixing the liquid crystal display panel to the frame-shaped mold in an area not including a display area of the liquid crystal display panel, and the fixing member is shaped like a ring, and inside of the ring of the fixing member, the liquid crystal display panel and the frame-shaped mold are disposed.
[0016] 2. According to 1, the flexible printed circuit is bent outside of the frame of the frame-shaped mold, and is partially disposed on the rear surface side of the frame-shaped mold, the flexible printed circuit is disposed in the ring of the fixing member, and the fixing member fixes, to the rear surface side of the frame-shaped mold, a bent portion of the flexible printed circuit disposed on the rear surface side of the frame-shaped mold.
[0017] 3. According to 1 or 2, the fixing member is at least provided to two of the area not including the display area of the liquid crystal display panel.
[0018] 4. According to any one of 1 to 3, the frame-shaped mold is formed with a notch on the side wall on one longer side, the fixing member is disposed across the notch, and with a clamping force of the fixing member, the notch is deformed, and the liquid crystal display panel is positioned on another side wall on the other longer side of the frame-shaped mold.
[0019] 5. According to any one of 1 to 3, the frame-shaped mold is formed with a notch on the side wall on one shorter side, the fixing member is disposed across the notch, and with a clamping force of the fixing member, the notch is deformed, and the liquid crystal display panel is positioned on another side wall on the other shorter side of the frame-shaped mold.
[0020] 6. According to any one of 1 to 3, the frame-shaped mold is formed with a notch on the side wall of one longer side, and on the side wall of one shorter side, the fixing member includes a longer-side fixing member and a shorter-side fixing member, the longer-side fixing member is disposed across the notch formed on the side wall of the one longer side of the frame-shaped mold, the shorter-side fixing member is disposed across the notch formed on the side wall of the one shorter side of the frame-shaped mold, and with a clamping force of the longer- and shorter-side fixing members, the notches formed on the side walls of the frame-shaped mold are deformed, and the liquid crystal display panel is positioned at a corner portion of the frame-shaped mold.
[0021] 7. According to 6, the longer-side fixing member is provided at least two portions in the area not including the display area of the liquid crystal display panel, including an upper-side area and a lower-side area than the display area.
[0022] 8. According to any one of 1 to 3, the liquid crystal display panel is provided with a conductive layer on the surface on a viewer side, the fixing member is conductive, and the fixing member is made to come in contact with the conductive layer of the liquid crystal display panel.
[0023] 9. According to 8, the fixing member is made to come in contact with a predetermined terminal of the flexible printed circuit.
[0024] 10. According to any one of 1 to 3, the liquid crystal display panel is provided with a semiconductor chip, the fixing member is light tight, and the fixing member is disposed to cover the semiconductor chip.
[0025] 11. According to any one of 1 to 10, the fixing member is a ring-shaped elastic body.
[0026] 12. According to any one of 1 to 10, the fixing member is a band-shaped clamping member.
[0027] 13. According to any one of 1 to 12, the frame-shaped mold is formed with a concave portion for use for positioning the fixing member.
[0028] 14. According to 13, the concave portion for use for positioning the fixing member is formed on the side surface of the frame-shaped mold.
[0029] 15. According to 13, the concave portion for use for positioning the fixing member is formed on the rear surface of the frame-shaped mold.
[0030] Note here that the configurations of 1 to 15 are all just examples, and surely not restrictive.
[0031] The effects derived by any typical disclosure of the invention are summarized as below.
[0032] The liquid crystal display device of the invention easily implements size and profile reduction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIGS. 1A and 1B are both a diagram showing a liquid crystal display module in a first embodiment of the invention;
[0034] FIGS. 2A and 2B are both a diagram for illustrating a liquid crystal display module for use for a mobile phone as an application of the invention;
[0035] FIGS. 3A and 3B are both a diagram for illustrating an exemplary shape of a mold of FIGS. 2A and 2B ;
[0036] FIGS. 4A and 4B are both a diagram showing a modified example of the liquid crystal display module in the first embodiment of the invention;
[0037] FIGS. 5A and 5B are both a diagram for illustrating a liquid crystal display module in a second embodiment of the invention;
[0038] FIGS. 5C and 5D are both a diagram for illustrating a modified example in the second embodiment of the invention;
[0039] FIGS. 6A and 6B are both a diagram showing a liquid crystal display module in a third embodiment of the invention;
[0040] FIGS. 7A and 7B are both a diagram showing a liquid crystal display module in a fourth embodiment of the invention;
[0041] FIGS. 8A and 8B are both a diagram for illustrating a previous liquid crystal display module for use for a mobile phone;
[0042] FIGS. 9A and 9B are both a diagram showing, in the liquid crystal display module of FIGS. 8A and 8B , the displacement position of a double-faced tape for use for fixing a liquid crystal display panel to a frame-shaped resin mold 1 ;
[0043] FIG. 10 is a diagram for illustrating an abutment assembly process of a previous liquid crystal display module; and
[0044] FIGS. 11A and 11B are both a diagram for illustrating a method of anti static electricity of the previous liquid crystal display module.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] In the below, embodiments of the invention are described in detail by referring to the accompanying drawings.
[0046] Note that, in all of the diagrams for use for illustrating the embodiments, any component having the same function and capability is under the same reference numeral, and not described twice.
[0047] A liquid crystal display module of embodiments of the invention is a color TFT module including a small-sized liquid crystal display panel with subpixels of about 240×320×3, and is used as a display section of portable equipment, e.g., mobile phone.
Exemplary Basic Configuration of Liquid Crystal Display Module as Application of Invention
[0048] FIGS. 2A and 2B are both a diagram for illustrating a liquid crystal display module for use for a mobile phone as an application of the invention. FIG. 2A is a cross sectional diagram showing the cross sectional configuration of a portion cut along a line A-A′ of FIG. 1A that will be described later, and FIG. 2B is a cross sectional diagram showing the cross sectional configuration of a portion cut along a line B-B′ of FIG. 1A that will be described later.
[0049] In the liquid crystal display module of FIGS. 2A and 2B , a backlight unit includes an optical sheet group 2 , a light guide plate 3 , a reflective sheet 4 , and a white light-emitting diode 15 . The optical sheet group 2 is configured by a downward diffusion sheet, two lens sheets, and an upward diffusion sheet. The reflective sheet 4 is disposed below the light guide plate 3 , and the white light-emitting diode 15 is disposed on the side surface of the light guide plate 3 . The backlight unit of the embodiments is configured by such components, i.e., the optical sheet group 2 , the light guide plate 3 , the reflective sheet 4 , and the white light-emitting diode 15 , which are disposed in the mold 1 with the layout shown in FIGS. 2A and 2B . Note here that the above configuration of the optical sheet group 2 is not the only possibility.
[0050] A liquid crystal display panel is configured as below. That is, glass substrates 5 and 6 are stacked together with a predetermined space therebetween. The glass substrate 6 is provided thereon with a pixel electrode, a thin film transistor, or others, and is referred also to as TFT substrate or active matrix substrate. The glass substrate 5 is formed thereon with a color filter or others, and is referred also to as opposing substrate. These substrates are then attached together using a frame-shaped sealing compound provided in the vicinity of edge portions between the substrates. The seal compound is partially formed with an aperture for injection of a liquid crystal material to inside of the seal compound between the substrates. After material injection as such, the aperture is closed, and then polarizers ( 7 , 8 ) are attached to the outer surfaces of the substrates, respectively.
[0051] As such, the liquid crystal display panel has the configuration in which the liquid crystal material is sandwiched between a pair of substrates. Note that the substrates serve well as long as they are being insulated, and the material therefor is not restrictive to glass, and plastic or others are also options. The color filter may be provided not to the opposing substrate side but to the TFT substrate side. If with monochrome display, the color filter is not in need. If with a field sequential liquid crystal display device, no color filter is provided, and a three-color light source may be used as an alternative to the white light-emitting diode.
[0052] If with a TN (Twisted Nematic) or VA (Vertically Aligned) liquid crystal display panel, an opposing electrode is provided on the opposing substrate side, and is provided on the TFT substrate side if with an IPS (In-Plane Switching) liquid crystal display panel.
[0053] In the invention, when there is no need to describe the internal configuration of the liquid crystal display panel, no detailed description will be given therefor. The invention is always applicable to liquid crystal display panels irrespective of configuration.
[0054] FIGS. 3A and 3B are both a diagram for illustrating an exemplary shape of the mold of FIGS. 2A and 2B . Specifically, FIG. 3A is a plan view (viewed from the side of a liquid crystal display panel, from the front surface side, or from the side of a viewer), and FIG. 3B is a bottom view.
[0055] The mold 1 of FIGS. 3A and 3B is configured with no bottom surface, and with an aperture portion at the center part, i.e., is a frame-shaped body of substantially square cross section (or tube-shaped body). With such a configuration, the reflective sheet 4 is affixed to the rear surface side of the frame-shaped mold 1 using a double-faced tape 9 .
[0056] The liquid crystal display panel is supported by and fixed to, at the edge portion of the lower glass substrate 6 , a height-different portion 50 b formed to the mold 1 .
[0057] Above the height-different portion 51 of the mold, the optical sheet group 2 is supported, and below the optical sheet group 2 , the light guide plate 3 is disposed.
[0058] Below the light guide plate 3 , the reflective sheet 4 is so disposed as to cover the aperture portion of the mold 1 .
[0059] The end portion of the lower polarizer 8 is disposed inside of another height-different portion 51 , i.e., when viewed from above, the end portion of the lower polarizer 8 is overlaid on the height-different portion 51 . That is, the lower polarizer 8 is so disposed as not to overlay the height-different portions 50 a and 50 b . Such a configuration enables to reduce any effect possibly caused by the thickness of the lower polarizer 8 , thereby favorably implementing thin profile.
[0060] As to the shorter sides of the mold, the side provided with the white light-emitting diode 15 is formed with the height-different portion 50 a similarly to the height-different portion 50 b . This height-different portion 50 a is formed wider than the height-different portion 50 b , and is formed with a back-side concave portion 16 carrying therein the white light-emitting diode 15 .
[0061] The light guide plate 3 is disposed more inward than the height-different portion 51 . By reducing the area of the light guide plate 3 as such, the luminance per unit area can be increased.
[0062] In FIGS. 2A and 2B , the height-different portions 50 a and 50 b are each provided with the double-faced tape 10 . For application of the invention, however, the double-faced tape 10 is not necessarily provided. If the double-faced tape 10 is provided for application of the invention, the area therefor can be reduced in size, or the double-faced tape 10 can be thinner for use because the adhesion level is not required so high.
[0063] When the FPC 11 is directed (bent) toward the rear surface side of the backlight unit for fixing, the electronic components provided on the FPC 11 can be partially housed inside of the mold 1 .
[0064] That is, as shown in FIG. 3B , the mold 1 is formed with concave portions ( 61 , 62 ) that open toward the lower side (rear surface side). These concave portions ( 61 , 62 ) can accommodate therein at least part of the electronic components provided on the FPC 11 .
First Embodiment
[0065] FIGS. 1A and 1B are both a diagram showing a liquid crystal display module in a first embodiment of the invention. Specifically, FIG. 1A is a plan view (viewed from the side of a liquid crystal display panel, from the front surface side, or from the side of a viewer), and FIG. 1B is a side view.
[0066] As shown in FIGS. 1A and 1B , the liquid crystal display module of this embodiment uses a fixing member 35 to fix both a liquid crystal display panel and a backlight unit at positions not including the display area of the liquid crystal display panel as if those being covered from outside. The fixing member 35 is a ring-shaped elastic body such as rubber band, or a band-shaped clamping member.
[0067] Also in this embodiment, the FPC 11 is bent and directed to the rear surface of the backlight unit for fixing to the rear surface side of the mold 1 . In FIGS. 1A and 1B , the bent portion of the FPC 11 is fixed to the rear surface side of the mold 1 using a double-faced tape ( 31 of FIG. 9B ). Alternatively, as indicated by A in FIG. 4B , the bent portion of the FPC 11 may be also fixed using the fixing member 35 .
[0068] As such, in this embodiment, the fixing member 35 is used as an alternative to the double-faced tape 10 to fix the liquid crystal display panel and the backlight unit as if those being covered from outside. This accordingly eliminates the previous need for area reservation for effective bonding using the double-faced tape 10 . The previous need with the double-faced tape 10 is also eliminated for flatness for the bonding surface of the resin mold 1 , and the repairability (recyclability) can be successfully increased.
[0069] Because of increasing demand for a thin-profile liquid crystal display module, for the liquid crystal display panel, the glass of 0.4 or 0.3 mm thickness is taking place of the currently-popular glass of 0.5 mm thickness. Because the glass strength is reduced with the square of the glass thickness, repairing the liquid crystal display panel (peeling off the panel from the backlight unit) will be difficult if the double-faced tape 10 is used to attach the panel to the backlight unit. With this being the case, however, the present embodiment is capable of increasing the repairability (recyclability).
[0070] In the configuration that the FPC 11 connected to a terminal portion of the liquid crystal display panel is bent and directed to the rear surface of the backlight unit, the FPC 11 often arises from the surface or bulge due to the bending repulsion (hereinafter, referred to as spring back force).
[0071] The double-faced tape 31 is previously used to press down the FPC 11 not to arise from the surface or bulge. As an alternative to the double-faced tape 31 , the fixing member 35 of this embodiment may be used to press down the FPC 11 from outside not to arise from the surface or bulge. If this is the case, the double-faced tape 31 may not be used, or used together with the fixing member 35 .
[0072] The double-faced tape 31 is not suitable for use when the spring back force is considerably large, or to any part always exposed to the remaining stress of the constant load. On the other hand, the fixing member 35 of the embodiment is applicable to such a part always exposed to the remaining stress of the constant load.
[0073] What is more, no metal plate is in need for pressing down the FPC 11 not to arise from the surface or the bulge so that the whole of the liquid crystal display module can be reduced in weight.
Second Embodiment
[0074] For the aim of reducing the variation in the position of a display screen of the liquid crystal display panel, i.e., variation observed when the liquid crystal display panel is equipped inside of the mold, as shown in FIG. 10 , the glass substrates ( 5 , 6 ) of the liquid crystal display panel are made to abut corners of the frame-shaped mold 1 for assembly.
[0075] The issue here is that such abutment assembly is performed manually, and thus has the problems of the poor assembly precision, the lower side walls of the resin mold 1 around the glass substrates ( 5 , 6 ), and a difficulty in assembly of corner abutment. The lower side walls of the resin mold 1 are resulted from the fact that the recent liquid crystal display module is low in profile, and the difficulty in assembly of corner abutment is resulted from the fact that the recent glass substrates ( 5 , 6 ) are getting thinner. There is also a concern about safety during the abutment assembly associated with the thinner glass substrates ( 5 , 6 ). That is, during the abutment assembly, fingers easily touch the corners of the glass substrates ( 5 , 6 ), especially the lower right corner portion of the glass substrates for upper-left abutment assembly indicated by A of FIG. 10 .
[0076] FIGS. 5A and 5B are both a diagram for illustrating a liquid crystal display module of a second embodiment of the invention. Specifically, FIG. 5A is a plan view (viewed from the side of a liquid crystal display panel, from the front surface side, or from the side of a viewer), and FIG. 5B is a side view.
[0077] Also in this embodiment, the fixing member 35 is used to fix both a liquid crystal display panel and a backlight unit as if those being covered from outside.
[0078] As shown in FIG. 5C , in the second embodiment, a side wall 1 a of the frame-shaped mold 1 is formed with notches 36 . As shown in FIG. 5A , one of the longer sides of the mold 1 is formed with two of the notches 36 , and one of the shorter sides of the frame-shaped mold 1 is formed with one of the notches 36 .
[0079] The fixing member 35 is disposed across these notches 36 . Accordingly, in this embodiment, the clamping force of the fixing member 35 deforms the notches 36 , and the liquid crystal display panel is moved and comes in contact with the corner portion of the frame-shaped mold 1 (in FIG. 5A , the upper left corner portion indicated by an arrow F). As such, the abutment assembly described above is automatically performed.
[0080] When the notch 36 is formed only to one of the longer sides of the mold 1 , the liquid crystal display panel is positioned on the other longer side of the mold 1 . Similarly, when the notch 36 is formed only to one of the shorter sides of the mold 1 , the liquid crystal display panel is positioned on the other shorter side of the mold 1 .
[0081] In the present embodiment, through fixing using the fixing member 35 , the liquid crystal display panel can be aligned at the corner portion so that the positioning accuracy can be accordingly increased. What is more, using the fixing member 35 eliminates the need for abutment and allows positioning even with the lower side walls of the frame-shaped mold 1 , and can be adapted for a case with the thinner liquid crystal display panel.
[0082] Note that, in this embodiment, as shown in FIG. 5A , the side wall 1 a of the frame-shaped mold 1 is formed with a concave portion 37 for use for positioning the fixing member 35 . As shown in FIG. 5D , this concave portion 37 is formed on the side surface of the side wall of the frame-shaped mold 1 , or on the back surface (rear surface).
Third Embodiment
[0083] The upper polarizer 7 is attached with a protection film, and when the product is actually put into use, the protection film layer has to be peeled off. The problem here is that peeling off this protection film generates static electricity. The glass substrate 5 is charged by this static electricity, thereby resulting in unusual display of the liquid crystal display panel.
[0084] For the aim of removing the static electricity, as shown in FIGS. 11A , to 11 B, the glass substrate 5 configuring the liquid crystal display panel is formed thereon with a transparent conductive layer, e.g., ITO (Indium-in-Oxide). Thus formed transparent conductive layer is then electrically connected to a predetermined terminal provided on the glass substrate 6 using a conductive resin material 39 .
[0085] Such a liquid crystal display module of FIGS. 11A and 11B requires, however, an additional process and any device and material for the use. The coating area is also required, whereby the liquid crystal display panel is increased in size. There is also another problem of needing a larger clearance for the coating area in the device on a client side, considering the thickness or running of the coating material.
[0086] FIGS. 6A and 6B are both a diagram for illustrating a liquid crystal display module of a third embodiment of the invention. Specifically, FIG. 6A is a plan view (viewed from the side of a liquid crystal display panel, from the front surface side, or from the side of a viewer), and FIG. 6B is a side view.
[0087] Also in this embodiment, the fixing member 35 is used to fix both a liquid crystal display panel and a backlight unit as if those being covered from outside.
[0088] In this embodiment, the fixing member 35 is provided with conductivity. This fixing member 35 is made to come in contact with a transparent conductive layer (not shown) formed on the glass substrate 5 configuring the liquid crystal display panel. As indicated by A in FIG. 6A , the fixing member 35 is also made to come in contact with a predetermined terminal (not shown) of the FPC 11 .
[0089] Such a configuration enables to discharge the static electricity built up when the protection film attached on the polarizer 7 is peeled off. Such electricity discharge is made via the conductive fixing member 35 and the predetermined terminal of the FPC 11 so that the liquid crystal display panel can be prevented from displaying something unusual.
[0090] What is more, in this embodiment, there is no need to any specific addition process and device, and the size of the previous liquid crystal display panel is applicable. As to the conductive area, there is no more need for a larger clearance in the device on a client side.
[0091] In this embodiment, as an IPS liquid crystal display panel, any panel of a configuration including no opposing electrode on the surface of the glass substrate 5 on the liquid crystal side is especially effective. However, such a configuration is surely not restrictive, and the configuration of including an opposing electrode on the surface of the glass substrate 5 on the liquid crystal side is also applicable.
Fourth Embodiment
[0092] A semiconductor chip is known to erroneously operate under the influence of incoming light. A semiconductor chip 12 is thus sometimes required to be light tight on the surface, and if this is the case, the semiconductor chip 12 is attached with a light tight tape.
[0093] With such a method, however, the adhesion of the tape and the like is considerably poor. This is because the surface of the semiconductor chip 12 is arisen due to coating of a resin material aiming to increase the resistance to moisture, and the area available for bonding is small in size. When the portion attached with nothing is made of a silicone material, there is a problem of a difficulty in attaching the tape not to come off.
[0094] FIGS. 7A to 7B are both a diagram for illustrating a liquid crystal display module of a fourth embodiment of the invention. Specifically, FIG. 7A is a plan view (viewed from the side of a liquid crystal display panel, from the front surface side, or from the side of a viewer), and FIG. 7B is a side view.
[0095] Also in this embodiment, the fixing member 35 is used to fix both a liquid crystal display panel and a backlight unit as if those being covered from outside.
[0096] In this embodiment, the fixing member 35 is made light tight. This light-tight fixing member 35 is so disposed as to cover the surface of the semiconductor chip 12 so that the surface of the semiconductor chip 12 becomes light tight.
[0097] In this embodiment, the surface of the semiconductor chip 12 can be light tight even if it is not flat and irrespective of the material of the surface of the light-tight portion of the semiconductor chip 12 .
[0098] As described above, according to the embodiment, a liquid crystal display module can be easily reduced in size and profile.
[0099] Note here that the embodiments described above may be combined as appropriate as long as no contradiction arises thereby.
[0100] The invention is not restrictive to a liquid crystal display device, and is surely applicable to other types of display device such as organic electroluminescent display devices. If with an application to voluntary-emission display devices such as organic electroluminescent display devices, there is no need for alight guide plate, a white light-emitting diode, and others.
[0101] Described in this embodiment is an exemplary case of applying the invention to the frame-shaped mold 1 with no bottom surface. This is surely not the only possibility, and the invention is applicable to a mold with a bottom surface. However, the mold with no bottom surface is considered preferable in consideration of the thickness increase by the bottom surface.
[0102] The fixing member 35 may be a tape, and may be wound around the mold once or more.
[0103] While the invention proposed by the inventors has been described in detail based on the embodiments, the foregoing description is in all aspects illustrative and not restrictive. It is understood that numerous other modifications and variations can be devised without departing from the scope of the invention. | A liquid crystal display device that includes: a liquid crystal display panel; a backlight unit disposed on the rear surface side of the liquid crystal display panel; and a flexible printed circuit whose end is connected to a terminal portion of the liquid crystal display panel. In the device, the backlight unit includes a frame-shaped mold, the liquid crystal display device includes at least a fixing member for use for fixing the liquid crystal display panel to the frame-shaped mold in an area not including a display area of the liquid crystal display panel, and the fixing member is shaped like a ring, and inside of the ring of the fixing member, the liquid crystal display panel and the frame-shaped mold are disposed. The resulting liquid crystal display device can implement size and profile reduction with ease. | 8 |
RELATED APPLICATIONS
This is a continuation-in-part of U.S. patent application Ser. Nos. 07/735,877 and 07/736,417, both filed Jul. 26, 1991, and now both abandoned, and of U.S. patent application Ser. No. 07/913,611, filed Jul. 20, 1992, now abandoned.
BACKGROUND OF THE INVENTION
The field of the invention is catalyst devices each of which comprise a multichannel or honeycomb, porous walled, substrate containing a high surface area oxide washcoat as the support for metal catalyst dispersed on and bonded to the washcoat. Such devices with noble metal catalyst are useful for catalytically converting pollutants in the exhaust gas emitted by an internal combustion engine.
In such field it is commonly and commercially known to provide a washcoat layer on the wall surfaces of the porous walled substrate. The surface area of the washcoat is desirably greater than 50 m 2 /g (or more likely 100 m 2 /g) and preferably at least 150 or 200 m 2 /g. Such substrate is usually a porous ceramic material, such as cordierite, but it can also be a porous metal material (in contrast to nonporous metal foil). These porous materials are customarily of relatively low surface area, e.g. less than 10 or 5 m 2 /g (and, for some ceramic materials, less than 2 m 2 /g), and formed by sintering plastically shaped or formed particulate materials that yield the porous ceramic or metal material of the substrate. Usually the substrate is formed by extrusion and sintering of a plasticized mixture, e.g. into a thin walled honeycomb as described in U.S. Pat. Nos. 3,790,654 and 3,824,196. However, the multichannel substrate can be formed in any other useful configuration and by any other suitable process, e.g. as described in U.S. Pat. Nos. 3,112,184. The washcoat is typically applied to the substrate by dipping the substrate in a slurry, usually in water, of oxide particles that will form the washcoat. Such slurry can also include a dissolved catalyst precursor compound, from which the precursor will adsorb and disperse on the particles, and that will decompose and yield the metal catalyst upon calcining or heat treating the washcoat to bind the latter to the substrate. Such heating also causes the metal catalyst to be dispersed and bonded on the washcoat.
Internal combustion engine performance, e.g. in an automobile, is related to the back pressure effect of the catalytic converter in the exhaust gas conduit extending from the combustion chambers of the engine. Such performance generally improves as the back pressure is decreased.
In order to decrease the back pressure and increase engine performance, the open frontal area (OFA) of the support, i.e. the aggregate open transverse cross sectional area of the flow-through channels or cells of the washcoated, multichannel or honeycomb substrate, should be increased. However, this approach until now has been hindered by problems and accommodated by less than the desired solution.
For example, such approach is limited on the one hand by the necessity of applying an adequate amount (i.e. not too thin layer) of washcoat for sufficient catalytic function of the device, and on the other hand by maintaining enough wall thickness for structural integrity of the support. A relatively great amount of high surface area oxide is necessary in order to accommodate a sufficient amount of noble metal catalyst dispersed and bonded thereon, which would not be provided by a decreased quantity of high surface area oxide layer.
A known approach to avoiding the washcoat layer taking up space in the channels or cells of the support is the manufacture of the substrate with the washcoat material mixed with the particulate material for the structural (e.g. ceramic) material so that the formed and sintered product is the catalyst support with the washcoat particles embedded in and distributed through the walls as described in U.S. Pat. Nos. 4,637,995 and 4,657,880. A catalyst may subsequently be deposited on those washcoat particles. Additionally, such washcoat particles may have metal catalyst deposited on them before being mixed with particles of the structural material and embedded in the walls as described in U.S. Pat. No. 4,888,317. In either form, the resulting catalyst device can be characterized as a catalyst-in-wall structure. To date, such a catalytic converter device has been found not to provide catalytic activities as good as catalytic converter devices with the conventional type of washcoat layer on the wall surfaces.
The washcoat materials known or accepted, prior to the new invention described herein, for suitable support of noble metal catalysts yielding desired catalytic activities generally contain substantial amounts of oxide particles having particle diameters greater than 1 μm. As a consequence of such relatively large particles, it has not been possible to cause a substantial amount of the oxide particles of the washcoat to go into the pores of the walls of the flow-through channels of the porous supports so as to leave a thinner surface layer thereof on the walls of the substrate and thereby yield greater OFA. In typical multichannel or honeycomb substrates, the total open porosity, by volume, is in the approximate range of 5-50% (or more likely 5-25% for metal substrates and 30-45% for ceramic), and the average pore size is in the approximate range of 1-50 μm (or more likely 3-10 μm). Such pores are too small to enable adequate amounts of washcoat particles to enter them.
However, in regard to the back pressure problem, commercial efforts have been reasonably successful over the years in successively reducing the thickness of honeycomb substrate walls from about 0.3 mm to about 0.17 mm and recently to some extent to 0.1 mm. Such wall thickness reductions provide correspondingly increased OFA for substantially similar transverse cross sectional cell density in the supports. The latter efforts were made possible with new substrate material of some improved intrinsic strength to approximately offset loss of bulk strength with thickness reduction.
Some ceramic materials, e.g. cordierite and aluminum titanate plus mullite, of substrates are characterized by advantageously having microcracks in their structure. Such microcracks contribute to higher resistance to thermally induced cracking by allowing the thermally expanding material to reduce their widths, which lowers the overall (i.e. average) thermal expansion of the ceramic substrate material, and thereby avoid thermal stresses that otherwise would develop in the material. However, washcoating of such microcracked substrates can cause a serious problem. U.S. Pat. Nos. 4,451,517 and 4,532,228 reveal that washcoats fill the microcracks and obstruct their beneficial function during thermal shock conditions. Such obstruction during repeated heating and cooling of the converter causes strains and cracking induced by thermal expansion of the substrate material that is not allowed to reduce the width of the obstructed microcracks. As the solution to this obstruction problem, these patents teach the filling of the microcracks with organic materials before applying the washcoat on the wall surfaces of the substrate, so that the washcoat cannot enter the microcracks, and then burning out the organic binder while calcining or heat treating the washcoat to bind it to the wall surfaces of the substrate.
These prior art teachings indicate that it should not be usefully possible to deposit a washcoat mainly in the pores of the walls of multichannel or honeycomb substrates and support a metal catalyst on the washcoat to effect catalytic activities at least comparable to the activities of conventionally washcoated converters known prior to the invention described herein.
In washcoating porous walled substrates with the prior known slurries of the high surface area oxide particles, where a substantial portion of those particles have particle diameters larger than 1 μm, typical formulations of the slurries have desirably high solids content of spray dried boehmite or calcined gamma alumina and, consequently, are characterized by relatively high viscosity. In some cases the slurries include dissolved noble metal precursors or compounds. Such slurries behave in a conventional slip casting mode, wherein their composition and flow properties significantly change during the coating operation. Such behavior presents a problem. After dipping a number of the substrates in such slurry, a disproportionate amount of water is taken up by the substrates. The slurry remaining after washcoating a number of substrates is depleted of water such that its viscosity is too high for continued use in washcoating. It is often difficult to reclaim such depleted slurry as it is not always easy to add water to it in a manner to reconstitute the necessary uniform slurry composition with uniform viscosity.
SUMMARY OF THE INVENTION
The invention overcomes the foregoing problems by providing a catalytic device comprising a novel porous catalyst support with a multichannel, e.g. honeycomb, substrate, and by providing a novel method of making such catalyst support by washcoating such substrate. The flow-through channels or cells respectively of the multichannel or honeycomb substrate of this invention have at most a minor amount and preferably little or no washcoat particles on their surfaces so as to substantially or fully maintain the OFA of the uncoated substrate. That feature allows flow-through of exhaust gases without substantial or any additional pressure drop that would otherwise be caused by a substantial thickness of washcoat particles significantly reducing the OFA. This reduced pressure drop relative to the conventionally washcoated multichannel catalyst supports allows the catalytic converter device of this invention to be advantageously used with automotive internal combustion engines where the highest engine performance is desired and can be maintained.
In the catalyst device of the invention, the porous catalyst support comprises a multichannel or honeycomb substrate having porous walls defining the channels or cells therein. A network of open pores is distributed through the walls. The walls contain washcoat particles bonded to the them, and all of those particles are of colloidal particle size and selected from the group consisting of alumina, rare earth oxide, silica, and zirconia. Over 50% of the washcoat particles contained by the walls are deposited within the pores on the surfaces of the pores (which are internal surfaces of the walls) and substantially throughout the walls. Any other portion of the washcoat particles (i.e. if optionally present) are deposited on the external surfaces of the walls.
The present invention also accommodates microcracked ceramic material for the multichannel substrates because the invention does not produce filling of the microcracks with washcoat particles. Thus, there is no need for the burden of preliminarily filling the microcracks with organic materials in order to prevent the washcoat from being deposited therein. In this case, the invention prevents undesirable thermal expansion cracking while also reducing back pressure.
However, the substrate of the invention can also be selected from non-microcracked ceramic material and metal material.
Each selected material for the substrate has the pores mentioned above. The total open porosity and average pore size in, and the surface area of, the substrate material generally are as described above.
Furthermore, the method of this invention provides washcoating with a flowable colloidal dispersion that does not significantly change composition or flow properties during extended washcoating with it. Such colloidal dispersion remains easily flowable, of relatively low viscosity, and nonthixotropic. It is a dispersion of particles wholly of colloidal particle size as defined below. Such particles do not settle out or separate from their dispersed state unless flocculated by a suitable electrolyte. Generally proportionate amounts of both colloidal particles and liquid in the colloidal dispersion infiltrate the pores of the substrate, thereby leaving the remaining colloidal dispersion not retained on the surfaces of the walls not degraded with usage. The general concept and nature of "colloidal dispersion" are known and understood by those skilled in such technology.
The basic method of washcoating the porous sustrate described above comprises:
a) providing a flowable colloidal dispersion of oxide particles in a first evaporable liquid, wherein the particles are wholly of colloidal particle size and selected from the group consisting of alumina, rare earth oxide, silica and zirconia;
b) contacting the walls of the substrate with the colloidal dispersion to cause the colloidal dispersion to infiltrate substantially all of the open pores;
c) removing the walls of the substrate, with colloidal dispersion contained thereon, from contact with substantially the remainder of the colloidal dispersion to provide within the pores on the surfaces thereof a quantity of the contained colloidal dispersion having over 50% of the particles in the contained colloidal dispersion, and to provide on the external surfaces of the walls any other portion of the contained colloidal dispersion (i.e. if optionally present) having any minor portion of the particles in the contained colloidal dispersion;
d) drying the infiltrated substrate to cause the first liquid to evaporate out of the substrate, to cause the over 50% of the particles on the walls to deposit on surfaces of the pores, and to cause any other minor portion of the particles on the walls (i.e. if optionally present) to deposit on the external surfaces of the walls.
For bonding the particles to the walls of the substrate for durability of the support, the dried substrate is heat treated or calcined. Such bonding is both direct and indirect, i.e. one portion of the particles are directly bonded to surfaces of the substrate and the remaining portion of the particles are bonded only to other particles, at least some of which are those bonded directly to such surfaces.
A metal catalyst precursor may be added to the washcoat oxide particles by one of two methods: after or before such particles are deposited and bonded on the walls.
In the first method, the bonded particles are contacted with a solution comprising a metal catalyst precursor in an evaporable liquid to cause the precursor to adsorb and disperse, as is known in catalyst preparation, on the bonded particles. Then the substrate with adsorbed precursor is heated to evaporate the second liquid out of the substrate, and to convert the precursor to the metal catalyst bonded and dispersed on the bonded particles.
The second method provides the advantage of a "one step" application of both the bonded particles and metal catalyst, which requires only one sequence of drying and heat treating or calcining of the washcoated substrate. The heat treating or calcining hardens and strengthens the deposits of particles as well as converts the precursor(s) to the corresponding metal(s) that constitute the catalyst.
For the "one step" application, the provision of the flowable colloidal dispersion includes incorporating a soluble catalyst metal precursor in the colloidal dispersion to cause the precursor to adsorb and disperse on the particles. In that case, the heat treating step includes heating to convert the precursor to the metal catalyst bonded and dispersed on the bonded particles.
The catalyst support of this invention with metal catalyst on the bonded colloidal particles provides a form of catalyst-in-wall structure or device that has excellent catalytic activities comparable to those of catalytic converter devices with the conventional type of washcoat layer, but with greater OFA minimizing back pressure degradation of engine performance. The former is believed to result from better gas accessibility to the metal catalyst in the pores than is the case with the earlier catalyst-in-wall structure or device mentioned above.
In one particular aspect, the invention is designed for use of noble metal as the metal catalyst. Desirably for catalytic devices to be used with internal combustion engines, the noble metal is selected from the platinum metal group, i.e. ruthenium, rhodium, palladium, osmium, iridium, and platinum. Platinum, palladium, and/or rhodium are preferred.
In an especially novel variation of the invention, the catalyst support comprises a first metal catalyst (e.g. platinum and/or palladium) dispersed on and bonded to first washcoat oxide (e.g. alumina) particles, and a second, different metal catalyst (e.g. rhodium) dispersed on and bonded to second, different washcoat oxide (e.g. ceria) particles. This support is made by the special variation of the "one step" application wherein the step of providing a flowable colloidal dispersion comprises:
(i) obtaining a first flowable colloidal dispersion of first oxide particles in a first evaporable liquid,
(ii) incorporating a first soluble precursor of a first catalyst metal in the first colloidal dispersion,
(iii) obtaining a second flowable colloidal dispersion of second oxide particles in a second evaporable liquid,
(iv) incorporating a second soluble catalyst metal precursor in the second colloidal dispersion, and
(v) mixing the first and second colloidal dispersions from steps (ii) and (iv).
When applying the method of the invention to a microcracked ceramic substrate, the colloidal dispersion is desirably prepared without inclusion of soluble inorganic constituent, such as salt of an oxide-forming metal. The undesirable presence of such constituent can yield the formation during the heat treating step of particles of its corresponding oxide in the microcracks in an amount that interferes with the ability of the microcracks to provide lower thermal expansion of the catalyst support and a corresponding greater resistance to thermal cracking. For other substrates within the invention, some soluble inorganic constituent may be included so long as it does not result in the deposition of its corresponding oxide in an amount to interfere with catalytic activities of the catalyst metal in the catalyst support.
The term "colloidal particle size" as used herein means particles having a particle size in the approximate range of 0.001 to 0.2 micrometer. More advantageously for the described effects of the invention, the noted particles should have a particle size in the approximate range of 0.001 to 0.1 micrometer and preferably in the approximate range of 0.001 to 0.05 micrometer. It is also desirable that the colloidal particles have an average diameter in the approximate range of 1 to 100 nanometers.
It is particularly notable that the invention is more advantageously carried out by providing within the pores of substrate walls at least 75% or 80% (and even at least 90% or 95% for outstanding effect as noted above) of the colloidal washcoat oxide particles contained on the walls of the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a typical prior art multichannel support used for catalytically converting exhaust effluent.
FIG. 2 is a cross-sectional view of FIG. 1, taken along lines 2--2, illustrating the channels of a substrate washcoated as typically accomplished in the prior art.
FIG. 3 is a cross-sectional view of the prior art washcoated substrate of FIG. 2, taken along lines 3--3.
FIG. 4 is a photomicrograph showing a partial, enlarged cross section of an uncoated wall of a typical multichannel substrate like that illustrated in FIGS. 2 and 3.
FIG. 5 is a photomicrograph showing a partial, enlarged cross section of a washcoated, substrate channel wall in accordance with this invention (with a 1 mm length reference mark).
FIG. 6 is a photomicrograph showing a further enlarged view of a wall of the substrate shown in FIG. 5 (with a 100 μm length reference mark).
FIGS. 7a and 7b are graphs of the catalytic activities of catalyst supports of this invention having metal substrates and containing noble metal catalysts.
FIG. 8 is a graph of the comparative thermal expansions and contractions of a conventionally coated ceramic substrate, a coated ceramic substrate of the invention, and an uncoated ceramic substrate.
FIGS. 9 and 10 are graphs of the comparative thermal expansions of four coated ceramic substrates and an uncoated ceramic substrate.
FIGS. 11a and 11b are graphs of the catalytic activities of catalyst supports of this invention having metal substrates and containing noble metal catalysts.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a typical honeycomb support 4 that has been used in the catalytic conversion of exhaust gases from internal combustion engines. The exhaust gases are passed in the direction of arrow 8 through the open-ended channels or cells 6, where they are catalytically converted to be substantially nonpolluting.
As shown in FIGS. 2 and 3, the support 4 comprises a honeycomb substrate constituted by porous walls 5 of typical ceramic or metal material, which is generally extruded and sintered to form the structure shown. The walls 5 define the channels 6. As illustrated in FIG. 4, a porous wall has a network of open pores 2 distributed through the material 1 of the wall between opposite external surfaces of the wall. The external surfaces 3 of walls 5 are coated with an oxide washcoat (and catalyst) layer 7 of the conventional type in the prior art. The washcoat layer 7 is deposited, by the process of dip-coating the substrate as is well known in the art, upon the surface 3 in the form of particles suspended in a slurry, a substantial portion of which have particle sizes greater than 1 μm. The built-up thickness of layer 7 reduces the OFA of support 4 and thereby restricts gas flow through the channels 6. This restricted flow is undesirable, since it increases the back pressure in the exhaust gas stream from an engine. The rise in back pressure consequently degrades engine performance.
In FIG. 4, the material 1 is sintered metal, which does not contain microcracks. However, the structure is also representative of the network of pores in a typical sintered ceramic material, including one that contains microcracks.
Porous walled honeycomb substrates, e.g. extruded as monoliths, of metal containing aluminum can be provided with an initial thin, adherent surface coating of alumina as result of oxidation heat treatment of the substrate. High surface area washcoats of this invention can be compatibly applied to such porous substrate.
FIGS. 5 and 6 show the typical wall of FIG. 4 after it has been washcoated with the high surface area oxide particles of colloidal particle size according to this invention, which is typical of the washcoated walls according to the following examples. The metal material 1, the pores 2, and the deposited washcoat oxide particles are more easily seen in FIG. 6. The darker shading substantially over the area of the pores 2, relative to the lighter shading of the metal 1, is the deposit of washcoat particles. Thus, it can be seen that the washcoat particles are mostly deposited in the pores of the wall as illustrated. Very small amounts of washcoat particles are deposited on or at the external surfaces of the wall. It is estimated that over about 90-95% of the washcoat particles of FIGS. 5 and 6 are within the pores 2 on surfaces thereof.
EXAMPLE 1
A washcoat slurry for dip-coating of porous ceramic and metal monoliths of honeycomb structure was prepared according to the following example.
93 grams of finely colloidal gamma alumina (Versal-GH) obtained from La Roche Chemicals Co. were blended with 7 grams of dispersible, finely colloidal ceria obtained from the Molycorp Co. The blended alumina and ceria were slowly added while stirring to 70 ml of distilled water. After the powders were completely added, the slurry had the appearance of a gel. To this slurry was slowly added 2 ml of dilute (1:1) nitric acid to adjust the pH to 5.5. The slurry was then transferred to a Nalgene bottle (500 ml), and 200 grams of 1 cm alumina balls were added. The slurry was rolled for 18 hours. The pH of the resultant dispersion was observed to be 5.6, and was then further adjusted to 3.7 by introducing additional nitric acid. The viscosity of the dispersion was between 34 and 36 cps.
Extruded and sintered porous samples of both metal and ceramic honeycombs were washcoated by dip-coating in the dispersion, as is well known in the art. The samples were then dried in an oven at 60° C. and next fired at 550° C. for 6 hours.
The weight loading results of dip-coating the alumina and ceria on cordierite honeycombs (2.5 cm diameter×2.5 cm length) are presented in Table 1.
TABLE 1______________________________________Initial Wt. Loaded Wt. Wt. Gain WashcoatSAMPLE (grams) (grams) (grams) Wt % g/cc______________________________________1 5.02 6.67 1.65 32.8 0.132 5.19 7.21 2.02 38.9 0.163 5.26 7.22 1.96 37.3 0.164 5.24 7.36 2.12 40.4 0.175 5.29 7.34 2.05 38.7 0.166 5.23 7.27 2.04 39.0 0.16______________________________________
The weight loading results of dip-coating the alumina and ceria on Fe-Al honeycombs (1.7 cm diameter×1.8 cm length), prefired in air at 600° C. for 12 hours to produce a 1% wt. grain as thin adherent oxide film, are show in Table 2.
TABLE 2______________________________________Initial Wt. Loaded Wt. Wt. Gain WashcoatSAMPLE (grams) (grams) (grams) Wt % g/cc______________________________________7 5.46 7.47 2.01 36.8 0.49(DOUBLE COATING)8 5.71 6.56 0.85 14.9 0.21______________________________________
The results of dip-coat loading of alumina and ceria on Fe-Al honeycombs (1.7 cm diameter×1.8 cm length), as sintered, are presented in Table 3.
TABLE 3______________________________________Initial Wt. Loaded Wt. Wt. Gain WashcoatSAMPLE (grams) (grams) (grams) Wt % g/cc______________________________________ 9 5.40 6.16 0.76 14.1 0.1810 5.19 6.12 0.93 17.9 0.23______________________________________
The results of dip-coat loading of alumina and ceria on Fe-al honeycombs (1.7 cm diameter×1.8 cm length), prefired in air at 1000° C. for 24 hours to produce a 5.5 to 6.2% wt. gain as thin adherent oxide film, are shown in Table 4.
TABLE 4______________________________________Initial Wt. Loaded Wt. Wt. Gain WashcoatSAMPLE (grams) (grams) (grams) Wt % g/cc______________________________________11 5.93 6.70 0.77 13.0 0.1912 5.95 6.78 0.83 13.9 0.2013 6.02 6.78 0.78 12.6 0.1814 6.04 6.89 0.85 14.0 0.20______________________________________
The results of dip-coat loading of alumina and ceria on Fe-Al honeycombs (1.7 cm diameter×1.8 cm length), prefired in air at 1000° C. for 24 hours to yield 2.9 to 3.1% wt. gain as thin adherent oxide film, are presented in Table 5.
TABLE 5______________________________________Initial Wt. Loaded Wt. Wt. Gain WashcoatSAMPLE (grams) (grams) (grams) Wt % g/cc______________________________________15 5.83 6.52 0.69 11.8 0.1716 5.90 6.73 0.83 14.0 0.2017 6.60 7.49 0.89 13.5 0.2218 5.77 6.53 0.76 13.2 0.18______________________________________
The results of dip-coat loading of alumina and ceria on Fe-al honeycombs (1.7 cm diameter×1.8 cm length), as sintered, are shown in Table 6.
TABLE 6______________________________________Initial Wt. Loaded Wt. Wt. Gain WashcoatSAMPLE (grams) (grams) (grams) Wt % g/cc______________________________________19 4.90 5.46 0.56 11.4 0.1420 4.92 5.39 0.57 11.8 0.14______________________________________
From the data presented in Tables 1-6, it appears that more washcoat per unit volume is deposited into the pores of the metal honeycomb substrates than those of the ceramic honeycomb substrates.
EXAMPLE 2
Extruded and sintered, porous Fe-Al honeycombs were prepared in accordance with the method disclosed in U.S. Pat. No. 4,758,272, which method is hereby incorporated herein by reference. The prepared honeycombs were 1.8 cm in diameter×2.3 cm in length, with a volume of 5.85 cc. The honeycombs were preoxidized at 1000° C. for 5 hours. The honeycomb samples had an average porosity of 45% with a mean pore size of 6 micrometers.
The raw materials used in the washcoat dispersion were:
(a) Colloidal alumina, Nyacol® Al-20 (Nyacol Products, Inc.) 20 wt. % Al 2 O 3 with normal particle size 20 nm, specific gravity 1.2, viscosity 10 cps, pH=4.
(b) Colloidal ceria, (Rhone Poulenc) 20 wt. % CeO 2 , particle size 12 nm, specific gravity 1.2, viscosity 5 cps, pH=3.
(c) Chloroplatinic acid solution, 9.73% Pt (Engelhard).
(d) Rhodium nitrate solution, 10.2% Rh (Engelhard).
120 ml of colloidal alumina (Al-20) and 30 ml of colloidal ceria were mixed as dispersions by stirring well. Preweighed porous metal honeycombs were dipped into the colloidal slurry mixture for 1 minute, followed by clearing the excess slurry with compressed air. The samples were dried at 100° C. for 2 hours, and then fired in an electric furnace at 700° C. for 2 hours (ramp 150° C./hr).
Coating and firing steps were repeated for second, third and fourth times.
The following tables illustrate how the loading progressively increased with each loading treatment:
TABLE 7______________________________________Initial Wt. 1st Loaded Wt. Loading Wt.SAMPLE (grams) (grams) (%) g/cc______________________________________21 6.28 6.50 3.50 0.037622 6.26 6.45 3.04 0.032523 6.32 6.58 4.11 0.044424 6.32 6.56 3.80 0.0410______________________________________
TABLE 8______________________________________ Washcoat Loading (g/cc) afterSAMPLE second third fourth______________________________________21 0.074 0.109 0.13722 0.070 0.104 0.13323 0.084 0.120 0.14924 0.082 0.115 0.144______________________________________
A portion of the colloidal dispersion mixture was dried in an oven and fired at 700° C. for 2 hours. BET surface area of this material (20% CeO 2 and 80% Al 2 O 3 ) was 138 m 2 /g. The samples were then loaded with platinum (25 g/ft 3 or 0.0012 g/cc) and with rhodium (5 g/ft or 0.00017 g/cc) noble metals using chloroplatinic acid and rhodium nitrate solutions, respectively. After each loading, the samples were dried in an oven at 100° C. for an hour, followed by firing at 550° C. for 6 hours.
The loaded samples were next tested for automotive catalytic activity in a 1 inch (25 mm) diameter bench reactor with a simulated automotive exhaust gas mixture. The gas mixture consisted of: 500 ppm of NO x , 300 ppm of propylene, 0.65% by volume CO, 0.2% by volume hydrogen, 0.46% by volume oxygen, 7.7% by volume carbon dioxide, 10% by volume water vapor, and the balance nitrogen gas. The space velocity of the gas mixture was 33,380 changes/hr. The gas conversions were measured as percent conversion compared to the inlet concentrations. The temperature of the reactor was raised to 600° C. in an hour. The catalytic conversions by Samples 23 and 24 are respectively illustrated in FIGS. 7a and 7b, as a function of temperature. These figures show that the conversions of the exhaust gases to harmless gases start at a low temperature and quickly reach a level of conversion of between 80 to 95%. The light off temperatures (at which 50% of each of carbon monoxide, hydrocarbons, and nitrogen oxides converts to nonpollutants) for Samples 23 and 24 are:
______________________________________ Temperature °C.Sample CO HC NOX______________________________________23 150 280 23024 160 285 280______________________________________
These light off temperatures are as good as commercial automotive catalysts with the conventional washcoat.
Putting the washcoat and catalyst into the pores of the substrate not only locks in the catalyst, preventing the attrition of the metal (such as noble metal) over the lifetime of the converter, but it also reduces the wall thickness of the support, resulting in low back pressure and improved engine performance.
EXAMPLE 3
Extruded and sintered, porous, Fe-Al monolith honeycombs were prepared in accordance with the method disclosed in U.S. Pat. No. 4,758,272. The prepared honeycombs had 6.6 to 7.15 cm diameter×7.6 to 8.25 cm length. The honeycombs were preoxidized at 1000° C. for 5 hours.
560 ml of colloidal alumina (Al-20) and 240 ml of colloidal ceria were mixed as a dispersion by stirring well. Preweighed porous metal honeycombs were dipped into the colloidal dispersion mixture for one minute, followed by clearing the excess slurry with compressed air. The samples were dried at 100° C. for 2 hours, and then fired in an electric furnace at 700° C. for 2 hours (ramp 150° C./hr).
Coating and firing steps were repeated for second, third, fourth and fifth times.
The following tables illustrate how the loading progressively increased with each loading treatment:
TABLE 9______________________________________ Initial Wt. 1st Loaded Wt. Loading Wt.SAMPLE (grams) (grams) (%) g/cc______________________________________25 (308.0 cc) 166.44 172.82 3.83 0.02126 (339.2 cc) 192.06 199.61 3.93 0.02227 (314.3 cc) 265.91 275.81 3.72 0.03128 (307.9 cc) 251.81 261.55 3.87 0.031______________________________________
TABLE 10______________________________________ Washcoat Loading (g/cc) afterSAMPLE second third fourth fifth______________________________________25 0.039 0.052 0.064 0.07726 0.044 0.062 0.075 0.09127 0.064 0.095 0.117 0.13728 0.064 0.093 0.116 0.135______________________________________
EXAMPLE 4
High porosity cordierite honeycomb substrates (Celcor® EX-47, Corning, Inc.) were prepared. The prepared honeycombs had 3 inches (7.62 cm) diameter×3 inches (7.62 cm) length (353.8 cc), 300 cells/in 2 or 46 cells/cm 2 , a 0.008 inch wall thickness, and about 66% OFA.
A dispersion mixture was prepared with 350 ml of colloidal alumina (Al-20) and 150 ml of colloidal ceria which were mixed with stirring well. Preweighted honeycombs were dipped into the colloidal dispersion mixture for 1 minute, followed by clearing the excess slurry with compressed air. The samples were dried at 100° C. for 2 hours, and then fired in an electric furnace at 700° C. for 2 hours (ramp 150° C./hr).
Coating and firing steps were repeated for second, and third times.
A portion of the coating slurry was dried in an oven and fired at 700° C./2 hrs. BET surface area of this material (30% CeO 2 and 70% Al 2 O 3 ) was 137 m 2 /g. Aged (970° C./4 hrs in 1% oxygen, 8% carbon dioxide, 10% water vapor, and the balance nitrogen) material has a lower surface area, 63.7 m 2 /g.
The following tables illustrate how the loading progressively increased with each loading treatment:
TABLE 11______________________________________ Initial Wt. 1st Loaded Wt. Loading Wt.SAMPLE (grams) (grams) (%) g/cc______________________________________29 161.3 176.17 9.22 0.04230 164.9 179.55 8.88 0.04131 163.7 179.26 9.51 0.044______________________________________
TABLE 12______________________________________ Washcoat Loading after second thirdSAMPLE wt. % g/cc wt. % g/cc______________________________________29 20.01 0.091 27.75 0.12730 17.56 0.082 24.37 0.11431 18.31 0.085 25.58 0.118______________________________________
Small samples were prepared (2.5 cm diameter×2.5 cm length) and core drilled from the larger aforementioned samples. These smaller samples were loaded with platinum (25 g/ft 3 or 0.00085 g/cc) and with rhodium (5 g/ft 3 or 0.00017 g/cc) using chloroplatinic acid and rhodium nitrate solutions, respectively. After each loading, samples were dried in an oven at 100° C. for an hour, followed by firing at 550° C. for 6 hours.
The noble metal loaded samples were tested for automotive catalytic activity in a 1 inch (25 mm) diameter bench test reactor with the simulated automotive gas mixture utilized in Example 2. Results comparable to commercial converters was obtained.
EXAMPLE 5
A porous cordierite honeycomb substrate (Celcor® Code 9475/EX-20, Corning, Inc.) was prepared with 400 cells/in 2 or 62 cells/cm 2 , a 0.006 inch (0.15 mm) wall thickness, and about 71% OFA. A 5 cm 2 by 13.75 cm length sample was cut from the substrate.
A slurry was prepared with 350 ml of colloidal alumina (Al-20) and 150 ml of colloidal ceria which were mixed by stirring well. The cut sample was preweighed and then dipped into the colloidal slurry mixture for 1 minute, followed by clearing the excess slurry with compressed air. The samples were dried at 100° C. for 2 hours, and then fired in an electric furnace (ramp 150° C./hr, 700° C./2 hrs).
Coating and firing steps were repeated for second, third, fourth and fifth times.
The following tables illustrate how the loading progressively increased with each loading treatment:
TABLE 13______________________________________ Initial Wt. 1st Loaded Wt. Loading Wt.SAMPLE (grams) (grams) (%)______________________________________32 64.17 67.38 5.0______________________________________
TABLE 14______________________________________ Washcoat Loading (wt. %) afterSAMPLE second third fourth fifth______________________________________32 9.47 13.20 16.02 18.89______________________________________
A sample (0.5 inch square by 3 inch length or 1.27×1.27×7.62 cm) was cut from the coated sample shown above, and a thermal expansion measurement was conducted. Two similar samples were also cut from the uncoated cordierite piece. One was left uncoated, and the other conventionally washcoated. Both were measured for thermal expansion as a comparison.
FIG. 8 illustrates the thermal expansion measurements of Sample 32, an uncoated Celcor substrate, and a conventionally washcoated Celcor substrate, the latter two being of the same porous cordierite as Sample 32. The conventionally coated sample is observed to possess a substantially larger thermal expansion than the uncoated sample. However, Sample 32 had a thermal expansion considerably less than the conventionally coated sample. This indicates that the invention provides substrates with a greater resistance to thermal shock than conventionally washcoated cordierite samples, and is indicative of the fact that the colloidal particle size washcoat particles according to this invention have been impregnated into the pores, but do not fill or enter the microcracks to the degree as do the conventional washcoat particles. All of the above samples of Examples 1 through 5 above were also examined with the SEM and found to have the coating substantially in the wall of the substrate, as shown in FIGS. 5 and 6.
EXAMPLE 6
An additional raw material for this example is colloidal ZrO 2 (Nyacol Products, Inc.) 20 wt. % ZrO 2 with normal particle size 5-10 nm, specific gravity 1.26, and viscosity 10 cps, pH=3.5.
High porosity cordierite honeycomb substrates (Celcor® EX-47, Corning Inc.) 1 inch (2.54 cm) diameter by 1 inch (2.54 cm) length, 300 cells/square inch or 46 cells/cm 2 , with 0.008 inch (0.2 mm) wall thickness were fabricated and treated as follows:
A coating slurry was made with 70 ml. of colloidal alumina (Nyacol®, AL-20), 25 ml of colloidal ceria (Rhone Poulenc) and 5 ml of colloidal zirconia (Nyacol Products, Inc.). Preweighed porous ceramic honeycomb substrates were dipped into the coating slurry for 1 minute, followed by clearing the excess slurry from the substrates with compressed air. The coated samples were dried in an oven at 100° C. for 2 hours followed by firing in an electric furnace at 700° C. (ramp 120° C./hr) for 2 hours. Coating and firing steps were repeated again for second, and third times.
The following tables show how the loading progressively increased with each coating treatment:
TABLE 15______________________________________Sample No. Initial Wt (g) 1st Loading (g) Loading wt. %______________________________________33 5.22 5.69 9.034 5.18 5.67 9.4635 5.22 5.69 9.0______________________________________
TABLE 16______________________________________Sample No. 2nd Loading Wt. % 3rd Loading Wt. %______________________________________33 17.43 24.334 17.95 25.7 5 17.82 25.5______________________________________
EXAMPLE 7
Separate aqueous colloidal dispersions of alumina and ceria were prepared with solids contents of approximately 20%. Then 0.833 wt. % Pt was added to the alumina dispersion, and 0.167 wt. % Rh was added to the ceria dispersion. All of the percentages of noble metals were based on 20% total solid content in the colloidal dispersions. The platinum was added in the form of H 2 PtCl 6 .6H 2 O, and the rhodium was added in the form of Rh(NO 3 ) 3 .2H 2 O.
After stirring the two dispersions together for five minutes with a magnetic bar and plate, Fe-Al monoliths, as previously described, were immersed into the dispersion, were allowed to remain for one minute, then removed from the slurry, allowed to drain, and then cleared with a compressed air blast through their cells.
Drying was done in a convection oven at 100° C. for two to three hours before firing at 700° C. for two hours (ramp 150° C/hr ).
The process was repeated until approximately 0.12 g/cc weight loadings were achieved on the catalyst device, which exhibited good catalytic activity.
EXAMPLE 8
15 g of colloidal ceria (obtained from Rhone-Poulenc as 20 wt. % ceria dispersion having a viscosity of 10 cps) was mixed with 35 g of colloidal alumina (AL-20 obtained from Nycol Products as 20 wt. % alumina dispersion having a viscosity of 10 cps). The mixture was stirred for one hour. 0.199 g of rhodium nitrate solution having 10 wt. % rhodium and 0.825 g of chloroplatinic acid solution having 10 wt. % of platinum was added to the colloidal dispersion. This mixture was stirred for 2 hours.
Porous Fe-Al monoliths (17 mm diameter by 17 mm length) were dip-coated with the above slurry for one minute. The channels were cleared with compressed air. The samples were dried in an oven at 100° C. for 2 hours, and then sintered at 700° C. for 2 hours.
The coating and sintering process was repeated until the sample was loaded with 20 g of noble metal per cubic foot (Pt:Rh=5:1).
The catalytic activity of the coated substrate of this example was found to compare equally with Example 8.
The following reagents were additionally used in further experiments for this invention: Ammonium tetrachloroplatinum (II), Engelhard (51.1% Pt) Dihydrogen hexahydroxyplatinum (IV), Engelhard (65.0% Pt) Tetrammine platinum (II) dichloride, Engelhard (55.4% Pt) Ammonium hexachlororhodium (III), Engelhard (27.8% Rh) Ammonium tetrachloropalladium (II), Engelhard.
The dispersions of this invention must have a working life that allows for repeated loadings, and should not cause a breakdown of the substrate when applied thereto. Experiments were conducted with various noble compounds which would provide the aforementioned objectives. Other objectives included:
(a) Water solubility: The composition should provide at least 2.08×10 -3 grams of Pt metal or 4.17×10 -4 grams of Rh per gram of colloidal mixture at a pH of 3.
(b) Substantially stable Ph: The composition must maintain a pH in the approximate range of from 3 to 4, so that the solution will not become too viscous.
(c) Negatively charged noble metal ion: The noble metals had to be adsorbed upon the protenated alumina or ceria surface to provide highly dispersed catalytic particles.
The following examples were tests conducted with several platinum compounds.
EXAMPLE 9
0.32 grams of ammonium tetrachloroplatinum (II) was added to 100 grams of an alumina/ceria colloidal mixture and stirred until completely dissolved. This took approximately 1.5 hours. No pH change was observed over this time period.
EXAMPLE 10
0.25 grams of dihydrogen hexahydroxyplatinum (IV) was added to 100 grams of the above slurry of Example 9. After stirring for one hour, approximately 25% of the solid was still visible. A pH change was observed from 3.0 to 2.9.
EXAMPLE 11
0.30 grams of tetrammine platinum (II) dichloride was added to 100 grams of the slurry of Example 9, and dissolved within 5 minutes with stirring. A pH change from 3.0 to 3.19 was observed after one hour, and rose to 3.4 after 20 hours.
The platinum compound of Example 9 was chosen as the best source of platinum of the three compounds for coated catalyst-in-wall loadings according to this invention.
Example 12
0.601 grams of ammonium hexachlororhodium (III) was dissolved in 50 grams of a colloidal ceria dispersion. Continuous stirring for 3.5 hours was required to dissolve the compound completely. No pH changes were observed over this time span. The dispersion was quite stable alone, but when added into the alumina dispersion (Al-20), it was caused to gel after 20 hours.
It was therefore decided that the platinum compound would be separately added to an alumina dispersion, the rhodium salt would be separately added to a ceria dispersion, and the two dispersions would be mixed just prior to performing the substrate coating process.
A coating of the preferred compounds was prepared using a 6:1 ratio of platinum to rhodium, and was applied to a metal monolith as aforementioned. Weight loadings of approximately 20 g/ft 3 of noble metals were achieved with three passes on porous metal monoliths using chloroplatinic acid/rhodium nitrate coatings.
21 g/ft 3 of noble metals on Celcor® EX-20 honeycombs and 22 g/ft 3 on porous Fe-Al monoliths utilizing three coating passes were also obtained with similar results.
BET surface area for this coating was determined to be 124 m 2 /g with fired substrates only, and 66.2 m 2 /g for fired and subsequently aged coatings. This is approximately 25% greater than conventionally coated ceramic substrates.
From the above experiments, it has been found that a superior coating process has been developed that provides catalyst application in a single step.
Example 13
Extruded and sintered, porous Fe-Al honeycombs were prepared according to U.S. Pat. No. 4,758,272. The honeycombs had 1.8 cm diameter, 2.3 cm length, and 5.85 cc volume. They were preoxidized at 1000° C. for 5 hours. These honeycombs had an average porosity of 45% with mean pore size of 6 μm.
0.297 grams of ammonium tetrachloroplatinum (II) was added to 70 grams of colloidal alumina (Al-20). This dispersion was stirred for 2 hours. 0.0433 grams of ammonium hexachlororhodium (III) was added to 30 grams of colloidal ceria (Rhone Poulenc) and stirred for 2 hours. These two dispersions were combined and stirred to form a mixed dispersion.
The honeycombs were weighed and then dipped into this mixed colloidal dispersion for one minute. The excess slurry was cleared from the honeycombs with compressed air. These samples were dried at 100° C. for 2 hours, and then fired in an electric furnace at 700° C. for 2 hours (ramp 150° C./hr). This coating procedure was repeated two more times.
Tables 18 and 19 set forth the incremental loading upon the honeycomb:
TABLE 18______________________________________ Initial Wt. Loaded Wt. Loading Wt.SAMPLE (grams) (grams) (%) g/cc______________________________________36 9.51 9.83 3.36 0.037637 6.42 6.62 3.12 0.0325______________________________________
TABLE 19______________________________________ Washcoat Loading (wt. %) afterSAMPLE second third______________________________________36 not measured 10.3037 not measured 8.41______________________________________
A portion of the colloidal dispersion was dried in an oven and fired at 700° C. for 2 hours. The BET surface area of this material (30% CeO 2 and 70% Al 2 O 3 ) was 124 m 2 /g. Aged material (970° C./4 hrs in 1% oxygen, 8% CO 2 , 10% water vapor, balance nitrogen) has a lower surface area of 66.2 m 2 /g.
These samples were tested for automotive catalytic activity by the procedure in Example 2. FIG. 11a shows the conversion results on Sample 37 for CO, HC, and NOx as a function of temperature. Conversion to harmless gases starts at a low temperature and quickly reaches a conversion percentage of 80 to 95%
Example 14
High porosity cordierite honeycombs (Celcor® EX-47, Corning, Inc.) had a 1 inch (2.54 cm) diameter, 1 inch (2.54 cm) length, 300 cells/in 2 (46 cells/cm 2 ), and 0.008 inch (0.2 mm) wall thickness.
0.247 grams of ammonium tetrachloroplatinum (II) was added to 52.5 grams of colloidal alumina (Nyacol® Al-20). This dispersion was stirred for 2 hours. 0.0908 grams of ammonium hexachlororhodium (III) was added to 22.5 grams of colloidal ceria (Rhone Poulenc) and stirred for 2 hours. These two dispersions were combined and stirred to form a mixed colloidal dispersion.
The honeycombs were dip-coated as in Example 13. Then that coating procedure was repeated for a second and third time. Tales 20 and 21 show the progression of loading upon the honeycomb with each subsequent coating and firing step:
TABLE 20______________________________________ Initial Wt. 1st Loaded Wt. Loading Wt.SAMPLE (grams) (grams) (%)______________________________________38 5.23 5.71 9.1839 5.16 5.6440 5.04 5.47 8.5341 5.05 5.56 10.142 5.19 5.70 9.83______________________________________
TABLE 21______________________________________ Washcoat Loading (wt %) afterSAMPLE second third______________________________________38 17.6 27.539 18.02 28.140 16.07 26.041 18.42 27.742 18.69 27.6______________________________________
The platinum and rhodium contents were analyzed for Sample 41, and the analytical results are: 0.155 wt % Pt 0.031 wt % Rh 22.0 g/cc Pt 4.4 g/cc Rh. Generally it is desired to have the weight ratio Pt:Rh in the range of 5-30.
The samples were tested for automotive catalytic activity by the procedure in Example 2. FIG. 11b shows the results of the testing. Conversion of CO, HC, and NOx as a function of temperature starts at low temperature and quickly reaches conversion percentages of 80 to 95%.
Example 15
Using the coating procedure of Example 13, separate EX-47 cordierite honeycomb samples 1 inch (2.54 cm) diameter and 3 inches (76.2 cm) length were washcoated with: (a) a dispersion of Al-20 alumina mixed with Rhone Poulenc (RP) colloidal ceria, (b) a mixed dispersion of Al-20, RP ceria, and cerium acetate (13% dissolved cerium acetate from Rhone Poulenc), and (c) the Rhone Poulenc cerium acetate. Table 22 sets forth the washcoat data (average of 2 samples):
TABLE 22______________________________________ Loading Coats Ce Acetate Al-20 CeO.sub.2SAMPLE wt. % Number wt. % wt. % wt. %______________________________________43 33.5 4 1.3 69.1 29.644 33.9 4 -- 70.0 30.045 11.0 4 100 -- --______________________________________
FIGS. 9 and 10 show the thermal expansion data for these three samples in comparison with uncoated EX-47 and conventionally coated EX-47. While all of samples 43-45 (curves c, d, and b, respectively) have lower expansions than the conventionally coated EX-47 (curve a) and have higher expansions than uncoated EX-47 (curve e), the more significant part of this data is the fact that the EX-47 honeycombs coated with either cerium acetate or the mixture of cerium acetate, alumina and ceria exhibit expansions much closer to the conventionally coated EX-47. This data illustrates the adverse effect of soluble inorganic constituents in the colloidal dispersion, which apparently more easily deposit, on heat treatment, particles of their corresponding oxide into the tips of microcracks to block the narrowing of them during thermal expansion of the EX-47 substrate, which is known to be a microcracked ceramic. As noted before, this adverse effect leads to thermal cracking. Thus, when applying this invention to washcoating of microcracked ceramic, it is beneficial to exclude soluble inorganic constituents from the washcoat colloidal dispersion.
Other colloidal dispersions that can be used in this invention are those of lanthania, yttria, and silica available from Nyacol Products Inc.
Besides using commercially available colloidal dispersions appropriate for this invention, existing washcoat materials that contain substantial amounts of colloidal particles can be milled to obtain the necessary smaller sized particles for entry into the pores.
The composition of the porous Fe-Al honeycombs mentioned herein is 23% Al and the balance Fe with less than 1% Mg plus incidental impurities. | A porous catalyst support which may be used in a catalytic converter for treating automotive exhaust gases. The support comprises a substrate having a multichannel structure of generally thin walls and washcoat particles of colloidal particle size mainly or wholly within the pores of the walls so as to increase open frontal area and reduce back pressure. Substrate is either ceramic or metal. In a ceramic substrate with microcracks in the walls, the washcoat colloidal dispersion is free of soluble inorganic constituents and the particles do not fill the microcracks so as to prevent undesirable increase in thermal expansion and corresponding decrease in thermal shock resistance. | 1 |
This application claims priority from provisional application No. 60/261,110 filed Jan. 12, 2001.
BACKGROUND OF THE INVENTION
This invention relates to compositions of matter classified in the art of organic chemistry as organic peroxides, more particularly as the peroxide derivatives of the hydroperoxide of 2-methyl-2,4 pentanediol(hexylene glycol hydroperoxide), specifically 4-(t-amylperoxy)-4-methyl-2-pentanol and higher branched chain alkyl analogs, their use in the molecular weight modification of polypropylene and also to articles made from such polypropylene which are suitable for use in regulated food, beverage, pharmaceutical and medical-device applications.
BACKGROUND ART
U.S. Pat. No. 3,144,436 teaches the use of organic peroxides for the molecular weight modification of polypropylene by reactive extrusion. A broad class of peroxides suitable for use in the process is defined in terms of a broad range of half-life temperatures and injection of solvent solutions of a peroxide into the melt zone of the extruder is the preferred method of operation. The broad class of peroxides defined does not enable one to select a peroxide which does not generate or only generates small amounts of t-butanol in practice, which can be used without solvents and which otherwise minimizes to an acceptable level safety hazards inherent in handling organic peroxides.
Over time, because of its safety in handling and decomposition temperature, one specific peroxide, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane (LUPEROX® 101), has become the industry standard for polypropylene modification.
While generally satisfactory from the viewpoint of efficiency, of being useable without solvent dilution and from the safe handling standpoint, this product is known to leave an amount of residual t-butanol in the extruded polypropylene which meets food grade standards but which for some uses is objectionable. Therefore, a substitute having similar safe handling without the need for solvents, roughly the same efficiency in actual use in the extrusion process for polypropylene molecular weight modification and which does not produce objectionable amounts of t-butanol as a decomposition product has long been sought by the industry.
An attempt to address this issue is shown in U.S. Pat. No. 4,707,524 which discloses the use of peroxides which do not decompose to t-butanol and which have a half-life in the range from about 1.0 to 10 hours at 128° C. for modification of the molecular weight of polypropylene. As shown by the actual data in the tables in that patent, however, LUPEROX 101 was far more efficient than either the 2,2 di(t-amyl)peroxy propane (LUPERSOL® 553) and 3,6,6,9,9-pentamethyl-3-n-propyl-1,2,4,5-tetraoxacyclononane (ESPERAL® 529) actually compared with it. The discussion of the background art at columns 2 and 3 of this patent may also be of interest in understanding the present invention.
EP 0853090 Al discloses the use of di-t-amyl peroxide as suitable for polypropylene molecular weight modification while avoiding the generation of t-butanol. However, di-t-amyl peroxide suffers from a very low flash-point that compromises safety and handling characteristics in polypropylene modification processes.
The majority of today's production processes require that the peroxide be mixed with solid polypropylene in a blender. Under such conditions, it is crucial that the peroxide have a high flash-point for safety. The flash-point of di-t-amyl peroxide is roughly 25° C. while the flash-point of LUPEROX 101 ranges from about 50° C. to 75° C. depending on quality. 4-(t-Amylperoxy)-4-methyl-2-pentanol also has a flash-point greater than 50° C. and can be used in similar fashion to LUPEROX 101 in current mixing equipment.
4-(t-Amylperoxy)-4-methyl-2-pentanol is among the hexylene glycol-derived perester and peroxide compounds generically disclosed in U.S. Pat. No. 3,236,872.
The compounds are stated to be useful in the crosslinking of substantially saturated polymers including polypropylene but no t-amyl derivatives were actually tested and crosslinking of polypropylene would increase molecular weight and is the exact opposite of the molecular weight reduction and variation narrowing which occurs during the normal polypropylene molecular weight modification process (lower molecular weight is equivalent to faster melt flow in viscosity measurements).
4-(t-Amylperoxy)4-methyl-2-pentanol has over the years found utility as a reactant or a reaction catalyst which made use of its hydroxy functionality for various purposes. Illustrations of these uses are contained in: U.S. Pat. Nos. 5,475,072; 5,494,988; and 5,489,699; Laerdere et al, Ann. Tech. Conf.—Soc. Plant. Eng. (1998); and Callais, Proc. Water-Borne High Solids Coat. Conf. (1990).
Nothing in any art known to applicants suggests that 4-(t-amylperoxy)-4-methyl-2-pentanol will have activity, on an equal active oxygen basis, approximating the efficiency of LUPEROX 101 in the modification of polypropylene while generating commercially acceptable levels of residual t-butanol in the modified polypropylene.
One other recent reference, U.S. Pat. No. 5,932,600 (and its related U.S. and European counterparts) teaches the use of cyclic ketone peroxides particularly methyl ethyl ketone cyclic trimer peroxide for polypropylene modification. The principal advantage of these products is that they do not produce t-butanol as a decomposition by-product. However, these peroxides suffer from excessively long half-lives and the required use of safety diluent. The long half-life is undesirable because it will lead to product quality problems (residual peroxide in resin) or lower productivity/higher resin color depending on the production changes made to avoid undecomposed peroxide in the resin (longer residence times or higher temperatures in the extruder). In addition, diluents are undesirable in at least some polypropylene grades because they may produce “smoking” or “dripping” in an end user's extruder. It has been reported that diluents are also undesirable for fiber or film grades where, for example, they may adversely affect the feel of the surface.
SUMMARY OF THE INVENTION
The invention provides in a first process aspect, a process for the molecular weight modification of polypropylene which comprises treating polypropylene with a molecular weight modifying effective amount of 4-(t-amylperoxy)-4-methyl-2-pentanol for a time and a temperature sufficient to induce decomposition of the 4-(t-amylperoxy)-4-methyl-2-pentanol and thereby modify the molecular weight of the polypropylene.
The first process aspect of the invention provides a process for the conversion of very high molecular weight, difficult to process polypropylene to low or moderate molecular weight, easy to process polypropylene at an efficiency approximately equal to the conversion efficiency of LUPEROX 101 at approximately equivalent active oxygen levels without the generation of commercially unacceptable levels of t-butanol, while minimizing the hazards such as those incurred in handling di-t-amylperoxide, the need of safety solvents or modifying process conditions to accommodate higher half-life initiators.
The invention provides in a first composition aspect, a non-toxic polypropylene containing composition adapted for the handling and packaging of foods, beverages, or pharmaceuticals, or for use in a medical devices comprising a polypropylene resin which has been molecular weight modified by the first process aspect of the invention and which contains less than 100 ppm (parts per million) t-butanol.
DETAILED DESCRIPTION
In practicing the processes of the invention to prepare the melt flow modified polypropylene resulting from their practice, conventional, well known, procedures for incorporating the peroxy compound into and reacting it with the polypropylene may be employed. These techniques are described in the previously cited references and no particular technique is considered particularly critical to the practice of the invention.
Conveniently, known amounts of peroxide are premixed with polypropylene flakes, powders or pellets containing conventional additives and/or stabilizers, preferably under an inert atmosphere (absence of molecular oxygen). The polypropylene contemplated as being modified by the invention includes copolymers with up to about 25% by weight ethylene. The peroxide material should be added to the polypropylene, pellets, flake or powder in concentrations of from 50 to 10,000 ppm by weight (molecular weight modifying amount). More desirable is from 100 to 2,000 ppm of peroxide. The components (polypropylene, peroxide and additives) may be premixed at room temperature or above and then in an extruder at temperatures not exceeding 550° F. (about 288° C.), or more desirably from 200 to 260° C., or the polypropylene powder, pellets or flakes and additives can be premixed at room temperature and fed concurrently with peroxide to an extruder, or all the ingredients can be preblended in a heated mixer, not exceeding 100° C. prior to adding to an extruder.
The mixture should be processed at a temperature of from about 350° F. (177° C.) to 550° F. (288° C.) (temperature sufficient to induce decomposition of the 4-(t-amylperoxy)-4-methyl-2-pentanol) for a time necessary to reduce the melt flow rate to the desired rate (which may be readily determined by a few pilot experiments by one of skill in the art). More particularly the present invention contemplates as a particular advantage its use at time and temperature profiles currently employed for LUPEROX 101, generally temperatures less than 240° C.
When 4-(t-amylperoxy)-4-methyl-2-pentanol is used in the above general procedure, no peroxide material remains in the polypropylene, and the amount of t-butanol contained in the peroxide is substantially less than the residual concentration left by LUPEROX 101 when used on an equal active oxygen basis.
Although the invention has been illustrated by the addition of the peroxide to the modification process as a master batch absorbed on polypropylene, one of skill in the art will understand that it may be used as a neat liquid injected directly into an early stage of the extrusion process, or as a master batch absorbed on an alternative, convenient carrier material.
Other materials contemplated as equivalent in the process and practice of the invention are: dihexylene glycol peroxide; 4-(t-hexylperoxy)-4-methyl-2-pentanol; 4-(t-octylperoxy)4-methyl-2-pentanol; 2-methyl-2-t-amylperoxy-4-pentanone; di-t-hexyl peroxide; di-t-octyl peroxide; the t-amyl, t-hexyl and t-octyl analogs of LUPEROX 101; mixed dialkyl peroxides such as t-amyl-t-hexyl peroxide and t-amyl-t-octyl peroxide; and mixtures thereof.
The following examples further illustrate the best mode contemplated by the inventors for the practice of their invention and should be construed as illustrative and not in limitation thereof.
EXAMPLES
In the following examples, Melt Flow Rate (MFR) was determined by the procedure of ASTM D-1238.
Half-life was determined by measuring the decomposition rate in the solvents or other medium shown.
Flash-point determinations were made using the small scale closed cup method (ASTM D3278).
Example 1
Comparison of Efficiency of Melt Flow Modification of Various Peroxides
A commercially available polypropylene random copolymer containing less than 5% by weight ethylene having an initial melt flow rate of 2 dg/min was treated in a 30 mm ZSK twin screw extruder having an essentially flat temperature profile (zone 1=210° C., zones 2 to 7=230° C.), at a feed rate of 200 grams per minute and at 300 RPM with equal active oxygen levels or A(O) (0.00081% A(O) or 5.08 meq/kg of polypropylene). The peroxide is added by first preparing a 2% by weight master batch of the neat liquid peroxide on polypropylene in particle form and then premixing with the polypropylene prior to addition to the extruder hopper.
The polypropylene is stabilized with 0.12 phr Irganox B225 [Ciba Chemicals Corporation, a blend of Irganox 1010, a hindered pnenolic antioxidant and Irgafos 168 (a phosphite heat stabilizer)] and 0.05 phr calcium stearate.
The resultant Melt Flow Rate (MFR) obtained from use of each peroxide in the above treatment is:
PEROXIDE
MFR (dg/min)
LUPEROX 101
37.8
2,2-di(t-amylperoxy)propane
24.3
di-t-amyl peroxide
36.3
4-(t-amylperoxy)-4-methyl-2-pentanol
39.1
This establishes that on an equal active oxygen basis the peroxide of the present invention is approximately as effective as LUPEROX 101 (the industry standard for efficiency) and di-t-amylperoxide in the melt flow modification of polypropylene. It also establishes that 2,2-di-(t-amylperoxy)propane is not as efficient in melt flow modification.
Example 2
Flash-point Comparisons
The flash-point is determined as described above.
PEROXIDE
FLASHPOINT (° C.)
LUPEROX 101 (92% assay)
49
LUPEROX 101 (95% assay)
78
di-t-amyl peroxide
25
4-(t-amylperoxy)-4-methyl-2-pentanol
>60° C.
(depending on preparation)
This establishes that 4-(t-amylperoxy)-4-methyl-2-pentanol has a flashpoint in the range of LUPEROX 101 and is superior to that of di-t-amylperoxide.
Example 3
Half-life Temperature (HLT) Comparisons
The half-life of the peroxides listed is determined as described above:
1 hr HLT (° C.)
1 hr HLT (° C.)
PEROXIDE
In dodecane
in polypropylene
LUPEROX 101
140
145
2,2-di(t-amylperoxy)propane
128
—
di-t-amyl peroxide
143
—
MEK cyclic trimer
—
158
4-(t-amylperoxy)4-methyl-2-
141
—
pentanol
This example demonstrates the close similarity of the half-life of 4-(t-amylperoxy)-4-methyl-2-pentanol to LUPEROX 101. This is contrasted to the significantly lower half-life of 2,2-di(t-amyperoxy)propane which makes it less efficient in polypropylene industrial processes.
Example 4
Comparison of Crosslinking Efficiency in Ethylene-co-Vinylacetate Copolymer
The crosslinking efficiency of di-t-amyl peroxide and 4-(t-amylperoxy)-4-methyl-2-pentanol was compared at equal active oxygen levels in ethylene-co-vinylacetate copolymers (EVA: EVATHANE 1020 VN-5-1, ATOFINA PETROCHEMICALS). Samples were prepared by absorbing the liquid peroxide into the EVA pellets at 40° C. for 1 to 3 hours in closed jars. Crosslinking efficiency was evaluated using an MDR 2000E cure rheometer at 1° of arc and three different cure temperatures: (175°, 180° and 195° C.). The maximum torque generated at the end of the cure (M H ) is recorded. M H increases with increased crosslink density and can, thus, be used as a convenient measure of peroxide efficiency in creating crosslinks.
The maximum torque results are shown in the Example 4 Table.
Example 4 Table
4-(t-amylperoxy)-4-
di-t-amyl peroxide at
methyl-2-pentanol at
A[O]phr
175° C.
180° C.
195° C.
175° C.
180° C.
195° C.
0.1
8.8
7.9
9.3
7.6
6.9
8.0
0.1
9.0
8.4
9.7
0.2
12.6
11.8
13.3
9.9
9.8
10.6
0.3
13.0
12.3
14.2
This demonstrates that 4-(t-amylperoxy)-4-methyl-2-pentanol is not an efficient crosslinking peroxide, contradicting the teachings of U.S. Pat. No. 3,236,872. Despite its poor crosslinking, the subject compound is efficient in polypropylene degradation or vis-breaking.
Example 5
Residual Decomposition Products in Polypropylene
In this example, samples of polypropylene modified by 4-(t-amylperoxy)-4-methyl-2-pentanol (designated “TAPMP” in the Example 5 Table) and LUPEROX 101 were compared for their content of residual decomposition products of the peroxides. Analysis was done on the following expected residuals: t-butanol, t-amyl alcohol, and hexylene glycol. Other very light residuals are expected (e.g. methane, ethane), but are quickly lost from the resin at the time of extrusion. The polypropylene was modified analogously to the procedure described in Example 1. The peroxide residuals in the polypropylene were determined by first extraction (in THF for t-butanol; in acetone for t-amyl alcohol and hexylene glycol) followed by GC analysis. The results were as follows:
Example 5 Table
t-butyl
t-amyl
Hexylene
Conc.
Conc.
MFR
alcohol
alcohol
Glycol
Peroxide
(ppm)
(% A[O])
(dg/min)
(ppm)
(ppm)
(ppm)
Luperox 101 (1)
581
0.0061
28.0 ± 0.5 (2)
60
n.d. (3)
n.d.
Luperox 101
775
0.0081
38.7 ± 1.1
70
n.d.
n.d.
TAPMP
775
0.0056
26.8 ± 1.0
30
4
n.d.
TAPMP
845
0.0061
28.8 ± 0.3
20
n.d.
n.d.
TAPMP
1126
0.0081
44.3 ± 0.9
40
5
n.d.
Detection limit
3
3
25
(1) Luperox 101 used at 95% assay; TAPMP used at 92% assay
(2) Reported error in MFR values is the standard deviation from three measurements
(3) n.d. - not detected; i.e. value is below the detection limit
From the data set given above it is evident that:
1. 4-(t-amylperoxy)-4-methyl-2-pentanol produces substantially less t-butanol than Luperox 101. Comparing at equal performance (i.e. equal melt flow rate), 4-(t-amylperoxy)-4-methyl-2-pentanol produces approximately ⅓ to ½ the amount of t-butanol.
2. The levels of t-butanol produced are significantly less than the FDA regulation maximum of 100 ppm [21 CFR 177.1520 (b)]
The subject matter which applicants regard as their invention is particularly pointed out and distinctly claimed as follows: | Molecular weight modification of polypropylene by 4-(t-amylperoxy)-4-methyl-2-pentanol and polypropylene so modified suitable for handling and packaging food, beverages and pharmaceuticals and for use in medical devices is disclosed. | 2 |
CROSS-REFERENCE
The invention described and claimed hereinbelow is also described in DE 10 2004 027 643.9, filed Jun. 5, 2004. This German Patent Application, whose subject matter is incorporated here by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The present invention relates to an electrical tool and also to a tool system.
Electrical tools are used in highly diverse applications. They are widespread as manually-guided electrical tools in highly diverse configurations depending on the intended purpose and site of application. Manually-guided electrical tools are designed either as mains-powered tools or as battery and/or rechargeable-powered tools. Electrical tools powered by rechargeables exist in configurations with permanently installed rechargeables and/or rechargeable packs, by way of which a compact design can be realized that is also extremely stable due to the fact that the housing design is typically closed. Electrical tools powered by rechargeables also exist in configurations with replaceable rechargeable packs.
Electrical tools with permanently installed rechargeables have the advantage that they are compact in size, since the cells can be placed in the housing in an optimum manner. The disadvantage of built-in cells, however, is that, when the rechargeable runs out, the operator must interrupt his work with the electrical tool for a long period of time to recharge the battery. Replacing damaged rechargeable cells is usually not economical and signals the end of the product service life. Rechargeables that are replaceable have the advantage, however, that a “dead” rechargeable pack can be replaced with a charged replacement rechargeable pack, thereby ensuring that work is interrupted only briefly. A defective rechargeable pack can be replaced very easily with another rechargeable pack.
The disadvantage of electrical tools with replaceable rechargeable packs is their large size and typically heavy weight resulting from the detachable connection that is required. The detachable connection between the rechargeable pack and the electrical tool furthermore results in additional housing volume, since rechargeable packs are inserted—either entirely or partially—into corresponding recesses in the housing of the electrical tool. This results in a double-wall construction, consisting of the wall of the housing of the electrical tool and the wall of the rechargeable pack to be inserted.
Electrical tools with replaceable rechargeable packs in particular exist in pistol shapes, for example, with which the rechargeable pack is attached as a separate component via a receptacle in the housing of the electrical tool on the lower end of the handle. The weight distribution and structural size are disadvantages in this case. Furthermore, electrical tools with rechargeable packs also exist as devices having a rod shape, in the case of which the replaceable rechargeable pack is housed in a housing extension aligned with the central longitudinal axis of the housing, the extension being configured as a handle part. With a few devices having a rod-shaped design, it is possible to vary the housing geometry using a joint between the motor part and the handle part.
The disadvantage of these rod-shaped configurations is the typically low rechargeable capacity, since the rod shape allows only relatively small rechargeable cells to be used, due to the limited installation space, in particular when replaceable rechargeable packs are used. The disadvantage of the joint-type design is its greater technical complexity, especially since it does not permit the realization of a housing geometry that is fixed reliably in position when force is applied.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an electrical tool as well as a tool system, which eliminates the disadvantages of the prior art.
In keeping with these objects and with others which will become apparent hereinafter, one feature resides, briefly stated in an electrical tool with an adjustable housing geometry, comprising a motor part; a handle part situated so that it is displaceable relative to said motor part via a connection; and a power supply block that is replaceable using a detachable connection, said power supply block being configured as said handle part, and said connection simultaneously forming said detachable connection.
The present invention has the advantage that the adjustable housing geometry is realized using a motor part and a handle part situated such that it is displaceable relative to said motor part via a connection, and power is supplied by a power supply block that is replaceable using a detachable connection, whereby the power supply block is configured as a handle part and the connection between motor part and handle part serves simultaneously as the detachable connection between the power supply block and the motor part. As a result, the power supply block is not housed in the handle part as a separate component, nor is it connected with the handle part, i.e., inserted therein. Instead, it is configured as the handle itself.
Due to a single-walled design according to the present invention, the double-wall configuration in particular can be eliminated. Different housing geometries are not achieved using a pivoting joint or the like, but rather using a different connection of the motor part to the handle part, whereby this connection serves simultaneously as the detachable connection for the power supply block.
According to a further development of the present invention, the power supply block is designed as a rechargeable block. The handle part is therefore composed of a replaceable rechargeable pack, so that, when the voltage in the rechargeable drops off, the entire handle is removed from the motor part and recharged, and another handle part, which is a rechargeable block, is attached to the motor part. The housing of the handle part is also the housing of the replaceable rechargeable pack.
According to another further development of the present invention, the detachable connection is designed as a coupling, in particular as a bayonet coupling. With an embodiment of this type, the handle part can be connected to the motor part very quickly, whereby an unambiguous attachment and locking geometry—and, ultimately, an unambiguous housing geometry—can be predetermined by the configuration of the coupling. The configuration as a bayonet coupling also offers the advantage that a small or large angle of rotation for detaching or attaching the handle part from or to the motor part can be selected depending on the requirements, and a simple, fast and defined coupling connection is enabled.
According to a preferred further development of the present invention, it is provided that the adjustable housing geometry is at least a rod shape, an offset rod (that is, a shape that could not be referred to as cylindrical in the strictest sense of the word), or an L shape. An L shape is largely understood to refer to a pistol shape, i.e., a housing geometry with which the housing central longitudinal axes of the motor part and the handle part form an angle that is not 90°, and, in particular, an angle that is between 90° and nearly 120°. This allows the handle part to be attached to the motor part in a manner that ensures optimal handling and controllability of the electrical tool for the desired application.
According to a further preferred embodiment of the present invention, it is provided that a connection surface of the connection forms an angle of approximately 45° with the housing central longitudinal axes of the motor part and the handle part. This makes it very easily possible to create a rod shape and an L shape using the two parts of the electrical tool. In one final position of the connection, the two connection surfaces abut each other—due to their 45° angle—such that, when together, they form an angle of nearly 90° and therefore create an L-shaped housing geometry. In another final position of the connection, the two connection surfaces abut each other such that they form an extended, rod-shaped housing geometry. Based on the axis through the geometric center point of the two connection surfaces, an angle of 180° is formed between these two final positions. This angle can be considered as the angle around which a coupling—that functions as a connection—snaps into place, displaced relative to the first final position.
According to a further embodiment of the present invention, the housing central longitudinal axes in the case of an L-shaped housing geometry form an angle of up to 120°. This configuration allows a pistol-shaped L-form of the housing geometry to be realized, which enables particularly good handling and power transfer from the operator to the electrical tool.
According to another further development of the present invention, the housing central longitudinal axes of the motor part and the handle part extend toward each other, offset and in parallel. The result, therefore, is not a continuous rod shape. Instead, the rod shape has an offset and/or right-angle bend in the region of the connection, which makes the electrical tool particularly easy to hold and handle.
According to a further embodiment of the present invention, the housing central longitudinal axes of the motor part and the handle part in the rod-shaped geometry form an angle of up to 30°. Accordingly, the rod shape has a slight U-bend in the region of the connection. As a result, good handling and force transfer is also obtained with a rod-shaped housing geometry, which is an advantage in particular in an unaccessible working environment with limited working space.
According to another further development of the present invention, the connection surface is configured as a connection plane and/or in a connection plane toward which a housing geometry rotational axis extends at a 90° angle through the geometric center point of the connection. If the final positions of the two components of the electrical tool, i.e., the motor part and the handle part, are rotated around this rotational axis, in particular by approximately 180°, a transition from the rod shape to the L shape is achieved. The housing geometry rotational axis is preferably also the rotational axis of the coupling that enables the motor part to be connected to the handle part. Various housing geometries can be predefined via offset coupling, which can be achieved, e.g., via a suitable arrangement of the coupling elements, i.e., in particular of the snap-in stages for the particular final positions.
According to another further development of the present invention, the housing central longitudinal axes of the motor part and the handle part each intersect the housing geometry rotational axis, whereby one intersection point is located at a distance from the connection plane and in the region of the motor part, and the other intersection point is located at a distance from the connection plane and in the region of the handle part. By way of this geometric configuration, it is possible to realize a simple displacement of the central longitudinal axes of the motor part and the handle part when they are joined in a rod shape.
According to another embodiment of the present invention, the angle at which the housing central longitudinal axes of the motor part and the handle part intersect the particular connection surfaces are not identical. Accordingly, the connection surface of the motor part and the handle part can each have a different angle relative to the particular component. Connections having different angles are obtainable as a result.
The present invention further proposes a tool system for providing an electrical tool according to one or more of the aforementioned embodiments, in which a plurality of different motor parts and at least one handle part are provided, whereby one motor part and one handle part configured as a power supply block form a single functional unit. Depending on the application, the operator can therefore select the associated motor part that is suitable for the intended application for use with the same handle, which is configured as a power supply block. In addition to a motor part designed as a screwdriver, a motor part can also be used that provides, e.g., a saw with a circulating, rotary oscillating motion or an oscillating stroking motion, a grinder with eccentric motion or rotary oscillating motion, a drill or a suction and/or blowing device. The operator can therefore easily switch from a screw application to a sawing application, whereby only one handle is needed. Costs and space are saved in particular as a result, since a complete machine is not needed for every application, but rather an appropriate motor part and a general-use handle part.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an electrical tool with an L-shaped housing geometry, and
FIG. 2 shows an electrical tool with an offset, rod-shaped housing geometry.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an electrical tool 1 . It is composed of two components 2 , namely a motor part 3 and a handle part 4 . Motor part 3 includes an electric motor 5 and a force coupling member 6 designed to receive the tool, both of which are located inside a housing 7 or on housing 7 of motor part 3 . A connection surface 9 is provided on side 8 of housing 7 diametrically opposed to force coupling member 6 . Said connection surface 9 forms a 45° angle with a housing central longitudinal axis 10 and is therefore slanted relative to the longitudinal orientation of housing 7 , and forms the termination of said housing 7 .
Handle part 4 includes a housing 11 . Its central longitudinal axis 12 forms a 45° angle with connection surface 13 facing motor part 3 . Connection surface 13 is the termination of housing 11 of handle part 4 that faces motor part 3 . Rechargeable cells 14 are located inside housing 11 of handle part 4 . Motor part 3 and handle part 4 are joined with each other via a connection 15 formed by connection surfaces 9 and 13 . Due to the fact that housing central longitudinal axes 10 , 12 of motor part 3 and handle part 4 form a 45° angle with connection surfaces 9 , 13 , an L-shaped housing geometry is created. The housing central longitudinal axes 10 and 12 of motor part 3 and handle part 4 therefore form an angle γ of 90°.
Connection surfaces 9 , 13 lie in or are parallel to a connection plane 16 , on which a housing geometry rotational axis 17 is perpendicularly located. Housing geometry rotational axis 17 passes through connection surfaces 9 , 13 at their geometric midpoints. Housing central longitudinal axes 10 , 12 both intersect housing geometry rotational axis 17 and form a 45° angle α and β, respectively, forming intersection points S 1 and S 2 . Intersection point S 1 is located inside handle part 4 and at a distance a from connection plane 16 . Intersection point S 2 is located inside motor part 3 and at a distance b from connection plane 16 .
Connection 15 is designed as a detachable connection 20 . This means that handle part 4 can be separated from motor part 3 at connection plane 16 and reattached thereto. Devices (not shown here) are provided for this purpose inside connection 15 (detachable connection 20 ) that enable a detachable, mechanical, non-positive connection between motor part 3 and handle part 4 and an electrical connection between rechargeable cells 14 located in handle part 4 and motor 5 located in motor part 3 . Detachable connection 20 is configured preferably as a coupling 18 , in particular as a bayonet coupling, thereby enabling decoupling of both components 2 from a given final position and, therefore, disconnection of motor part 3 and handle part 4 from each other at an angle of rotation, selected accordingly, around housing geometry rotational axis 17 , and enabling easy coupling and, therefore, connection of motor part 3 and handle part 4 by rotating in the reverse direction.
By designing handle part 4 as a power supply block, in particular as a rechargeable block 21 , handle part 4 not only enables handling in terms of holding the electrical tool and transferring force to it, but it also serves as the power supply. Due to the fact that handle part 4 can be separated from motor part 3 via detachable connection 20 , when rechargeable cells 14 become fully discharged, handle 4 can be replaced with another handle 4 with charged rechargeable cells 14 . It is also possible to use the same handle 4 with another motor part 3 designed for other types of work, i.e., in particular one with a force coupling member 6 designed for other tools (e.g., a sawing device instead of a screwing or drilling device). Due to the fact that handle part 4 itself contains rechargeable cells 14 , i.e., it is configured in entirety as a rechargeable block 21 , the housing need not have a double-wall construction, as is the case, for example, when replaceable rechargeables or replaceable rechargeable blocks are inserted into a housing.
FIG. 2 shows the same electrical tool 1 as in FIG. 1 . In deviation from the depiction in FIG. 1 , motor part 3 and handle part 4 are joined by connection 15 offset by 180° around housing geometry rotational axis 17 , resulting in the offset rod shape of the housing geometry. In this case as well, housing central longitudinal axes 10 , 12 of motor part 3 and handle 4 form 45° angles β and α, respectively, with housing geometry rotational axis 17 , resulting again in intersection points S 2 and S 1 . Intersection point S 1 is again located inside handle part 4 and at a distance a from connection plane 16 , and intersection point S 2 is located inside motor part 3 and at a distance b from connection plane 16 . In contrast to FIG. 1 , in which housing central longitudinal axes 10 , 12 form an angle of approximately 90°, housing central longitudinal axes 10 , 12 extend in parallel with each other in FIG. 2 . The parallel offset of the two housing central longitudinal axes 10 , 12 results in the offset rod shape. Coupling 18 can be configured such that handle part 4 and motor part 3 can be positioned relative to each other in different angular stages via housing geometry rotational axis 17 . This results in different housing geometries, from the offset rod shape shown in FIG. 2 to the L shape shown in FIG. 1 .
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 constructions differing from the types described above.
While the invention has been illustrated and described as embodied in an electrical tool and a tool system, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
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. | An electrical tool with an adjustable housing geometry has a motor part, a handle part situated so that it is displaceable relative to the motor part via a connection, and a power supply block that is replaceable using a detachable connection, the power supply block being configured as the handle part, and the connection simultaneously forming the detachable connection. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/149,244, filed Feb. 2, 2009, which is incorporated by reference in its entirety herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to tissue-supporting medical devices and drug delivery systems, and more particularly to expandable devices that are implanted within a body lumen of a living animal or human to support the organ, maintain patency and/or deliver drugs or agents.
[0004] 2. Summary of the Related Art
[0005] In the past, permanent or biodegradable devices have been developed for implantation within a body passageway to maintain patency of the passageway and/or locally deliver drug or agent. These devices are typically introduced percutaneously, and transported transluminally until positioned at a desired location. These devices are then expanded either mechanically, such as by the expansion of a mandrel or balloon positioned inside the device, or expand themselves by releasing stored energy upon actuation within the body. Once expanded within the lumen, these devices, typically referred to as stents, become encapsulated within the body tissue and remain a permanent implant.
[0006] Known stent designs include monofilament wire coil stents (U.S. Pat. No. 4,969,458); welded metal cages (U.S. Pat. Nos. 4,733,665 and 4,776,337); and, most prominently, thin-walled metal cylinders with axial slots formed around the circumference (U.S. Pat. Nos. 4,733,665, 4,739,762, and 4,776,337). Known construction materials for use in stents include polymers, organic fabrics and biocompatible metals, such as, stainless steel, gold, silver, tantalum, titanium, cobalt chromium and shape memory alloys such as Nitinol.
[0007] U.S. Pat. Nos. 4,733,665, 4,739,762, and 4,776,337 disclose expandable and deformable interluminal vascular grafts in the form of thin-walled tubular members with axial slots allowing the members to be expanded radially outwardly into contact with a body passageway. After insertion, the tubular members are mechanically expanded beyond their elastic limit and thus permanently fixed within the body. The force required to expand these tubular stents is proportional to the thickness of the wall material in a radial direction. To keep expansion forces within acceptable levels for use within the body (e.g., 5-10 atm), these designs must use very thin-walled materials (e.g., stainless steel tubing with 0.0025 inch thick walls). However, materials this thin are not visible on conventional fluoroscopic and x-ray equipment and it is therefore difficult to place the stents accurately or to find and retrieve stents that subsequently become dislodged and lost in the circulatory system.
[0008] Further, many of these thin-walled tubular stent designs employ networks of long, slender struts whose width in a circumferential direction is two or more times greater than their thickness in a radial direction. When expanded, these struts are frequently unstable, that is, they display a tendency to buckle, with individual struts twisting out of plane. Excessive protrusion of these twisted struts into the bloodstream has been observed to increase turbulence, and thus encourage thrombosis. Additional procedures have often been required to attempt to correct this problem of buckled struts. For example, after initial stent implantation is determined to have caused buckling of struts, a second, high-pressure balloon (e.g., 12 to 18 atm) would be used to attempt to drive the twisted struts further into the lumen wall. These secondary procedures can be dangerous to the patient due to the risk of collateral damage to the lumen wall.
[0009] In addition, many of the known stents display a large elastic recovery, known in the field as “recoil,” after expansion inside a lumen. Large recoil necessitates over-expansion of the stent during implantation to achieve the desired final diameter. Over-expansion is potentially destructive to the lumen tissue. Known stents of the type described above experience recoil of up to about 6 to 12% from maximum expansion.
[0010] Large recoil also makes it very difficult to securely crimp most known stents onto delivery catheter balloons. As a result, slippage of stents on balloons during interlumenal transportation, final positioning, and implantation has been an ongoing problem. Many ancillary stent securing devices and techniques have been advanced to attempt to compensate for this basic design problem. Some of the stent securing devices include collars and sleeves used to secure the stent onto the balloon.
[0011] Another problem with known stent designs is non-uniformity in the geometry of the expanded stent. Non-uniform expansion can lead to non-uniform coverage of the lumen wall creating gaps in coverage and inadequate lumen support. Further, over expansion in some regions or cells of the stent can lead to excessive material strain and even failure of stent features. This problem is potentially worse in low expansion force stents having smaller feature widths and thicknesses in which manufacturing variations become proportionately more significant. In addition, a typical delivery catheter for use in expanding a stent includes a balloon folded into a compact shape for catheter insertion. The balloon is expanded by fluid pressure to unfold the balloon and deploy the stent. This process of unfolding the balloon causes uneven stresses to be applied to the stent during expansion of the balloon due to the folds causing the problem non-uniform stent expansion.
[0012] It is desirable to provide flexibility in stents to facilitate introduction of the stent into vessels that are difficult to reach. Often, however, characteristics of the stent that provide longitudinal flexibility, which is desirable when introducing the stent into the vessel, can be disadvantageous in terms of keeping the stent in an expanded condition. For example, stents formed from interconnected rings with closed cell structures or generally diamond-shaped cells are typically less flexible than stents formed from one or more helices, but are usually more uniformly and consistently expandable than helical stents. It is desirable to provide a stent with substantial flexibility that is adapted to be expanded in a uniform and consistent fashion.
[0013] In WO 03/015664, which is incorporated by reference, a stent having interconnected struts with openings for drug delivery is disclosed. However, elements for bridging the struts are generally thinner and spaced further apart than the struts. Thus, for such drug-eluting stents, the bridging element can provide an area of reduced or less consistent drug delivery. It is desirable to provide a drug-eluting stent in which areas of reduced or less consistent drug delivery can be reduced.
SUMMARY OF THE INVENTION
[0014] The present invention relates to tissue-supporting medical devices and drug delivery systems, and more particularly to expandable, devices that are implanted within a body lumen of a living animal or human to support the organ, maintain patency and/or deliver drugs or agents.
[0015] In one embodiment of the invention the flexible stent has proximal and distal end portions and a cylindrical shape, with luminal and abluminal surfaces and a thickness there between. The cylindrical shape defines a longitudinal axis. The flexible stent comprises a helical section having of a plurality of longitudinally oriented strut members and a plurality of circumferentially oriented hinge members connecting circumferentially adjacent strut members to form a band. The band is wrapped about the longitudinal axis in a substantially helical manner to form a plurality of helical windings. Each strut member has a substantially rectangular shape with opposing longitudinally oriented long sides and opposing circumferentially oriented short sides. Each hinge member is connected to the strut members along the short side of each strut member. At least one connector member extends between longitudinally adjacent helical windings of the band and is attached on each end to the short side of a strut member. The connector member not attached to the hinge members.
[0016] In another embodiment of the invention the tubular flexible stent has a cylindrical shape with proximal and distal end portions and defining a longitudinal axis. The flexible stent comprises a helical section having of a plurality of longitudinally oriented strut members and a plurality of circumferentially oriented hinge members connecting circumferentially adjacent strut members to form a band. The band is wrapped about the longitudinal axis in a substantially helical manner to form a plurality of helical windings. The helical section comprises a proximal transition zone, a distal transition zone, and a central zone there between, each having a pitch and an incident angle, wherein the pitch and incident angle of the proximal and distal transition zones are different than the central zone.
[0017] In still another embodiment of the present invention, the tubular flexible stent has a cylindrical shape with proximal and distal end portions and defining a longitudinal axis. The flexible stent comprises a helical section having of a plurality of longitudinally oriented strut members and a plurality of circumferentially oriented hinge members connecting circumferentially adjacent strut members to form a band. The band is wrapped about the longitudinal axis in a substantially helical manner to form a plurality of helical windings. The helical section further comprises strings formed from groups of contiguous strut members and hinge members organized to form a string pattern, wherein contiguous strings along the band have different string patterns.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A is a perspective view of a flexible stent in the expanded (deployed) state according to one embodiment of the present invention.
[0019] FIG. 1B is a perspective view of a flexible stent in the crimped state according to one embodiment of the present invention.
[0020] FIG. 1C is a perspective view of a flexible stent in the “as cut” (manufactured) state according to one embodiment of the present invention.
[0021] FIG. 2 is plan view of a flexible stent according to one embodiment of the present invention.
[0022] FIG. 3 is an exploded plan view of the flexible stent of FIG. 2 .
[0023] FIG. 4A is a close-up plan view of a strut from a flexible stent according to one embodiment of the present invention.
[0024] FIG. 4B is a close-up plan view of a strut from a flexible stent according to one embodiment of the present invention.
[0025] FIG. 4C is a close-up plan view of a strut from a flexible stent according to one embodiment of the present invention.
[0026] FIG. 4D is a close-up plan view of an organically optimized strut from a flexible stent according to one embodiment of the present invention.
[0027] FIG. 5A is a close-up plan view of a ductile hinge from a flexible stent according to one embodiment of the present invention.
[0028] FIG. 5B is a close-up plan view of a ductile hinge from a flexible stent according to one embodiment of the present invention.
[0029] FIG. 6A is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0030] FIG. 6B is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0031] FIG. 6C is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0032] FIG. 6D is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0033] FIG. 6E is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0034] FIG. 6F is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0035] FIG. 6G is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0036] FIG. 6H is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0037] FIG. 6I is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0038] FIG. 6J is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0039] FIG. 6K is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0040] FIG. 6L is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0041] FIG. 6M is a close-up plan view of a circular hinge region from a flexible stent according to one embodiment of the present invention.
[0042] FIG. 7 is a close-up plan view of an index hinge from a flexible stent according to one embodiment of the present invention.
[0043] FIG. 8 is a close-up plan view of the central zone depicted in FIG. 3 to illustrate the incident angle of the helical band (wrap).
[0044] FIG. 9A is a close-up plan view of a connector strut string that is part of the repeating pattern that forms the central zone of the flexible stent illustrated in FIG. 2 according to one embodiment of the present invention.
[0045] FIG. 9B is a close-up plan view of a free strut string that is part of the repeating pattern that forms the central zone of the flexible stent illustrated in FIG. 2 according to one embodiment of the present invention.
[0046] FIG. 10 is plan view of a flexible stent according to one embodiment of the present invention.
[0047] FIG. 11 is an exploded plan view of the flexible stent of FIG. 10 .
[0048] FIG. 12 is plan view of a flexible stent according to one embodiment of the present invention.
[0049] FIG. 13 is an exploded plan view of the flexible stent of FIG. 12 .
[0050] FIG. 14 is plan view of a flexible stent according to one embodiment of the present invention.
[0051] FIG. 15 is an exploded plan view of the flexible stent of FIG. 14 .
[0052] FIG. 16 is a close-up plan view of the free strut string and the connector strut string that are part of the repeating pattern that form the central zone of the flexible stent illustrated in FIG. 14 according to one embodiment of the present invention.
[0053] FIG. 17 is a close-up plan view of the free strut string and the connector strut string that are part of the repeating pattern that form the central zone of the flexible stent illustrated in FIG. 12 according to one embodiment of the present invention.
[0054] FIG. 18 is a close-up plan view of the free strut string and the connector strut string that are part of the repeating pattern that form the central zone of the flexible stent illustrated in FIG. 10 according to one embodiment of the present invention.
[0055] FIG. 19 is a plan view of a flexible stent without depots according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0056] The stent of the present invention is very flexible and deliverable, while still providing sufficient radial strength to maintain vessel patency. The stent can be formed in any suitable manner, such as by laser cutting a tube made from a suitable material, including cobalt chromium alloys, stainless steel alloys or nickel titanium alloys. Although coronary flexible stents of the present invention are disclosed to illustrate one embodiment of the present invention, one of ordinary skill in the art would understand that the disclosed invention can be equally applied to other locations and lumens in the body, such as, for example, vascular, non-vascular and peripheral vessels, ducts, and the like.
[0057] In accordance with one aspect of the present invention, the flexible stent is designed to be crimped down to a reduced diameter and percutaneously delivered through a body lumen to a target site by a delivery catheter. The target site may be, for example, a cardiac artery. Once deployed the flexible stent functions to maintain vessel patency and, if desired, deliver controlled amounts of drug or agent.
[0058] Perspective views of a flexible stent 100 in the expanded (deployed), crimped, and “as cut” or manufactured state according to one embodiment of the present invention are illustrated in FIGS. 1A , 1 B and 1 C respectively. The stent 100 has an “as cut” diameter when first manufactured of D 3 , as illustrated in FIG. 1C . The stent 100 is crimped down to a first diameter D 1 , illustrated in FIG. 1B , for insertion into a patient and navigation through the vessels, and a second diameter D 2 , illustrated in FIG. 1A , for deployment into the target area of a vessel, with the second diameter being greater than the first diameter.
[0059] The flexible stent 100 is cylindrical with a tubular configuration of structural elements having luminal and abluminal surfaces, 101 , 102 respectively, and thickness (wall thickness) “T” there between. The cylindrical shape of the stent defines a longitudinal axis 103 and has proximal and distal ends portions 104 , 105 respectively.
[0060] The terms proximal and distal are typically used to connote a direction or position relative to a human body. For example, the proximal end of a bone may be used to reference the end of the bone that is closer to the center of the body. Conversely, the term distal can be used to refer to the end of the bone farthest from the body. In the vasculature, proximal and distal are sometimes used to refer to the flow of blood to the heart, or away from the heart, respectively. Since the flexible stent described in this invention can be used in many different body lumens, including both the arterial and venous system, the use of the terms proximal and distal in this application are used to describe relative position in relation to the direction of delivery. For example, the use of the term distal end portion in the present application describes the end portion of the stent first introduced into the vasculature and farthest from the entry point into the body relative to the delivery path. Conversely, the use of the term proximal end portion is used to describe the back end portion of the stent that is closest to the entry point into the body relative to the delivery path.
[0061] FIGS. 2 and 3 are plan views of the stent 100 in a partially expanded condition according to one embodiment of the present invention. As used herein, the term plan view is understood to be a two-dimensional (2-D) view of a stent that has been cut along the longitudinal axis and laid out flat, such that the bottom edge could be wrapped around a cylinder and connected to the top edge.
[0062] The stent 100 architecture generally includes ring-like end sections 106 , 107 along the proximal and distal ends, 104 , 105 respectively, and a helical interior section 108 there between. The helical interior section 108 further includes a central zone 111 and proximal and distal transition zones 109 , 110 respectively. The transition zones 109 , 110 transition between the central zone 111 and the proximal and distal ring-like end sections 106 , 107 . FIG. 3 is an exploded plan view of the stent 100 illustrating the different sections and zones.
[0063] The stent 100 includes a plurality of longitudinally oriented struts 113 connected by a series of circumferentially oriented ductile hinges 114 . Circumferentially adjacent struts 113 are connected at opposite ends by the hinges 114 in a substantially S or Z shaped sinusoidal-like pattern to form a band. Flexible connectors 112 are distributed throughout the stent 100 architecture for structural stability under a variety of loading conditions. The stent design illustrated in FIGS. 1 through 3 have a flexible connector geometry, however, a wide variety of connector geometries are contemplated. See generally FIGS. 6B through 6H .
[0064] The region in the stent 100 where the interior helical section 108 is first connected to the ring-like end sections 106 , 107 is referred to as an anchor point, and the hinge 114 at that location is referred to as an “anchor hinge”. This “take off” point may vary based on design constraints. Additionally the incident angle, strut thickness, strut width, hinge width, hinge length, depot position and size, and connection length may vary based on optimization and design constraints.
[0065] As used herein the terms longitudinally, circumferentially and radially oriented are known to denote a particular direction relative to the stent 100 and the longitudinal axis 103 . A longitudinally oriented member is directed, end to end (along its axis), generally in the direction of the longitudinal axis 103 . It obvious after reviewing the figures that the longitudinal direction of the strut 113 is closer to being parallel to the longitudinal axis when the stent 100 is in the crimped state as illustrated in FIG. 1B , then when the stent 100 is in the expanded, deployed state as illustrated in FIG. 1A . Regardless, in each case, the strut 113 is considered to be longitudinally oriented as the axis of the strut 113 is substantially oriented in the same direction as the longitudinal axis. A circumferentially oriented member, such as hinge 114 , is directed substantially along the circumference of the tubular stent 100 . Similarly, a radial direction or radially oriented is along a radius that extends generally from the longitudinal axis outward to the circumference of the tubular stent 100 in cross-section.
[0066] FIGS. 4A , 4 B and 4 C illustrate typical struts 113 according to various embodiments of the present invention. Each strut 113 is a substantially rectangular shaped member having longitudinally extending long sides 115 and circumferentially extending short sides 116 . Opposing long sides 115 and short sides 116 may be substantially parallel to one another forming a near perfect rectangular as depicted by the strut 113 illustrated in FIG. 4A , or may be canted or angled to form a tapered strut 113 as depicted by the strut 113 illustrated in FIG. 4B . As can be seen in FIGS. 4A and 4B , the hinges 114 attached to the strut 113 along the short sides 116 of the strut, however the width of the strut (length of the short side 116 ) is greater than the width of the hinge 114 in a preferred embodiment of the invention. As illustrated in FIG. 4B , the flexible connectors 112 connect to the struts 113 along the short sides 116 of the struts 113 , but do not connect to the hinges 114 .
[0067] FIG. 4C represents a unique strut 113 that may be found in some embodiments of the stent 100 design. The strut 113 depicted in FIG. 4C is characterized by two connection points to circular hinges 114 (as hereinafter described) and two connection points to flexible connectors 112 . This strut 113 is widest at the proximal and distal ends (at the connection points of the hinges 114 and flexible connectors 112 ) and tapers to its minimum width near the mid-point in the longitudinal strut 113 length. That is to say the length of the short side 116 of the strut 113 depicted in FIG. 4C is greater than the width near the longitudinal center point of the strut 113 .
[0068] The struts 113 may have one or more depots 117 for containing at least one agent. The depots 117 may be any form of recess, channel, hole or cavity capable of holding an agent, but are preferably through holes precisionly formed through the stent 100 . In a preferred embodiment, the through hole passes through the strut from the luminal to abluminal surface. This preferred configuration may allow an agent or agents to be delivered both in a radially inward and outward direction along the luminal and abluminal sides of the stent 100 . In addition, the depots 117 may be filled with a polymer inlay, either alone or containing one or more agents in solution or otherwise. Various depots 117 in the same stent may be filled with the same or different agents, and may have the same or different concentrations of agents. Any individual depot 117 may be filed with one or multiple agents, and the agents may be separated by a barrier layer. The barrier layer may be position in various configurations in the depot 117 as need to separate the agents. In a preferred embodiment, the barrier layer is oriented parallel to the luminal stent surface.
[0069] The struts 113 may have symmetrically sized depots 117 as illustrated in FIGS. 4A-4C , or may include organically optimized depots 117 as illustrated in FIG. 4D . Organically optimized depots 117 are designed to maximize the depot 117 volume for any given strut 113 size, while reducing the stress state of the entire feature through the addition or removal of material critical to maintaining structural integrity upon stent 100 expansion.
[0070] As the term is used herein, the agent can be any therapeutic or pharmaceutic agent or drug, including the following: antiproliferative/antimitotic agents including natural products such as vinca alkaloids (i.e. vinblastine, vincristine, and vinorelbine), paclitaxel, epidipodophyllotoxins (i.e. etoposide, teniposide), antibiotics (dactinomycin (actinomycin D) daunorubicin, doxorubicin and idarubicin), anthracyclines, mitoxantrone, bleomycins, plicamycin (mithramycin) and mitomycin, enzymes (L-asparaginase which systemically metabolizes L-asparagine and deprives cells which don't have the capacity to synthesize their own asparagine; antiproliferative/antimitotic alkylating agents such as nitrogen mustards (mechlorethamine, cyclophosphamide and analogs, melphalan, chlorambucil), ethylenimines and methylmelamines (hexamethylmelamine and thiotepa), alkyl sulfonates-busulfan, nitrosoureas (carmustine (BCNU) and analogs, streptozocin), trazenes—dacarbazinine (DTIC); antiproliferative/antimitotic antimetabolites such as folic acid analogs (methotrexate), pyrimidine analogs (fluorouracil, floxuridine, and cytarabine), purine analogs and related inhibitors (mercaptopurine, thioguanine, pentostatin and 2-chlorodeoxyadenosine {cladribine}); platinum coordination complexes (cisplatin, carboplatin), procarbazine, hydroxyurea, mitotane, aminoglutethimide; hormones (i.e. estrogen); Anticoagulants (heparin, synthetic heparin salts and other inhibitors of thrombin); fibrinolytic agents (such as tissue plasminogen activator, streptokinase and urokinase), aspirin, dipyridamole, ticlopidine, clopidogrel, abciximab; antimigratory; antisecretory (breveldin); anti-inflammatory: such as adrenocortical steroids (cortisol, cortisone, fludrocortisone, prednisone, prednisolone, 6α-methylprednisolone, triamcinolone, betamethasone, and dexamethasone), non-steroidal agents (salicylic acid derivatives i.e. aspirin; para-aminophenol derivatives i.e. acetominophen; Indole and indene acetic acids (indomethacin, sulindac, and etodalac), heteroaryl acetic acids (tolmetin, diclofenac, and ketorolac), arylpropionic acids (ibuprofen and derivatives), anthranilic acids (mefenamic acid, and meclofenamic acid), enolic acids (piroxicam, tenoxicam, phenylbutazone, and oxyphenthatrazone), nabumetone, gold compounds (auranofin, aurothioglucose, gold sodium thiomalate); immunosuppressive: (cyclosporine, tacrolimus (FK-506), sirolimus (rapamycin), azathioprine, mycophenolate mofetil); angiogenic: vascular endothelial growth factor (VEGF), fibroblast growth factor (FGF); nitric oxide donors; anti-sense oligo nucleotides and combinations thereof.
[0071] One or more agents may be distributed in one or more of the depots 117 , along at least a portion of the luminal or abluminal stent 100 surfaces, or any combination of depots and/or stent surfaces. In a preferred embodiment, the agent is distributed in the depots 117 only, such that the exposed agent surface area is limited to the cross-sectional area of the depot opening in the stent 100 surface (luminal, abluminal or both). This design allows for agent delivery from the stent 100 having a surface area upon insertion into the patient that is substantially bare metal. In a preferred embodiment, the exposed bare metal surface area of the stent 100 is between 40 and 95 percent upon insertion of the stent 100 into a patient, and is most preferably approximately 75 percent bare metal upon insertion of the stent 100 into a patient. That is, the surface area of the stent 100 is approximately 25 percent agent and approximately 75 percent bare metal. As the agent is released, the stent 100 becomes a purely bare metal stent.
[0072] In a preferred embodiment, the depots 117 are distributed nearly uniformly throughout the strut pattern to provide a consistent agent dosage per unit surface area of the deployed stent 100 independent of the diameter or length of the stent used. The struts 113 may be of varying lengths, incident angle, depot configuration, and widths as needed to meet the product design.
[0073] Ductile hinges 114 are used as the connection element between two circumferentially adjacent struts 113 . There are two types of ductile hinges 114 found in stent 100 . FIGS. 5A and 5B illustrate the two typical ductile hinges found in one embodiment of the present invention. FIG. 5A represents a single “free hinge” 114 a that connects two circumferentially adjacent struts 113 . In a preferred embodiment, this free hinge 114 a is “C” shaped and is substantially symmetric about reference line “A” drawn though the apex point on the curved section. FIG. 5B represents a ductile hinge 114 b that connects two circumferentially adjacent struts 113 , where one of the struts is further connected to a flexible connector 112 . This ductile hinge 114 b is more circular in shape than the “C” shaped free hinge 114 a disclosed in FIG. 5A , and is sometimes referred hereto as a “circular hinge” 14 b . Although free hinges 114 a and connector hinges 114 b are identified separately here, they are sometimes generally both referred to as ductile hinges 114 . The regions surrounding the circular hinge 14 b is referred to as a circular hinge region. While the flexible connector 112 and circular ductile hinge 114 b both connect to the same short side 116 of the strut 113 in the circular hinge region, they are not connected to one another.
[0074] FIG. 6A provides greater detail of the “circular hinge region” 118 that serves as a connection point between two strut pairs on adjacent windings of the helical section 108 . This hinge region 118 includes several components, and provides a ductile region in between circumferentially adjacent struts 113 that form a strut pair, while providing the necessary connectivity between longitudinally adjacent strut pairs by the flexible connector 112 . When combined, the longitudinally adjacent strut pairs and interconnecting flexible connector 112 create regions known as “quad hinge regions”. These regions are comprised of four struts that are directly or indirectly connected through the circular hinges 114 b and flexible connectors 112 . The incident angle, hinge 114 b width, degree of taper, length, and hole pattern are subject to change based on the stents intended design, the location of the feature and stent performance optimization. FIGS. 6B through 6M illustrated various connectors 112 that can be use to connect adjacent strut pairs in the circular hinge region 118 .
[0075] FIG. 7 illustrates another key stent attribute important during the manufacturing process of the stent 100 . The encircled ductile hinge 114 is known as the “index hinge”. This “index hinge” is characterized by longer strut 113 lengths, which causes the ductile hinge or strut 113 head to protrude beyond the plane of the strut 113 heads on the remaining struts within the sinusoidal end ring. For ease of illustration, reference line A has been drawn perpendicular to the longitudinal axis 103 and tangent to the curved surfaces of both the hinges 114 above and below the index hinge. Reference line B has been drawn perpendicular to the longitudinal axis 103 and tangent to the curved surface of the hinge 114 representing the index hinge. The distance between reference lines A and B along the longitudinal axis is the offset provided by the index. This offset serves as a reference point to help determine the orientation of the stent 100 . The “index hinge” may occur at any location along the proximal and distal ring-like end sections 106 , 107 .
[0076] Generally speaking, the ductile hinges 114 are deformable elements that are substantially thinner in width than the surrounding struts 113 . This allows the ductile hinges 114 to sustain plastic deformation while still remaining flexible in the deformed state. The struts 113 are therefore much stiffer than the ductile hinges 114 , and thus do not experience any plastic deformation during stent expansion. The struts 113 essentially rotate as rigid bodies, while the ductile hinges 114 are designed to the bear the plastic strains associated with stent expansion. As a result, the depots 117 in the struts 113 are shielded from undue stress during expansion that may cause damage or dislodgement of the agents and/or polymer inlays. The depots 117 are ideally in a stress-free state throughout the stent deployment process.
[0077] In a preferred embodiment of the present invention, the ductile hinges 114 are optimized, through the use of width tapering, such that they offer sufficient radial stiffness to the stent 100 while simultaneously ensuring that peak plastic strains at full expansion do not exceed the strain carrying capability of the material. This width tapering is optimized, for each hinge 114 type, to achieve a smooth and uniform distribution of plastic strains along the length of the ductile hinge 114 . By smoothing the strain distribution and thus eliminating strain concentrations in the ductile hinge 114 , the width, and thereby stiffness, is maximized. Maximizing the stiffness of the ductile hinge 114 is advantageous in providing radial stiffness and fatigue durability for the stent 100 .
[0078] In general the width of the tapered ductile hinge 114 gradually increases while approaching the root of the hinge 114 , where the hinge 114 meets an abrupt transition into the wider strut 113 (or stiffer structure). This prevents plastic strains from concentrating at the roots of the hinges since the tapered hinge root is stiffer and therefore distributes plastic strain to the central portion of the hinge 114 . The central portion of the ductile hinge 114 , which encompasses the apex of the curve, generally has a uniform width.
[0079] Turning again to FIGS. 2 and 3 , the ring-like end sections 106 , 107 include a plurality of circumferentially arranged, longitudinally oriented strut members 113 connected at opposite ends by a plurality of circumferentially oriented ductile hinges 114 in a substantially sinusoidal S or Z shaped pattern so as to form the band into an endless ring. In the illustrated embodiment, the end sections 106 , 107 are formed from struts 113 of varying length as needed optimize the stent design and provide the necessary geometry for the connection at the anchor point where the interior helical section 108 is first connected to the ring-like end sections 106 , 107 .
[0080] Between the ring-like end sections 106 , 107 lies the interior helical section 108 of the stent 100 , where the band of sinusoidally arranged struts 113 and hinges 114 follow a helical path. The helical band of the interior section 108 is achieved by arranging the struts 113 in a repeating pattern of alternating short and long lengths. The helical interior section 108 may be further divided into proximal and distal transition zone 109 , 110 respectively, and a central zone 111 .
[0081] The central zone 111 comprises strings (collections of elements) formed from groups of contiguous strut members 113 and hinge members 114 organized to form a string pattern. In one embodiment of the invention, contiguous strings have different string patterns and repeating strings are geometrically symmetric to form a repeating central pattern. In a preferred embodiment of the invention, the repeating central pattern consists of two different repeating strings. The central zone 111 therefore has a constant pitch and incident angle.
[0082] As used herein the term pitch is understood to mean the number of sinusoidal turns over a given area. This is similar nomenclature to the diametral pitch of a gear. The greater the pitch, the greater the number of sinusoidal turns, i.e. the greater number of struts 113 and ductile hinges 114 , will be found per wrap as the sinusoidal band winds about the longitudinal axis 103 . This creates a very dense pattern of struts 113 and hinges 114 . Conversely, the smaller the pitch, the smaller number of sinusoidal turns, and thus the smaller number of struts 113 and hinges 114 will be found per wrap as the sinusoidal band winds about the longitudinal axis 103 . The term incident angle refers specifically to the helical winding section of the stent 100 and is understood to mean the angle at which the sinusoidal band makes (wraps) with the longitudinal axis.
[0083] FIG. 8 is a close up 2 dimensional view of the central zone 111 depicted in FIG. 3 . A first reference line “A” has been drawn parallel to the longitudinal axis 103 . A second reference line “B” has been drawn to represent the direction of the sinusoidal band. The incident angle (a) is the angle between reference line A and reference line B.
[0084] FIGS. 9A and 9B illustrate the two strut strings that are part of the repeating pattern that form the central zone 111 of the stent 100 according to one embodiment of the present invention. Referring to FIGS. 3 , 8 , 9 A and 9 B, the central zone 111 starts at the proximal end of the distal transition zone 110 with a free strut string 119 illustrated in FIG. 9B . The illustrated free strut string 119 includes a long three depot strut 113 connected on each end to a short two depot strut 113 by a free hinge 114 a . The free strut string 119 is attached on its proximal end to the distal end of a connector strut string 120 . The connector strut string 120 includes a connector hinge 114 b at its proximal and distal ends, and an alternating arrangement of three long (three depot) struts 113 and two short (two depot) struts 113 connected by free hinges 114 a . This pattern of alternating free strut strings 119 and connector strut strings 120 continue until the central zone 111 meets the proximal transition zone 109 . The embodiment illustrated in FIG. 3 has a central zone that includes five free strut strings 119 and four connector strut strings 120 . The length of the stent 100 can be changed by adding or shortening the central zone 111 , i.e. by adding or removing free strut strings 119 or connector strut strings 120 as necessary to maintain the repeating pattern, while maintaining the proximal and distal transition zones 109 , 110 , and proximal and distal ring-like end section 106 , 107 as disclosed.
[0085] The proximal and distal transition zones 109 , 110 are sections of variable pitch, and in which there is no repeatability or symmetry. The proximal and distal transition zones 109 , 110 are constructed so as to afford a gradual decrease in pitch in transitioning between the central zone 111 and the proximal and distal ring-like end sections 105 , 107 . The proximal and distal transition zones 109 , 110 are connected to the proximal and distal ring-like end section 106 , 107 , respectively, by a connecting geometry called an anchor hinge.
[0086] The stent 100 designs depicted in the aforementioned figures are known as an open cell design, meaning that connectors between longitudinally adjacent windings of sinusoidal elements occur only intermittently through the structure rather than spanning every longitudinally adjacent hinge 114 or strut 113 . A design in which every longitudinally adjacent hinge or strut is connected is known as a closed cell design. An open-celled architecture is generally more flexible than a closed-cell architecture.
[0087] As previously described, the general architecture of the stent 100 includes a helical interior section 108 with ring-like end sections 106 , 107 at each end, and connectors 112 distributed through the architecture for structural stability under a variety of loading conditions. The helical interior section 108 may be further separated into a central zone 111 having a constant pitch and incident angle, and proximal and distal transition zones 109 , 110 respectively. This general architecture remains the same for various stents of different sizes; however, the geometry and pattern of the elements (struts, hinges and flex connectors) may change as need to adapt to various desired stent diameters.
[0088] FIGS. 10 through 15 illustrate various embodiments of the stent designs for different diametrically size stents. FIGS. 10 , 12 and 14 are two-dimensional plan views, similar to FIG. 2 , illustrating stents 200 , 300 , 400 , respectively, of different sizes and patterns. FIGS. 11 , 13 and 15 are exploded plan views, similar to FIG. 3 , of the stents 200 , 300 , 400 , respectively, illustrating the different sections and zones. For ease of illustration, like reference numerals have been assigned to like elements of the stent 100 , and it is understood that the description of elements related to stent 100 applies equally to like elements in stents 200 , 300 and 400 .
[0089] Each stent pattern design is customized to target optimal results based on the treatment of the stent's intended target vessel. FIGS. 10 and 11 represents one embodiment of a stent 200 intended for extra small diameter target vessel lesions. The extra small diameter stent family has been optimized for very small vessel diameters via several design features, and is meant to be fabricated from a smaller diameter tubing material.
[0090] The current embodiment for an extra small stent includes sinusoidal proximal and distal ring-like end sections 206 , 207 comprised of ten struts 213 in each ring-like end sections 206 , 207 . Between the ring-like end sections 206 , 207 lies the interior helical section 208 of the stent 200 , where the sinusoidal arrangement of struts 213 and hinges 214 follow a helical path. The helical path of the interior section 208 is achieved by arranging the struts 213 in a repeating pattern of alternating short and long lengths to form a band. There are nine struts 213 per winding in each the interior bands. The fewer number of struts allows for increased stent performance while maintaining critical processing parameters. The helical interior section 208 may be further divided into proximal and distal transition zones 209 , 210 respectively and a central zone 211 as illustrated in FIG. 11 .
[0091] The central zone 211 consists of repeating strut strings, or collections of struts, which are geometrically symmetric to form a repeating pattern in the band. The central zone 211 therefore has a constant pitch and incident angle. The repeating interior pattern is comprised of two 3-strut patterns that alternate to form the 9-strut repeating interior pattern.
[0092] FIG. 18 illustrates the two strut strings 219 , 220 that are part of the repeating pattern from the central zone 211 of the stent 200 according to one embodiment of the present invention. Referring to FIGS. 10 , 11 and 18 , the central zone 211 starts at the distal end of the proximal transition zone 209 with a free strut string 219 illustrated in FIG. 18 . The illustrated free strut string 219 includes a long (four depot) strut 213 connected on each end to a short (two depot) strut 213 by a free hinge 214 a . The free strut string 219 is attached on its distal end to the proximal end of a connector strut string 220 . The connector strut string 220 includes a connector hinge 214 b at its proximal and distal ends, and an alternating arrangement of two long (four depot) struts 213 and one short (two depot) strut 213 connected by free hinges 214 a . This pattern of alternating free strut strings 219 and connector strut strings 220 continue until the central zone 211 meets the distal transition zone 210 . The embodiment illustrated in FIGS. 10 and 11 have a central zone that includes six free strut strings 219 and six connector strut strings 220 .
[0093] The current embodiment for a medium sized stent includes sinusoidal proximal and distal ring-like end sections 306 , 307 comprised of twelve strut 313 end rings. Between the ring-like end sections 306 , 307 lies the interior helical section 308 of the stent 300 , where the sinusoidal arrangement of struts 313 and hinges 314 in the band follow a helical path. The helical path of the interior section 308 is achieved by arranging the struts 313 in a repeating pattern of alternating short and long lengths to form the band. There are thirteen struts 313 per band winding in the interior helical section 108 . The increased number of struts allows for increased stent performance while maintaining critical processing parameters. The helical interior section 308 may be further divided into proximal and distal transition zones 309 , 310 respectively and a central zone 311 as illustrated in FIG. 13 .
[0094] The central zone 311 consists of repeating strut strings, or collections of struts, which are geometrically symmetric to form a repeating pattern. The central zone 311 therefore has a constant pitch and incident angle. The repeating interior pattern is comprised of one 3-strut pattern and one 5-strut pattern that alternate to form the 13-strut repeating interior pattern.
[0095] FIG. 17 illustrates the two strut strings 319 , 320 that are part of the repeating pattern forming the central zone 311 of the stent 300 according to one embodiment of the present invention. Referring to FIGS. 12 , 13 and 17 , the central zone 311 starts at the distal end of the proximal transition zone with a connector strut string 320 illustrated in FIG. 17 . The illustrated connector strut string 720 includes a connector hinge 314 b at its proximal and distal ends, and an arrangement of three long (three depot) struts 313 connected by free hinges 314 a . The free strut string 319 is attached on its proximal end to the distal end of the connector strut string 320 . The illustrated free strut string 319 includes a series of three long (three depot) struts 313 interconnected by a free hinge 314 a . The three, three depot struts 313 are connected on each end to a short two depot strut 313 by free hinges 314 a . The pattern of alternating connector strut strings 320 and free strut strings 319 continue until the central zone 311 meets the distal transition zone 310 . The embodiment illustrated in FIGS. 12 and 13 has a central zone that includes three connector strut strings 320 and two free strut strings 319 . The length of the stent 300 can be changed by adding or shortening the central zone 311 , i.e. by adding or removing connector strut strings 320 or free strut strings 319 as necessary to maintain the repeating pattern, while maintaining the proximal and distal transition zones 309 , 310 and proximal and distal ring-like end section 306 , 307 as disclosed.
[0096] FIGS. 14 and 15 represents one embodiment of a stent 400 intended for a large diameter target vessel lesions. The large diameter stent family has been optimized for larger vessels via several design features. Like previous designs, the current embodiment contains sinusoidal proximal and distal ring-like end sections 406 , 407 comprised of twelve struts 413 . The struts 413 in said end sections 406 , 407 are of varying length; however, on the whole they are longer in the large diameter stent design than the typical strut of an equivalent smaller nominal stent design. The end sections 406 , 407 are connected via several points to the proximal and distal transition zones 409 , 410 as illustrated in FIG. 15 .
[0097] FIG. 16 illustrates the two strut strings that are part of the repeating pattern from the central zone 411 of the stent 400 according to one embodiment of the present invention. Referring to FIGS. 14 , 15 and 16 , the central zone 411 starts at the proximal end of the distal transition zone 410 with a free strut string 419 illustrated in FIG. 16 . The illustrated free strut string 419 includes an alternating arrangement of short (three depot) struts 113 and long (four depot) struts interconnected on each end by a free hinge 414 a . The free strut string 419 is attached on its proximal end to the distal end of a connector strut string 420 . The connector strut string 420 is three struts 413 long, and includes a connector hinge 414 b at its proximal and distal ends. The three struts in the connector string 420 include an alternating arrangement of long (four depot) struts 413 and a short (three depot) strut 413 connected by free hinges 414 a . This pattern of alternating free strut strings 419 and connector strut strings 420 continue until the central zone 411 meets the proximal transition zone 409 . The embodiment illustrated in FIG. 15 has a central zone that includes three free strut strings 419 and two connector strut strings 420 .
[0098] The present invention also contemplates the use of solid struts in similar strut/hinge orientations as those disclosed in FIGS. 2 , 10 , 12 , and 14 . FIG. 19 illustrates a stent 500 having similar design architecture without depots along the struts 513 . Stent 500 can be used as a bare metal stent or can be partially or completely coated with an agent and/or appropriate carrier as is known in the art. | The present invention relates to tissue-supporting medical devices and drug delivery systems, and more particularly to tubular flexible stents that are implanted within a body lumen of a living animal or human to support the organ, maintain patency and/or deliver drugs or agents. The tubular flexible stent has a cylindrical shape defining a longitudinal axis and includes a helical section having of a plurality of longitudinally oriented strut members and a plurality of circumferentially oriented hinge members connecting circumferentially adjacent strut members to form a band. The band is wrapped about the longitudinal axis in a substantially helical manner to form a plurality of helical windings. At least one connector member extends between longitudinally adjacent helical windings of the band. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application is the National Phase application of International Application No. PCT/KR2011/008074 filed on Oct. 27, 2011, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a hybrid excavator provided with an actuator impact reduction system. More particularly, the present invention relates to a hybrid excavator provided with an actuator impact reduction system, in which in the hybrid excavator that controls the expansion and contraction of the hydraulic cylinder as the electric motor is rotated in a forward and reverse rotation direction, a shuttle valve operated by a difference in pressure of flow paths is driven according to a direction of a force exerted to a piston of a hydraulic cylinder, so that an impact generated at the start of the operation of a boom cylinder or the like can be reduced.
BACKGROUND OF THE INVENTION
In general, in a hybrid excavator, a boom cylinder or the like is expanded and contracted by a hydraulic fluid discharged from a hybrid actuator (e.g., hydraulic pump-motor) in response to the drive of an electric motor to cause a work apparatus, i.e., an attachment such as a boom or the like to be manipulated. In other words, as the electric motor is rotated in a forward and reverse direction, the expansion and contraction of the boom cylinder can be controlled. In a work mode in which the boom descends, a high pressure is generated in a large chamber of the boom cylinder by the boom's own weight, and the hydraulic pump-motor is driven by a hydraulic fluid discharged from the large chamber to cause the electric motor to generate electricity.
A general hybrid excavator shown in FIGS. 1 to 5 includes:
an electric motor 11 ;
a hydraulic pump-motor 12 that is connected to the electric motor 11 and is driven in a forward or reverse direction;
a hydraulic cylinder 15 (e.g., not limited to a boom cylinder) that is expanded and contracted by a hydraulic fluid that is supplied along first and second flow paths 13 and 14 connected to the hydraulic pump-motor 12 ;
first and second hydraulic valves 16 and 17 that are installed in the first and second flow paths 13 and 14 between the hydraulic pump-motor 12 and the hydraulic cylinder 15 , respectively, and are shifted to control the first and second flow paths 13 and 14 in response to a control signal applied thereto from the outside; and
a third hydraulic valve 21 (shifted using a pressure of the first and second flow paths 13 and 14 as a pilot signal pressure) that is installed in a connection path 20 connected to first and second branch flow paths 18 and 19 that are branch-connected to the first and second flow paths 13 a and 14 a on an upstream side of the first and second hydraulic valves 16 and 17 and the first and second flow paths 13 b and 14 b on a downstream side of the first and second hydraulic valves 16 and 17 , respectively, and compensates for or bypasses a flow rate of the hydraulic fluid in order to overcome a difference in flow rate of the hydraulic fluid, which occurs due to a difference in cross section between a large chamber 15 b and a small chamber 15 a of the hydraulic cylinder 15 when the hydraulic pump-motor 12 is rotated in a forward and reverse direction.
In this case, the configuration of an attachment 6 consisting of a boom 1 , an arm 2 , and a bucket 3 , which are driven by respective hydraulic cylinders 15 , 4 and 5 , and an operator's cab 7 is the same as that of an excavator in the art to which the present invention pertains, and thus the detailed description of the configuration and operation thereof will be omitted to avoid redundancy.
Hereinafter, an operation example of the hybrid excavator will be described with reference to the accompanying drawings.
As shown in FIG. 1 , as the hydraulic pump-motor 12 is rotated in a forward or reverse direction, a hydraulic fluid from the hydraulic pump-motor 12 is supplied to the large chamber 15 b of the hydraulic cylinder 15 through the second flow path 14 : 14 a; 14 b , or a hydraulic fluid from the hydraulic pump-motor 12 is supplied to the small chamber 15 a of the hydraulic cylinder 15 through the first flow path 13 : 13 a; 13 b so that the hydraulic cylinder 15 can be expanded or contracted.
As shown in FIG. 2 , in a state in which a high pressure is generated in the large chamber 15 b of the hydraulic cylinder 15 by a direction 1 of a load applied to the 10 hydraulic cylinder 15 , the hydraulic fluid from the hydraulic pump-motor 12 is supplied to the large chamber 15 b of the hydraulic cylinder 15 through the second flow path 14 in response to the drive of the electric motor 11 , and the hydraulic fluid from the small chamber 15 a of the 15 hydraulic cylinder 15 is drained through the first flow path 13 to cause the hydraulic cylinder 15 to be expanded.
A pressure formed in the second flow path 14 is higher than that formed in the first flow path 13 , and thus the third hydraulic valve 21 using the hydraulic fluid of the 20 first and second flow paths 13 and 14 as a pilot signal pressure is shifted to the top on the drawing sheet. In this case, since the cross section of the large chamber 15 b of the hydraulic cylinder 15 is larger than that of the small chamber 15 a of the hydraulic cylinder 15 , the hydraulic fluid compensated through a drain line 22 is supplied to the large chamber 15 b of the hydraulic cylinder 15 .
As shown in FIG. 3 , in a state in which a high pressure is generated in the large chamber 15 b of the hydraulic cylinder 15 by a direction 1 of a load applied to the 5 hydraulic cylinder 15 , the hydraulic fluid from the hydraulic pump-motor 12 is supplied to the small chamber 15 a of the hydraulic cylinder 15 through the first flow path 13 in response to the drive of the electric motor 11 , and the hydraulic fluid from the large chamber 15 b of the 10 hydraulic cylinder 15 is drained through the second flow path 14 to cause the hydraulic cylinder 15 to be contracted.
The high-pressure hydraulic fluid returned from the large chamber 15 b of the hydraulic cylinder 15 is introduced into the hydraulic pump-motor 12 to cause the hydraulic 15 pump-motor 12 to generate electricity. A pressure formed in the second flow path 14 is higher than that formed in the first flow path 13 , and thus the third hydraulic valve 21 is shifted to the top on the drawing sheet. In this case, since the cross section of the large chamber 15 b of the 20 hydraulic cylinder 15 is larger than that of the small chamber 15 a of the hydraulic cylinder 15 , the hydraulic fluid compensated through a drain line 22 is supplied to the large chamber 15 b of the hydraulic cylinder 15 . At this time, since a flow rate of the hydraulic fluid discharged from the large chamber 15 b of the hydraulic cylinder 15 is higher than that of the hydraulic fluid introduced into the small chamber 15 a thereof, the hydraulic fluid flowing in the second flow path 14 is partially moved to the hydraulic tank T while passing through the connection 20 and the drain line 22 .
As shown in FIG. 4 , in a state in which a high pressure is generated in the small chamber 15 a of the hydraulic cylinder 15 by a direction 2 of a load applied to the hydraulic cylinder 15 , the hydraulic fluid from the hydraulic pump-motor 12 is supplied to the large chamber 15 b of the hydraulic cylinder 15 through the second flow path 14 in response to the drive of the electric motor 11 , and the hydraulic fluid from the small chamber 15 a of the hydraulic cylinder 15 is drained through the first flow path 13 to cause the hydraulic cylinder 15 to be expanded. At this time, the high-pressure hydraulic fluid returned from the small chamber 15 a of the hydraulic cylinder 15 is introduced into the hydraulic pump-motor 12 to cause the hydraulic pump-motor 12 to be driven to generate electricity.
A pressure formed in the first flow path 13 is higher than that formed in the second flow path 14 , and thus the third hydraulic valve 21 is shifted to the bottom on the drawing sheet. Since a flow rate of the hydraulic fluid needed by the large chamber 15 b of the hydraulic cylinder 15 is higher than that of the hydraulic fluid discharged from the small chamber 15 a thereof. In this case, the hydraulic fluid from the hydraulic tank T is sucked in by the third hydraulic valve 21 through the drain line 22 , and then joins the hydraulic fluid on the second flow path 14 through the first branch flow path 18 .
As shown in FIG. 5 , in a state in which a high pressure is generated in the small chamber 15 a of the hydraulic cylinder 15 by a direction 2 of a load applied to the hydraulic cylinder 15 , the hydraulic fluid from the hydraulic pump-motor 12 is supplied to the small chamber 15 a of the hydraulic cylinder 15 through the first flow path 13 in response to the drive of the electric motor 11 , and the hydraulic fluid from the large chamber 15 b of the hydraulic cylinder 15 is drained through the second flow path 14 to cause the hydraulic cylinder 15 to be contracted.
A pressure formed in the first flow path 13 is higher than that formed in the second flow path 14 , and thus the third hydraulic valve 21 is shifted to the bottom on the drawing sheet. Since a flow rate of the hydraulic fluid discharged from the large chamber 15 b of the hydraulic cylinder 15 is higher than that of the hydraulic fluid introduced into the hydraulic pump-motor 12 . In this case, the hydraulic fluid flowing in the second flow path 14 is partially moved to the hydraulic tank T through the first branch flow path 18 , the third hydraulic valve 21 , and the drain line 22 .
As shown in FIG. 6 , in the case where the operation of the machine is stopped in a position of an attachment 6 consisting of the boom 1 and the like, a low load occurs in the above-mentioned load direction 1 (e.g., the case where the hydraulic cylinder is contracted) in the respective hydraulic cylinders 15 , 4 and 5 . In this case, the first and second hydraulic valves 16 and 17 are shifted to a position in which the first and second flow paths 13 and 14 are closed in order to prevent the hydraulic fluid from leaking to the outside when the hydraulic cylinders are not driven, and thus the internal pressure of the hydraulic cylinders is not dropped.
In the meantime, since the hydraulic fluid has somewhat compressibility, vibration may occur due to the abrupt stop of the attachment 6 or the operation (e.g., the case where the drive of the boom cylinder 15 is stopped while the arm cylinder 4 is driven) of another hydraulic cylinder.
As shown in FIG. 7 , even in the case where the first and second hydraulic valves 16 and 17 are closed, the hydraulic fluid of the hydraulic cylinder 15 is compensated so that a constant pressure is generated even after occurrence of the vibration. The cross section of the large chamber 15 b of the hydraulic cylinder 15 is larger than that of the small chamber 15 a thereof (e.g., twice larger than that of the small chamber 15 a in a general excavator). Thus, even in the case where the same pressure is generated in the large and small chambers, a force allowing the piston to be moved in the large chamber 15 b is larger than in the small chamber 15 a . When a pressure of the large chamber 15 b is a half that of the small chamber 15 a , the forces of the large chamber 15 b and the small chamber 15 a , which push each other, become the same. In the case where the boom cylinder 15 is contracted by the load direction 1 , a pressure (a) of the small chamber 15 a is higher than a pressure (b) of the large chamber 15 b (see FIGS. 7 and 8 ).
As shown FIGS. 8 and 9 , the first and second hydraulic valves 16 and 17 are shifted to an opened position through 15 the application of a control signal thereto to perform a work under the conditions where an external force is applied to the hydraulic cylinder 15 by the load direction 1 , so that a high pressure is formed in the first flow path 13 and a low pressure is formed in the second flow path 14 to 20 cause the third hydraulic valve 21 to be shifted to the bottom on the drawing sheet.
As shown in FIGS. 9 and 10 , when the pressure formed in the large chamber 15 b is released while the piston of the hydraulic cylinder 15 is moved by several millimeters (mm), the third hydraulic valve 21 is shifted to the top on the drawing sheet to cause the hydraulic cylinder 15 to be operated normally.
As shown in FIGS. 8 and 9 , in the process in which the first and second hydraulic valves 16 and 17 are shifted to an opened position from a closed position, and the third hydraulic valve 21 in a neutral position is shifted to the bottom on the drawing sheet by the pressure of the first flow path 13 , the piston of the hydraulic cylinder 15 is moved by several millimeters (mm). In this case, although the movement distance of the piston of the hydraulic cylinder 15 is not long, a distal end of the attachment 6 is moved by several meters (m), thereby causing a problem in that manipulability and workability are deteriorated.
DETAILED DESCRIPTION OF THE INVENTION
Technical Problems
Accordingly, the present invention has been made to solve the aforementioned problem occurring in the prior art, and it is an object of the present invention to provide a hybrid excavator provided with an actuator impact reduction system, in which a shuttle valve that controls a difference in flow rate of the hydraulic fluid, which occurs due to a difference in cross section between a large chamber and a small chamber of the hydraulic cylinder is driven according to a direction of a force exerted to a piston of a hydraulic cylinder, so that an impact generated at the start of the operation of the boom cylinder or the like can be reduced, thereby improving manipulability and workability.
Technical Solution
To accomplish the above object, in accordance with an embodiment of the present invention, there is provided a hybrid excavator provided with an actuator impact reduction system, wherein the actuator impact reduction system includes:
an electric motor;
a hydraulic pump-motor connected to the electric motor and configured to be driven in a forward or reverse direction;
a hydraulic cylinder configured to be expanded and contracted by a hydraulic fluid that is supplied along first and second flow paths connected to the hydraulic pump-motor;
first and second hydraulic valves installed in the first and second flow paths between the hydraulic pump-motor and the hydraulic cylinder, respectively, and configured to be shifted to control the first and second flow paths in response to a control signal applied thereto from the outside;
a third hydraulic valve installed in a connection path connected to first and second branch flow paths that are branch-connected to the first and second flow paths on an upstream side of the first and second hydraulic valves and the first and second flow paths on a downstream side of the first and second hydraulic valves, respectively, and configured to be shifted to compensate for or bypass a flow rate of the hydraulic fluid in order to overcome a difference in flow rate of the hydraulic fluid, which occurs due to a difference in cross section between a large chamber and a small chamber of the hydraulic cylinder; and
first and second pilot chambers configured to supply a pressure of the first and second flow paths to the third hydraulic valve as a pilot signal pressure so as to shift the third hydraulic valve, the first and second pilot chambers being formed to have different cross sections.
In accordance with a preferred embodiment of the present invention, the ratio of the cross section between the first and second pilot chambers of the third hydraulic valve may be made equal to the ratio of the cross section between the small chamber and the large chamber of the hydraulic cylinder.
The ratio of the cross section between the first and second pilot chambers of the third hydraulic valve may be 1:2.
The hydraulic cylinder may be anyone of a boom cylinder, an arm cylinder, and a bucket cylinder.
Advantageous Effect
The hybrid excavator provided with an actuator impact reduction system in accordance with an embodiment of the present invention as constructed above has the following advantages.
The shuttle valve operated by a difference in pressure of flow paths between the hydraulic pump and the hydraulic cylinder is configured such that the ratio of the cross section between the first and second pilot chambers of the shuttle valve is made equal to the ratio of the cross section between the small chamber and the large chamber of the hydraulic cylinder 15 , so that the shuttle valve is driven according to a direction of a force exerted to the piston of the hydraulic cylinder. Thus, an impact generated at the start of the operation of the boom cylinder or the like can be reduced, thereby improving manipulability.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects, other features and advantages of the present invention will become more apparent by describing the preferred embodiments thereof with reference to the accompanying drawings, in which:
FIG. 1 is a schematic view showing a hybrid excavator to which an actuator impact reduction system in accordance with an embodiment of the present invention is applied;
FIGS. 2 to 5 are hydraulic circuit diagrams showing the operation of the hybrid excavator shown in FIG. 1 ;
FIG. 6 is a view showing a state in which a low load occurs in a direction in which an actuator is contracted in a hybrid excavator to which an actuator impact reduction system in accordance with an embodiment of the present invention is applied;
FIG. 7 is a graph showing a state in which a pressure of a small chamber of an actuator is higher than that of a large chamber of the actuator when a load occurs in a direction in which the actuator is contracted in a hybrid excavator to which an actuator impact reduction system in accordance with an embodiment of the present invention is applied;
FIG. 8 is a hydraulic circuit diagram showing a state in which a pressure of a small chamber of an actuator is higher than that of a large chamber of the actuator when a load occurs in a direction in which the actuator is contracted in a hybrid excavator to which an actuator impact reduction system in accordance with an embodiment of the present invention is applied;
FIG. 9 is a hydraulic circuit diagram showing an erroneous operation of a shuttle valve during the drive of an actuator piston in a neutral position of the shuttle valve shown in
FIG. 8 in a hybrid excavator to which an actuator impact reduction system in accordance with an embodiment of the present invention is applied;
FIG. 10 is a hydraulic circuit diagram showing a state in which an actuator piston is driven by a predetermined amount and a shuttle valve returns to a normal position in a hybrid excavator to which an actuator impact reduction system in accordance with an embodiment of the present invention is applied; and
FIG. 11 is a schematic view showing main elements of a shuttle valve in a hybrid excavator to which an actuator impact reduction system in accordance with an embodiment of the present invention is applied.
EXPLANATION ON REFERENCE NUMERALS OF MAIN ELEMENTS IN THE DRAWINGS
11 : electric motor
12 : hydraulic pump-motor
13 : first flow path
14 : second flow path
15 : hydraulic cylinder
16 : first hydraulic valve
17 : second hydraulic valve
18 : first branch flow path
19 : second branch flow path
20 : connection path
30 : third hydraulic valve
31 : first pilot chamber
32 : second pilot chamber
Preferred Embodiments of the Invention
Now, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. The matters defined in the description, such as the detailed construction and elements, are nothing but specific details provided to assist those of ordinary skill in the art in a comprehensive understanding of the invention, and the present invention is not limited to the embodiments disclosed hereinafter.
In a hybrid excavator provided with an actuator impact reduction system in accordance with an embodiment of the present invention as shown in FIGS. 1 to 11 , the actuator impact reduction system includes:
an electric motor 11 ;
a hydraulic pump-motor 12 that is connected to the electric motor 11 and is driven in a forward or reverse direction;
a hydraulic cylinder 15 that is expanded and contracted by a hydraulic fluid that is supplied along first and second flow paths 13 and 14 connected to the hydraulic pump-motor 12 ;
first and second hydraulic valves 16 and 17 that are installed in the first and second flow paths 13 and 14 between the hydraulic pump-motor 12 and the hydraulic cylinder 15 , respectively, and are shifted to control the first and second flow paths 13 and 14 in response to a control signal applied thereto from the outside;
a third hydraulic valve 30 that is installed in a connection path 20 connected to first and second branch flow paths 18 and 19 that are branch-connected to the first and second flow paths 13 a and 14 a on an upstream side of the first and second hydraulic valves 16 and 17 and the first and second flow paths 13 b and 14 b on a downstream side of the first and second hydraulic valves 16 and 17 , respectively, and is shifted to compensate for or bypass a flow rate of the hydraulic fluid in order to overcome a difference in flow rate of the hydraulic fluid, which occurs due to a difference in cross section between a large chamber 15 b and a small chamber 15 a of the hydraulic cylinder 15 ; and
first and second pilot chambers 31 and 32 that supplies a pressure of the first and second flow paths 13 and 14 to the third hydraulic valve 30 as a pilot signal pressure so as to shift the third hydraulic valve 30 (i.e., the third hydraulic valve is driven according to a direction of a force exerted to a piston of the third hydraulic valve 30 so that an impact occurring at the start of the operation of the hydraulic cylinder 15 can be reduced), the first and second pilot chambers being formed to have different cross sections.
In this case, the ratio of the cross section between the first and second pilot chambers 31 and 32 of the third hydraulic valve 30 is made equal to the ratio of the cross section between the small chamber 15 a and the large chamber 15 b of the hydraulic cylinder 15 .
The ratio of the cross section between the first and second pilot chambers 31 and 32 of the third hydraulic valve 30 is 1:2.
The hydraulic cylinder 15 is any one of a boom cylinder, an arm cylinder, and a bucket cylinder.
In the case, the configuration of the hybrid excavator provided with an actuator impact reduction system in accordance with an embodiment of the present invention is the same as that of the conventional hybrid excavator shown in FIG. 1 , except the third hydraulic valve 30 including the first and second pilot chambers 31 and 32 of the third hydraulic valve 30 , between which the ratio of the cross section is made equal to the ratio of the cross section between the small chamber 15 a and the large chamber 15 b of the hydraulic cylinder 15 and which are formed to have different cross sections. Thus, the detailed description of the same configuration and cooperation thereof will be omitted to avoid redundancy, and the same elements are denoted by the same reference numerals.
Hereinafter, a use example of the hybrid excavator provided with an actuator impact reduction system in accordance with an embodiment of the present invention will be described in detail with reference to the accompanying drawings.
As shown in FIGS. 1 to 11 , when a hydraulic fluid from the hydraulic pump-motor 12 is supplied to the hydraulic cylinder 15 by the drive of the electric motor 12 as the electric motor 12 is rotated in a forward and reverse direction, a difference in flow rate of the hydraulic fluid, which occurs due to a difference in cross section between the large chamber 15 b and the small chamber 15 a of the hydraulic cylinder 15 , can be overcome. In other words, the ratio of the cross section between the first and second pilot chambers 31 and 32 of the third hydraulic valve 30 is made equal to the ratio of the cross section between the small chamber 15 a and the large chamber 15 b of the hydraulic cylinder 15 .
For this reason, when the hydraulic fluid discharged from the hydraulic pump-motor 12 is supplied to the hydraulic cylinder 15 by the drive of the electric motor 12 , the third hydraulic valve 30 compensates for a flow rate of the hydraulic fluid by a difference in flow rate of the hydraulic fluid, which occurs due to a difference in cross section between the large chamber 15 b and the small chamber 15 a of the hydraulic cylinder 15 or drains a surplus hydraulic fluid to a hydraulic tank T. Thus, the hydraulic fluid discharged from the hydraulic pump-motor 12 can be supplied to the hydraulic cylinder 15 including the large chamber 15 b and the small chamber 15 a whose cross sections are different from each other under the optimal conditions.
While the present invention has been described in connection with the specific embodiments illustrated in the drawings, they are merely illustrative, and the invention is not limited to these embodiments. It is to be understood that various equivalent modifications and variations of the embodiments can be made by a person having an ordinary skill in the art without departing from the spirit and scope of the present invention. Therefore, the true technical scope of the present invention should not be defined by the above-mentioned embodiments but should be defined by the appended claims and equivalents thereof.
INDUSTRIAL APPLICABILITY
As described above, according to the hybrid excavator provided with an actuator impact reduction system in accordance with an embodiment of the present invention, in the hybrid excavator that controls the expansion and contraction of the hydraulic cylinder as the electric motor is rotated in a forward and reverse rotation direction, the shuttle valve is configured such that the ratio of the cross section between the first and second pilot chambers of the shuttle valve is made equal to the ratio of the cross section between the small chamber and the large chamber of the hydraulic cylinder 15 , so that the shuttle valve is driven according to a direction of a force exerted to the piston of the hydraulic cylinder. As a result, an impact generated at the start of the operation of the boom cylinder or the like can be reduced. | Disclosed is a hybrid excavator which reduces the impact generated at the start of the operation of the boom cylinder, or the like, of a hybrid excavator. The hybrid excavator according to the present invention comprises: a hydraulic pump motor connected to an electric motor and operated in the forward or reverse direction; a hydraulic cylinder connected to the hydraulic pump motor and operated in an expanding manner; a first and second hydraulic valve installed in a first and second passage, respectively, between the hydraulic pump motor and the hydraulic cylinder, for blocking the first and second passages when switched by an external control signal; a third hydraulic valve installed in the connecting path connected to first and second dividing passages. | 4 |
FIELD OF THE INVENTION
The present invention relates to a process for the manufacture of 1,1,1,2,3-pentafluoropropane by hydrogenation of 1,2,3,3,3-pentafluoropropene.
BACKGROUND OF THE INVENTION
2,3,3,3-Tetrafluoropropene is known for its properties of refrigerant and heat-exchange fluid. The process for the manufacture of 2,3,3,3-tetrafluoropropene from 1,2,3,3,3-pentafluoropropene comprises a stage of hydrogenation of 1,2,3,3,3-pentafluoropropene.
The document by Knunyants et al., Journal of the USSR Academy of Sciences, Chemistry Department, “Reactions of fluoro-olefins”, Report 13, “Catalytic hydrogenation of perfluoro-olefins”, 1960, describes the hydrogenation of 1,2,3,3,3-pentafluoropropene (HFO-1225ye) at ambient temperature over a palladium catalyst supported on alumina to give a mixture of 1,1,1,2,3-pentafluoropropane (HFC-245eb) and 1,1,1,2-tetrafluoropropane (HFC-254eb). 1,1,1,2-Tetrafluoropropane is produced in a significant amount (that is to say, approximately 50% with respect to the 1,1,1,2,3-pentafluoropropane).
The document WO 2008/030440 describes a method for the preparation of 2,3,3,3-tetrafluoropropene comprising at least one hydrogenation stage during which 1,2,3,3,3-pentafluoropropene is brought into contact with hydrogen in the presence of a catalyst. According to this document, the hydrogenation catalyst which may be suitable comprises a metal from Group VIII or rhenium and the metal can be supported.
Example 1 of the document WO 2008/030440 describes the hydrogenation reaction of 1,2,3,3,3-pentafluoropropene at 85° C. in the presence of a catalyst comprising 0.5% by weight of palladium supported on charcoal to give a stream comprising 92% of HFC-245eb and 8% of HFC-254eb.
The tests of the abovementioned prior art were carried out on the laboratory scale and the documents are completely silent with regard to the lifetime of these catalysts.
The hydrogenation reactions as described above are highly exothermic reactions and present problems on the industrial scale. In addition, a not insignificant amount of byproduct (HFC-254eb) is formed, due probably to the successive hydrogenolysis reaction of the HFC-245eb (that is to say, the replacement of a fluorine atom of the desired product by a hydrogen atom with formation of hydrofluoric acid).
The presence of a compound other than the reactants in the reaction stream can also be the cause of a rapid deactivation of the catalyst.
Furthermore, the document EP 1 916 232 provides a multistage hydrogenation reaction of an olefinic compound in order to obtain a high conversion and a high selectivity. Example 2 describes the hydrogenation in stages of 1,2,3,3,3-pentafluoropropene in the presence of a palladium catalyst supported on charcoal in four reactors with an outlet temperature of the first reactor of 99° C., an outlet temperature of the second reactor of 95° C., for a conversion of 54%, a temperature at the outlet of the third reactor of 173° C. and a temperature at the outlet of the fourth reactor of 104° C. Provision is made for cooling stages between the reactors with a temperature of the first bath of 59° C. and a temperature of the second bath of 116° C.
The process as described in the document EP 1 916 232 is expensive and, in addition, it is not easy to carry out.
DETAILED DESCRIPTION OF THE INVENTION
The present patent application provides a continuous or semicontinuous process for the manufacture of 1,1,1,2,3-pentafluoropropane from 1,2,3,3,3-pentafluoropropene which makes it possible to solve, in all or in part, the abovementioned disadvantages.
The process according to the present invention makes it possible more particularly to control the exothermicity of the hydrogenation reaction and/or to limit the hydrogenolysis reaction of HFC-245eb and/or to reduce the deactivation of the catalyst.
The process according to the present invention is characterized in that (i) 1,2,3,3,3-pentafluoropropene is reacted in the gas phase with hydrogen in a superstoichiometric amount, at a temperature of between 80 and 250° C., preferably of between 110 and 160° C., in the presence of a hydrogenation catalyst in a reactor; (ii) a portion of the gaseous output stream resulting from the reactor, comprising 1,1,1,2,3-pentafluoropropane, unreacted hydrogen, optionally unreacted 1,2,3,3,3-pentafluoropropene, 1,1,1,2-tetrafluoropropane and hydrofluoric acid, is recycled and (iii) the 1,1,1,2,3-pentafluoropropane is recovered from the other portion of the output stream resulting from the reactor, optionally after a purification stage.
Preferably, the temperature at the inlet of the catalytic bed is between 50 and 200° C., advantageously between 80 and 140° C.
The stream recycled to the reactor and also the reactants can be preheated before introduction into the reactor.
The process according to the present invention is preferably carried out with a hydrogen/HFO-1225ye molar ratio of between 1.2 and 40, advantageously of between 3 and 10. This ratio is generally obtained by addition of 1,2,3,3,3-pentafluoropropene and hydrogen to the recycling stream.
The contact time, defined as the ratio of the volume of the catalytic bed to the flow rate by volume of the total stream under standard temperature and pressure conditions, is preferably between 0.1 and 20 s and advantageously between 0.5 and 5 s.
The hydrogenation reaction according to the present invention is preferably carried out at a pressure of between 0.5 and 20 bar absolute and advantageously of between 1 and 5 bar absolute.
The gaseous output stream at the outlet of the reactor preferably comprises from 5 to 96% by volume of the 1,1,1,2,3-pentafluoropropane, from 2 to 90% by volume of hydrogen, from 1 to 20% of 1,1,1,2-tetrafluoropropane and from 0 to 10% of the 1,2,3,3,3-pentafluoropropene.
Advantageously, the gaseous output stream at the outlet of the reactor comprises from 5 to 91% by volume of the 1,1,1,2,3-pentafluoropropane, from 8 to 50% by volume of hydrogen, from 1 to 5% by volume of 1,1,1,2-tetrafluoropropane and from 0 to 0.1% by volume of the 1,2,3,3,3-pentafluoropropene.
According to the process of the present invention, use is preferably made of an adiabatic reactor.
The portion of the gaseous output stream which is recycled to the reactor preferably represents at least 80% by volume of the whole of the output stream at the outlet of the reactor, advantageously at least 90% by volume. Particularly preferably, the portion of the output stream recycled to the reactor represents between 93 and 98% by volume of the total output stream at the outlet of the reactor.
Mention may in particular be made, as catalyst, of those based on a metal from Group VIII or rhenium. The catalyst can be supported, for example on carbon, alumina, aluminium fluoride, and the like, or can be unsupported, such as Raney nickel. Use may be made, as metal, of platinum or palladium, in particular palladium, advantageously supported on carbon or alumina. It is also possible to combine this metal with another metal, such as silver, copper, gold, tellurium, zinc, chromium, molybdenum and thallium.
The preferred catalyst comprises optionally supported palladium. The catalyst very particularly preferred according to the present invention is a catalyst comprising palladium on a support based on alumina. The amount of palladium in the catalyst is preferably between 0.05 and 10% by weight and advantageously between 0.1 and 5%.
The specific surface of the catalyst is preferably greater than 4 m 2 /g. The alumina used as catalytic support is advantageously provided in the a polymorphic form.
The Applicant Company has noticed, surprisingly, that the amount of HFC-254eb byproduct remains low despite the recycling of a portion of the gaseous output stream at the outlet of the reactor. This amount is even lower in comparison with the prior art in the absence of recycling.
The process according to the present invention makes it possible to obtain a high conversion of the HFO-1225ye and a high selectivity for HFC-245eb. In addition, these performances are stable over time. This makes it possible to limit the presence of hydrofluoric acid (a highly corrosive product) in the recycling loop.
Experimental Part
The following tests were carried out with a device which makes it possible to recycle a portion of the output stream to the reactor.
The conversion is defined as being the percentage of HFO-1225ye which is converted.
The selectivity for product X is defined as being the percentage of the number of moles of product X formed with regard to the number of moles of HFO-1225ye converted.
Example 1
Use is made of a tubular reactor made of stainless steel, with an internal diameter of 2.1 cm and a length of 120 cm, containing 469 g, i.e. 320 cm 3 , of catalyst in the form of a fixed bed. The catalyst comprises 0.2% by weight of palladium supported on α-alumina.
For the duration of the reaction, 1.41 mol/h of hydrogen and 0.7 mol/h of 1,2,3,3,3-pentafluoropropene are continuously injected and the flow rate of the recycling loop is 0.490 Sm 3 , i.e. 93.7% by volume of the gaseous output stream at the outlet of the reactor. The hydrogen/HFO-1225ye molar ratio at the inlet of the catalytic bed is 16. The pressure is 1 bar absolute. The temperature at the inlet of the reactor is 60° C. and the maximum reactor temperature achieved during the reaction is 124° C. The contact time is 2.3 seconds,
A conversion of HFO-1225ye of 100%, a selectivity for HFC-245eb of 95.7% and a selectivity for HFC-254eb of 4.1% are obtained.
No deactivation was observed during 80 h of operation.
Example 2
The same device as above is used with the same catalyst. For the duration of the reaction, 0.84 mol/h of hydrogen and 0.7 mol/h of 1,2,3,3,3-pentafluoropropene are continuously injected and the flow rate in the recycling loop is 0.970 Sm 3 /h, i.e. a percentage of recycling by volume of 98%. The hydrogen/HFO-1225ye molar ratio at the inlet of the reactor is 1.18. The pressure is 2 bar absolute. The temperature at the inlet of the catalytic bed is 63° C. and the maximum reactor temperature achieved during the reaction is 90° C. The contact time is 1.2 S.
A conversion of HFO-1225ye of 100%, a selectivity for HFC-245eb of 79% and a selectivity for HFC-254eb of 20.0% are obtained.
Example 3
The operation is carried out under the same conditions as Example 2, except that the hydrogen/HFO-1225ye molar ratio at the inlet of the reactor is 5.2 and that the temperature at the inlet of the catalytic bed is 100° C. The maximum temperature achieved during the reaction is 123° C.
A conversion of HFC-1225ye of 100%, a selectivity for HFC-245eb of 89.6% and a selectivity for HFC-254eb of 10.2% are obtained. | The present invention relates to a method for producing 1,2,3,3,3-pentafluoropropane, involving reacting gaseous phase 1,2,3,3,3-pentafluoropropene with hydrogen in a superstoichimetric amount in the presence of a hydrogenation catalyst in a reactor, and recirculating a part of the gaseous effluent from the reactor. | 8 |
INCORPORATION BY REFERENCE
The present application claims priority under 35 U.S.C. §119 to Japanese Patent Application Nos. 2003-424401 filed Dec. 22, 2003; 2003-424402 filed Dec. 22, 2003; 2004-040764 filed Feb. 18, 2004; 2004-058682 filed Mar. 3, 2004; 2004-058683 filed Mar. 3, 2004 and 2004-058686 filed Mar. 3, 2004. The content of the applications are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a surface-coated cermet cutting tool (hereinafter, referred to as a coated cermet tool) of which a hard coating layer exhibits excellent chipping resistance, in particular, during high-speed intermittent cutting of steel, cast iron, etc.
2. Description of the Related Art
Conventionally, a coated cermet tool is known, which is generally formed by coating, on a surface of a substrate (hereinafter, generally referred to as a tool substrate) made of tungsten carbide (hereinafter, referred to as WC)-based cemented carbide or titanium carbonitride (hereinafter, referred to as TiCN)-based cermet, a hard-coating layer including the following upper and lower layers (a) and (b):
(a) as the lower layer, a titanium compound layer having at least one or two of titanium carbide (hereinafter, referred to as TiC) layer, a titanium nitride (hereinafter, referred to as TiN) layer, a titanium carbonitride (hereinafter, referred to as TiCN) layer, a titanium carboxide (hereinafter, referred to as TiCO) layer, and a titanium oxycarbonitride (hereinafter, referred to as TiCNO) layer, all of which are formed by chemical vapor deposition, the titanium compound layer having a total average thickness of 3 to 20 μm, and
(b) as the upper layer, a deposited α-type aluminum oxide (hereinafter, referred to as Al 2 O 3 ) layer having an α-type crystal structure deposited by chemical vapor deposition and an average thickness of 1 to 15 μm. It is also known that the coated cermet tool is widely used for, for example, continuous or intermittent cutting of steel or cast iron.
Generally, it is also well known that a titanium compound layer or the Al 2 O 3 layer constituting the hard-coating layer of a coated cermet tool has a granular crystal structure, and further the TiCN layer constituting the titanium compound layer has a longitudinal growth crystal structure formed by carrying out chemical vapor deposition in a moderate temperature range of 700 to 950° C. using as a reaction gas a mixed gas which includes organic carbonitride, for example, CH 3 CN in a conventional chemical vapor deposition reactor for the purpose of increasing the strength of the layer.
[Patent Document 1] Japanese Unexamined Patent Application Publications No. 6-31503
[Patent Document 2] Japanese Unexamined Patent Application Publications No. 6-8010.
In recent years, the performance of cutting tools has been markedly enhanced, and demands for labor saving and energy saving in cutting work and cost reduction have been increased. Accordingly, the cutting work is more often carried out at a higher speed range. The conventional coated cermet tools generally present no problem when they are used in the continuous cutting or intermittent cutting of steel, cast iron or the like under normal conditions. However, when the conventional cutting tools are used in a high-speed intermittent cutting under the severest cutting condition, i.e., in the high-speed intermittent cutting where mechanical and thermal impacts are repeatedly applied to the cutting edge at very short pitches, a titanium compound layer which is typically the lower layer of a hard-coating layer has high strength and exhibits excellent impact resistance. However, the deposited α-type Al 2 O 3 layer that constitutes the upper layer of a hard-coating layer, despite its hardness in high temperature and excellent heat resistance, is very brittle against the mechanical and thermal impacts. As a result, chipping easily occurs in the hard coating layer, consequently shortening the usable life of cermet cutting tools.
SUMMARY OF THE INVENTION
Considering the above problems, the inventors have conducted studies for improving the chipping resistance of a deposited α-type Al 2 O 3 layer that constitutes the upper layer of the hard coating layer of the coated cermet tools, and have obtained the following results.
On a surface of a tool substrate, the Ti compound layer as a lower layer is formed under normal conditions using a conventional chemical vapor deposition reactor. An Al oxide layer (hereinafter, referred to as an (Al, Zr) 2 O 3 layer) having a κ-type or θ-type crystal structure and satisfying the composition formula: (Al 1-X Zr X ) 2 O 3 (where value X is 0.003 to 0.05 in an atomic ratio when measured by an electron probe micro-analyzer (EPMA)) is deposited under the same normal conditions. Next, the surface of the (Al, Zr) 2 O 3 layer is processed using the chemical vapor deposition reactor under the following conditions:
Composition of reaction gas: in volume %, TiCl 4 : 0.2 to 3%, CO 2 : 0.2 to 10%, Ar: 5 to 50%, and H 2 : balance,
Temperature of reaction atmosphere: 900 to 1020° C.,
Pressure of reaction atmosphere: 7 to 30 kPa, and
Time: 1 to 10 min.
Then, titanium oxide particulates satisfying the composition formula: TiO Y , (where value Y is 1.2 to 1.9 in an atomic ratio to Ti when measured by Auger Electron Spectroscopy) are dispersedly distributed on the surface of the (Al, Zr) 2 O 3 layer. In this state, by carrying out a heat-transforming treatment in an atmosphere of Ar gas, preferably, under the following conditions: a pressure of 7 to 50 kPa, a temperature of 1000 to 1200° C., and a holding duration of 10 to 120 minutes, the (Al, Zr) 2 O 3 layer having the κ-type or θ-type crystal structure is transformed into the (Al, Zr) 2 O 3 layer having an α-type crystal structure. Then, since the titanium oxide particulates uniformly distributed on the surface of the (Al, Zr) 2 O 3 layer before the transformation serve as starting points of cracks generated at the time of the transformation of the κ-type or θ-type crystal structure into the a-type crystal structure in the heat-transformed α-type (Al, Zr) 2 O 3 layer, the cracks generated at the time of the transformation become extremely fine and the titanium oxide particulates are uniformly and dispersedly distributed. Further, since the strength of the (Al, Zr) 2 O 3 layer itself is markedly enhanced by action of Zr as a constituent element thereof, the heat-transformed α-type (Al, Zr) 2 O 3 layer has a uniformed structure in which the cracks generated by the transformation process become fine over the entire layer, in addition to high strength, high strength, thereby having very strong resistance against mechanical and thermal impacts and excellent chipping resistance. Accordingly, in the coated cermet tool having a hard-coating layer including the heat-transformed α-type (Al, Zr) 2 O 3 layer as the upper layer and the titanium compound layer (this titanium compound layer does not exhibit any change during the heat-transforming treatment under the above-mentioned conditions) as the lower layer, the heat-transformed α-type (Al, Zr) 2 O 3 layer exhibits excellent chipping resistance, even in a high-speed intermittent cutting accompanied with severe mechanical and thermal impacts, with the same high temperature hardness and heat resistance as the excellent high temperature hardness and heat resistance inherent to an α-type Al 2 O 3 layer. As a result, with the presence of the titanium compound layer having high strength, the occurrence of chipping in the hard coating layer is markedly suppressed and an excellent wear resistance is exhibited for a prolonged period of time.
An implementation of the present invention is contrived based on the results of studies described above, and there is thus provided a surface-coated cermet cutting tool formed by coating, on a surface of a tool substrate made of WC-based cemented carbide or TiCN-based cermet, a hard-coating layer including the following upper and lower layers (a) and (b):
(a) as the lower layer, a Ti compound layer having at least one or two of a TiC layer, a TiN layer, a TiCN layer, a TiCO layer and a TiCNO layer, all of which are deposited by chemical vapor deposition, the titanium compound layer having a total average thickness of 3 to 20 μm, and
(b) as the upper layer, a heat-transformed α-type (Al, Zr) 2 O 3 layer formed by carrying out a heat-transforming treatment in a state that titanium oxide particulates satisfying the composition formula: TiO Y , (where value Y is 1.2 to 1.9 in an atomic ratio to Ti when measured by Auger Electron Spectroscopy) and chemically deposited as a transformation starting material are dispersedly distributed on a surface of an (Al, Zr) 2 O 3 layer having a κ-type or θ-type crystal structure deposited by chemical vapor deposition and satisfying the composition formula: (Al 1-X Zr X ) 2 O 3 (where value X is 0.003 to 0.05 in an atomic ratio when measured by an electron probe micro-analyzer (EPMA)) to thereby transform the crystal structure of the (Al, Zr) 2 O 3 layer having the κ-type or θ-type crystal structure into an α-type crystal structure, the heat-transformed α-type (Al, Zr) 2 O 3 layer having an average thickness of 1 to 15 μm.
Next, the reasons for limiting the numerical values in the layers constituting the hard coating layer of the coated cermet layer of an implementation of the present invention as described above will be described below.
(a) Average Thickness of Lower Layer (Ti Compound Layer)
The titanium compound layer inherently has high strength, and the hard-coating layer has high temperature strength by effect of the existence of the titanium compound layer. In addition, the titanium compound layer is firmly adhered to both of the tool substrate and the heat-transformed α-type (Al, Zr) 2 O 3 layer that is the upper layer. Accordingly, it contributes to improving the adherence of the hard coating layer to the tool substrate. However, when the total average thickness is less than 3 μm, the above function cannot be sufficiently obtained. On the other hand, when the total average thickness is greater 20 μm, thermal plastic deformation is apt to occur, particularly in a high-speed intermittent cutting accompanied by the generation of high heat, which causes partial wear. Accordingly, the average thickness is preferably set to 3 to 20 μm.
(b) Value Y of Titanium Oxide Particulates
As described above, since the titanium oxide particulates serve as starting points of the cracks generated at the time of transformation of the deposited κ-type or θ-type (Al, Zr) 2 O 3 layer into the α-type (Al, Zr) 2 O 3 layer, the cracks generated at the time of the transformation in the heat-transformed α-type (Al, Zr) 2 O 3 layer are made fine and are uniformly and dispersedly distributed. As a result, the heat-transformed α-type (Al, Zr) 2 O 3 layer has excellent chipping resistance. However, when value Y thereof to Ti is less than 1.2 in an atomic ratio and when value Y is greater than 1.9, the effect of making the cracks generated at the time of the transformation fine cannot be sufficiently obtained. Therefore, value Y is set to 1.2 to 1.9 in an atomic ratio to Ti.
(c) Content Ratio of Zr in Upper Layer [a Heat-Transformed α-type (Al, Zr) 2 O 3 Layer] and Average Thickness thereof
since the heat-transformed α-type (Al, Zr) 2 O 3 layer has excellent high temperature hardness and heat resistance by action of Al as a constituent element thereof, and has high strength by action of Zr as a constituent element thereof, the heat-transformed α-type (Al, Zr) 2 O 3 layer exhibits excellent wear resistance and chipping resistance. However, when the content ratio (value X) of Zr is less than 0.003 in an atomic ratio (this is true of the following ratios) which is a ratio to the total content with Al, sufficient high temperature strength cannot be secured. On the other hand, when the content ratio of Zr is greater than 0.05, instability is caused in the transformation, which makes it difficult to sufficiently transform the κ-type or θ-type crystal structure into the α-type crystal structure during the heat-transforming treatment. Thus, the content ratio (value X) of Zr is preferably set to 0.003 to 0.05.
Further, when the average thickness of the heat-transformed α-type (Al, Zr) 2 O 3 layer is less than 1 μm, the hard coating layer cannot have sufficient high temperature hardness and heat resistance. On the other hand, when the average thickness of the heat-transformed α-type (Al, Zr) 2 O 3 layer is greater than 15 μm, chipping is apt to occur, so that the average thickness of the heat-transformed α-type (Al, Zr) 2 O 3 layer is preferably set to 1 to 15 μm.
Furthermore, for the purpose of identifying the cutting tool before and after using the cutting tool, the TiN layer having a gold color tone may be deposited as needed. In this case, the average thickness of the TiN layer is preferably 0.1 to 1 μm. This is because, when the average thickness is less than 0.1 μm, sufficient identification cannot be achieved, and the identification due to the TiN layer can be sufficiently obtained only with an average thickness of up to 1 μm.
Moreover, the inventors have conducted studies for improving the chipping resistance of a deposited α-type Al 2 O 3 layer that constitutes the upper layer of the hard coating layer of the conventional coated cermet tools, and have obtained the following results.
On a surface of a tool substrate, the Ti compound layer as a lower layer is formed under normal conditions using a conventional chemical vapor deposition reactor. An Al oxide layer (hereinafter, referred to as an (Al, Ti) 2 O 3 layer) having a κ-type or θ-type crystal structure and satisfying the composition formula: (Al 1-X Ti X ) 2 O 3 (where value X is 0.01 to 0.05 in an atomic ratio when measured by an electron probe micro-analyzer (EPMA)) is deposited under the same normal conditions. Next, the surface of the (Al, Ti) 2 O 3 layer is processed using the chemical vapor deposition reactor under the following conditions:
Composition of reaction gas: in volume %, TiCl 4 : 0.2 to 3%, CO 2 : 0.2 to 10%, Ar: 5 to 50%, and H 2 : balance,
Temperature of reaction atmosphere: 900 to 1020° C.,
Pressure of reaction atmosphere: 7 to 30 kPa, and
Time: 1 to 10 min.
Then, titanium oxide particulates satisfying the composition formula: TiO Y , (where value Y is 1.2 to 1.9 in an atomic ratio to Ti when measured by Auger Electron Spectroscopy) are dispersedly distributed on the surface of the (Al, Ti) 2 O 3 layer. In this state, by carrying out a heat-transforming treatment in an atmosphere of Ar gas, preferably, under the following conditions: a pressure of 7 to 50 kPa, a temperature of 1000 to 1200° C., and a holding duration of 10 to 120 minutes, the (Al, Ti) 2 O 3 layer having the κ-type or θ-type crystal structure is transformed into the (Al, Ti) 2 O 3 layer having an α-type crystal structure. Then, since the titanium oxide particulates uniformly distributed on the surface of the (Al, Ti) 2 O 3 layer before the transformation serve as starting points of cracks generated at the time of the transformation of the κ-type or θ-type crystal structure into the α-type crystal structure in the heat-transformed α-type (Al, Ti) 2 O 3 layer, the cracks generated at the time of the transformation become extremely fine and the titanium oxide particulates are uniformly and dispersedly distributed. Further, since the crystal growth at the time of the heat transformation is suppressed by action of Ti as a constituent element thereof and the fineness of the crystal is thus accomplished, excellent chipping resistance can be obtained. Accordingly, in the coated cermet tool having a hard-coating layer including the heat-transformed α-type (Al, Ti) 2 O 3 layer as the upper layer and the titanium compound layer (this titanium compound layer does not exhibit any change during the heat-transforming treatment under the above-mentioned conditions) as the lower layer, the heat-transformed α-type (Al, Ti) 2 O 3 layer exhibits excellent chipping resistance, even in a high-speed intermittent cutting accompanied with severe mechanical and thermal impacts, with the same high temperature hardness and heat resistance as the excellent high temperature hardness and heat resistance inherent to an α-type Al 2 O 3 layer. As a result, with the presence of the titanium compound layer having high strength, the occurrence of chipping in the hard coating layer is markedly suppressed and an excellent wear resistance is exhibited for a prolonged period of time.
An implementation of the present invention is contrived based on the results of studies described above, and there is thus provided a surface-coated cermet cutting tool formed by coating, on a surface of a tool substrate made of WC-based cemented carbide or TiCN-based cermet, a hard-coating layer including the following upper and lower layers (a) and (b):
(a) as the lower layer, a Ti compound layer having at least one or two of a TiC layer, a TiN layer, a TiCN layer, a TiCO layer and a TiCNO layer, all of which are deposited by chemical vapor deposition, the titanium compound layer having a total average thickness of 3 to 20 μm, and
(b) as the upper layer, a heat-transformed α-type (Al, Ti) 2 O 3 layer formed by carrying out a heat-transforming treatment in a state that titanium oxide particulates satisfying the composition formula: TiO Y , (where value Y is 1.2 to 1.9 in an atomic ratio to Ti when measured by Auger Electron Spectroscopy) and chemically deposited as a transformation starting material are dispersedly distributed on a surface of an (Al, Ti) 2 O 3 layer having a κ-type or θ-type crystal structure deposited by chemical vapor deposition and satisfying the composition formula: (Al 1-X Ti X ) 2 O 3 (where value X is 0.01 to 0.05 in an atomic ratio when measured by an electron probe micro-analyzer (EPMA)) to thereby transform the crystal structure of the (Al, Ti) 2 O 3 layer having the κ-type or θ-type crystal structure into an α-type crystal structure, the heat-transformed α-type (Al, Ti) 2 O 3 layer having an average thickness of 1 to 15 μm.
Next, the reasons for limiting the numerical values in the layers constituting the hard coating layer of the coated cermet layer of an implementation of the present invention as described above will be described below.
(a) Average Thickness of Lower Layer (Ti Compound Layer)
The titanium compound layer inherently has high strength, and the hard-coating layer has high temperature strength by effect of the existence of the titanium compound layer. In addition, the titanium compound layer is firmly adhered to both of the tool substrate and the heat-transformed α-type (Al, Ti) 2 O 3 layer that is the upper layer. Accordingly, it contributes to improving the adherence of the hard coating layer to the tool substrate. However, when the total average thickness is less than 3 μm, the above function cannot be sufficiently obtained. On the other hand, when the total average thickness is greater 20 μm, thermal plastic deformation is apt to occur, particularly in a high-speed intermittent cutting accompanied by the generation of high heat, which causes partial wear. Accordingly, the average thickness is preferably set to 3 to 20 μm.
(b) Value Y of Titanium Oxide Particulates
As described above, since the titanium oxide particulates serve as starting points of the cracks generated at the time of transformation of the deposited κ-type or θ-type (Al, Ti) 2 O 3 layer into the α-type (Al, Ti) 2 O 3 layer, the cracks generated at the time of the transformation in the heat-transformed α-type (Al, Ti) 2 O 3 layer are made fine and are uniformly and dispersedly distributed. As a result, the heat-transformed α-type (Al, Ti) 2 O 3 layer has excellent chipping resistance. However, when value Y thereof to Ti is less than 1.2 in an atomic ratio and when value Y is greater than 1.9, the effect of making the cracks generated at the time of the transformation fine cannot be sufficiently obtained. Therefore, value Y is set to 1.2 to 1.9 in an atomic ratio to Ti.
(c) Content Ratio of Ti in Upper Layer [a Heat-Transformed α-type (Al, Ti) 2 O 3 Layer] and Average Thickness thereof
since the heat-transformed α-type (Al, Ti) 2 O 3 layer has excellent high temperature hardness and heat resistance by action of Al as a constituent element thereof and the crystal growth at the time of the heat transformation is suppressed by action of Ti as a constituent element thereof to thereby make the crystal finer, excellent wear resistance and chipping resistance can be obtained together with uniform and fine distribution of the cracks generated at the time of the heat transformation. However, when the content ratio (value X) of Ti is less than 0.01 in an atomic ratio (this is true of the following ratios) which is a ratio to the total content with Al, a sufficient fine crystal structure cannot be secured. On the other hand, when the content ratio of Ti is greater than 0.05, instability is caused in the transformation, which makes it difficult to sufficiently transform the κ-type or θ-type crystal structure into the α-type crystal structure during the heat-transforming treatment. Thus, the content ratio (value X) of Ti is preferably set to 0.01 to 0.05, and more preferably to 0.015 to 0.035.
Further, when the average thickness of the heat-transformed α-type (Al, Ti) 2 O 3 layer is less than 1 μm, the hard coating layer cannot have sufficient high temperature hardness and heat resistance. On the other hand, when the average thickness of the heat-transformed α-type (Al, Ti) 2 O 3 layer is greater than 15 μm, chipping is apt to occur, so that the average thickness of the heat-transformed α-type (Al, Ti) 2 O 3 layer is preferably set to 1 to 15 μm.
Furthermore, for the purpose of identifying the cutting tool before and after using the cutting tool, the TiN layer having a gold color tone may be deposited as needed. In this case, the average thickness of the TiN layer is preferably 0.1 to 1 μm. This is because, when the average thickness is less than 0.1 μm, sufficient identification cannot be achieved, and the identification due to the TiN layer can be sufficiently obtained only with an average thickness of up to 1 μm.
Moreover, the inventors have conducted studies for improving the chipping resistance of a deposited α-type Al 2 O 3 layer that constitutes the upper layer of the hard coating layer of the conventional coated cermet tools, and have obtained the following results.
On a surface of a tool substrate, the Ti compound layer as a lower layer is formed under normal conditions using a conventional chemical vapor deposition reactor. An Al oxide layer (hereinafter, referred to as an (Al, Cr) 2 O 3 layer) having a κ-type or θ-type crystal structure and satisfying the composition formula: (Al 1-X Cr X ) 2 O 3 (where value X is 0.005 to 0.04 in an atomic ratio when measured by an electron probe micro-analyzer (EPMA)) is deposited under the same normal conditions. Next, the surface of the (Al, Cr) 2 O 3 layer is processed using the chemical vapor deposition reactor under the following conditions:
Composition of reaction gas: in volume %, TiCl 4 : 0.2 to 3%, CO 2 : 0.2 to 10%, Ar: 5 to 50%, and H 2 : balance,
Temperature of reaction atmosphere: 900 to 1020° C.,
Pressure of reaction atmosphere: 7 to 30 kPa, and
Time: 1 to 10 min.
Then, titanium oxide particulates satisfying the composition formula: TiO Y , (where value Y is 1.2 to 1.9 in an atomic ratio to Ti when measured by Auger Electron Spectroscopy) are dispersedly distributed on the surface of the (Al, Cr) 2 O 3 layer. In this state, by carrying out a heat-transforming treatment in an atmosphere of Ar gas, preferably, under the following conditions: a pressure of 7 to 50 kPa, a temperature of 1000 to 1200° C., and a holding duration of 10 to 120 minutes, the (Al, Cr) 2 O 3 layer having the κ-type or θ-type crystal structure is transformed into the (Al, Cr) 2 O 3 layer having an α-type crystal structure. Then, since the titanium oxide particulates uniformly distributed on the surface of the (Al, Cr) 2 O 3 layer before the transformation serve as starting points of cracks generated at the time of the transformation of the κ-type or θ-type crystal structure into the α-type crystal structure in the heat-transformed α-type (Al, Cr) 2 O 3 layer, the cracks generated at the time of the transformation become extremely fine and the titanium oxide particulates are uniformly and dispersedly distributed. Further, since fineness of the cracks generated at the time of the transformation is further promoted by action of Cr as a constituent element thereof, excellent chipping resistance can be obtained. Accordingly, in the coated cermet tool having a hard-coating layer including the heat-transformed α-type (Al, Cr) 2 O 3 layer as the upper layer and the titanium compound layer (this titanium compound layer does not exhibit any change during the heat-transforming treatment under the above-mentioned conditions) as the lower layer, the heat-transformed α-type (Al, Cr) 2 O 3 layer exhibits excellent chipping resistance, even in a high-speed intermittent cutting accompanied with severe mechanical and thermal impacts, with the same high temperature hardness and heat resistance as the excellent high temperature hardness and heat resistance inherent to an α-type Al 2 O 3 layer. As a result, with the presence of the titanium compound layer having high strength, the occurrence of chipping in the hard coating layer is markedly suppressed and an excellent wear resistance is exhibited for a prolonged period of time.
An implementation of the present invention is contrived based on the results of studies described above, and there is thus provided a surface-coated cermet cutting tool formed by coating, on a surface of a tool substrate made of WC-based cemented carbide or TiCN-based cermet, a hard-coating layer including the following upper and lower layers (a) and (b):
(a) as the lower layer, a Ti compound layer having at least one or two of a TiC layer, a TiN layer, a TiCN layer, a TiCO layer and a TiCNO layer, all of which are deposited by chemical vapor deposition, the titanium compound layer having a total average thickness of 3 to 20 μm, and
(b) as the upper layer, a heat-transformed α-type (Al, Cr) 2 O 3 layer formed by carrying out a heat-transforming treatment in a state that titanium oxide particulates satisfying the composition formula: TiO Y , (where value Y is 1.2 to 1.9 in an atomic ratio to Ti when measured by Auger Electron Spectroscopy) and chemically deposited as a transformation starting material are dispersedly distributed on a surface of an (Al, Cr) 2 O 3 layer having a κ-type or θ-type crystal structure deposited by chemical vapor deposition and satisfying the composition formula: (Al 1-X Cr X ) 2 O 3 (where value X is 0.005 to 0.04 in an atomic ratio when measured by an electron probe micro-analyzer (EPMA)) to thereby transform the crystal structure of the (Al, Cr) 2 O 3 layer having the κ-type or θ-type crystal structure into an α-type crystal structure, the heat-transformed α-type (Al, Cr) 2 O 3 layer having an average thickness of 1 to 15 μm.
Next, the reasons for limiting the numerical values in the layers constituting the hard coating layer of the coated cermet layer of an implementation of the present invention as described above will be described below.
(a) Average Thickness of Lower Layer (Ti Compound Layer)
The titanium compound layer inherently has high strength, and the hard-coating layer has high temperature strength by effect of the existence of the titanium compound layer. In addition, the titanium compound layer is firmly adhered to both of the tool substrate and the heat-transformed α-type (Al, Cr) 2 O 3 layer that is the upper layer. Accordingly, it contributes to improving the adherence of the hard coating layer to the tool substrate. However, when the total average thickness is less than 3 μm, the above function cannot be sufficiently obtained. On the other hand, when the total average thickness is greater 20 μm, thermal plastic deformation is apt to occur, particularly in a high-speed intermittent cutting accompanied by the generation of high heat, which causes partial wear. Accordingly, the average thickness is preferably set to 3 to 20 μm.
(b) Value Y of Titanium Oxide Particulates
As described above, since the titanium oxide particulates serve as starting points of the cracks generated at the time of transformation of the deposited κ-type or θ-type (Al, Cr) 2 O 3 layer into the α-type (Al, Cr) 2 O 3 layer, the cracks generated at the time of the transformation in the heat-transformed α-type (Al, Cr) 2 O 3 layer are made fine and are uniformly and dispersedly distributed. As a result, the heat-transformed α-type (Al, Cr) 2 O 3 layer has excellent chipping resistance. However, when value Y thereof to Ti is less than 1.2 in an atomic ratio and when value Y is greater than 1.9, the effect of making the cracks generated at the time of the transformation fine cannot be sufficiently obtained. Therefore, value Y is set to 1.2 to 1.9 in an atomic ratio to Ti.
(c) Content Ratio of Cr in Upper Layer [a Heat-Transformed α-type (Al, Cr) 2 O 3 Layer] and Average Thickness thereof
since the heat-transformed α-type (Al, Cr) 2 O 3 layer has excellent high temperature hardness and heat resistance by action of Al as a constituent element thereof and the fineness of the cracks generated at the time of the transformation using the Ti oxide particulates dispersedly distributed on the surface of the deposited α-type (Al, Cr) 2 O 3 layer is further promoted by action of Cr as a constituent element thereof to thereby make the crystal finer, excellent wear resistance and chipping resistance can be obtained together with uniform and fine distribution of the cracks generated at the time of the heat transformation. However, when the content ratio (value X) of Cr is less than 0.005 in an atomic ratio (this is true of the following ratios) which is a ratio to the total content with Al, sufficient fineness of the cracks generated at the time of the transformation cannot be secured. On the other hand, when the content ratio of Cr is greater than 0.04, instability is caused in the transformation, which makes it difficult to sufficiently transform the κ-type or θ-type crystal structure into the α-type crystal structure during the heat-transforming treatment. Thus, the content ratio (value X) of Cr is preferably set to 0.005 to 0.04, and more preferably to 0.012 to 0.035.
Further, when the average thickness of the heat-transformed α-type (Al, Cr) 2 O 3 layer is less than 1 μm, the hard coating layer cannot have sufficient high temperature hardness and heat resistance. On the other hand, when the average thickness of the heat-transformed α-type (Al, Cr) 2 O 3 layer is greater than 15 μm, chipping is apt to occur, so that the average thickness of the heat-transformed α-type (Al, Cr) 2 O 3 layer is preferably set to 1 to 15 μm.
Furthermore, for the purpose of identifying the cutting tool before and after using the cutting tool, the TiN layer having a gold color tone may be deposited as needed. In this case, the average thickness of the TiN layer is preferably 0.1 to 1 μm. This is because, when the average thickness is less than 0.1 μm, sufficient identification cannot be achieved, and the identification due to the TiN layer can be sufficiently obtained only with an average thickness of up to 1 μm.
In the coated cermet tool according to an implementation of the present invention, since the heat-transformed α-type (Al, Zr) 2 O 3 layer or the heat-transformed α-type (Al, Ti) 2 O 3 layer or the heat transformed α-type (Al, Cr) 2 O 3 layer constituting the upper layer of the hard coating layer exhibits excellent high temperature hardness and heat resistance and more excellent chipping resistance even in the high-speed intermittent cutting of steel, cast iron, etc. having high mechanical and thermal impacts, excellent wear resistance can be obtained without chipping in the hard coating layer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, a coated cermet tool according to the present invention will be described in detail in conjunction with embodiments.
First Embodiment
The following powders, each having a mean particle size in a range of 1 to 3 μm, were prepared as raw materials for substrates: WC powder, TiC powder, ZrC powder, VC powder, TaC powder, NbC powder, Cr 3 C 2 powder, TiN powder, TaN powder and Co powder. Those raw powders were compounded with each other based on the compounding compositions shown in Table 1, mixed with each other in an acetone solution having wax added thereto for 24 hours using a ball mill, and then were dried under reduced pressure. Thereafter, the resultant powder mixture was press-formed into a green compact having a predetermined shape at a pressure of 98 Mpa. The green compact was then sintered in a vacuum under the following conditions: a pressure of 5 Pa, a predetermined temperature in a range of 1370° C. to 1470° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to horning (R: 0.07 mm) to manufacture tool substrates A to F made of WC-based cemented carbide and having a throwaway tip shape defined in ISO Standard•CNMG120408.
Further, the following powders, each having a mean particle size in a range of 0.5 to 2 μm, were prepared as raw materials for substrates: TiCN (TiC/TiN=50/50 in weight ratio) powder, Mo 2 C power, ZrC power, NbC powder, TaC powder, WC power, Co powder and Ni powder. Those raw powders were compounded with each other based on the compounding composition shown in Table 2, were wet-mixed with each other for 24 hours using a ball mill, and were dried. Thereafter, the resulting powder mixture was press-formed into a green compact at a pressure of 98 MPa. The green compact was then sintered in a nitrogen atmosphere under the following conditions: a pressure of 1.3 kPa, a temperature of 1540° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to horning (R: 0.07 mm) to manufacture tool substrates a to f made of TiCN-based cermet and having a chip shape defined in ISO Standard•CNMG120412.
Next, using a general chemical vapor deposition reactor, on the surfaces of the tool substrates A to F and the tool substrates a to f, titanium compound layers as lower layers of the hard-coating layers were deposited with combinations and target thicknesses shown in Table 5 under conditions shown in Table 3 (in Table 3, l-TiCN represents formation conditions of TiCN layers having a longitudinal growth crystal structure described in Japanese Unexamined Patent Application Publication No. 6-8010, and the others represent formation conditions of general granular crystal structure). Next, similarly, (Al, Zr) 2 O 3 layers having a κ-type or θ-type crystal structure were deposited with combinations and target thicknesses shown in Table 5 under conditions shown in Table 3. Subsequently, on a surface of each of the (Al, Zr) 2 O 3 layers having κ-type or θ-type crystal structure, a titanium oxide particulates were deposited with a combination shown in Table 5 under conditions shown in Table 4. In this state, heat-transforming treatment was performed in an Ar atmosphere under the following conditions: a pressure of 30 kPa, a temperature of 1100° C., and a predetermined holding duration in a range of 20 to 100 minutes to transform the (Al, Zr) 2 O 3 layers having a κ-type or θ-type crystal structure into (Al, Zr) 2 O 3 layers having an α-type crystal structure. As a result, coated cermet tools 1 to 13 according to the embodiments of the present invention having the heat-transformed α-type (Al, Zr) 2 O 3 layers as upper layers of the hard-coating layers were manufactured, respectively.
Furthermore, in manufacturing the coated cermet tools 1 to 13 according to the embodiments of the present invention, separate test pieces were prepared, and the test pieces were loaded into the same chemical vapor deposition reactor. The test pieces were taken out of the chemical vapor deposition reactor at the time point when the titanium oxide particulates are formed on the surfaces of the test pieces, and compositions (value Y) of the titanium oxide particulates were measured using an Auger Electron Spectroscopy.
For the purpose of comparison, as shown in Table 6, the deposited α-type Al 2 O 3 layers as upper layers of the hard coating layers with the target thicknesses shown in Table 6 were formed under the same conditions as those shown in Table 3. Then, the conventional cermet tools 1 to 13 were manufactured under the same conditions as the above ones, except that the formation of the titanium oxide particulates and the heat-transforming treatment under the conditions mentioned above were not performed.
The layers constituting of the hard coating layers of the coated cermet tools 1 to 13 according to the embodiments of the present invention and the conventional coated cermet tools 1 to 13 were observed (longitudinal sections of the layers were observed) using an electron probe micro-analyzer (EPMA) and an Auger Electron Spectroscopy. As a result, the former all comprised the Ti compound layer and the heat-transformed α-type (Al, Zr) 2 O 3 layer having substantially the same composition as the target composition, and the Ti oxide particulates deposited on the surfaces before the heat transformation treatment had substantially the same composition as the target composition in the aforementioned observation. On the other hand, it was confirmed that the latter all had the Ti compound layer and the deposited α-type Al 2 O 3 layer having substantially the same composition as the target composition. In addition, the thicknesses of the layers constituting the hard coating layer of the coated cermet tool were measured (the longitudinal sections thereof were measured) using a scanning electron microscope. Here, the thicknesses all exhibited substantially the same average thicknesses (an average of values measured at five points) as the target thicknesses.
Next, in a state in which each of the above-mentioned coated cermet tools was screw-fixed to a tip of a bite made of tool steel with a fixing jig, the coated cermet tools 1 to 13 according to the embodiments of the present invention and the conventional coated cermet tools 1 to 13 were subjected to the following tests:
A dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) of bearing steel under the following condition (referred to as cutting condition A):
Workpiece: a JIS•SUJ2 round bar having four longitudinal grooves equidistantly arranged in the longitudinal direction,
Cutting speed: 350 m/min,
Cutting depth: 1.5 mm,
Feed rate: 0.20 mm/rev,
Cutting time: 5 min;
A dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) of alloyed steel under the following condition (referred to as cutting condition B):
Workpiece: a JIS•SCM440 round bar having four longitudinal grooves equidistantly arranged in the longitudinal direction,
Cutting speed: 400 m/min,
Cutting depth: 1.5 mm,
Feed rate: 0.22 mm/rev,
Cutting time: 5 min; and
A dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) of dark-tiled cast iron under the following condition (referred to as cutting condition C):
Workpiece: a JIS•FCD400 round bar having four longitudinal grooves equidistantly arranged in the longitudinal direction,
Cutting speed: 400 m/min,
Cutting depth: 2.0 mm,
Feed rate: 0.30 mm/rev,
Cutting time: 5 min,
Then, the width of flank wear of a cutting edge was measured in each test. The measurement results are shown in Table 7.
TABLE 1
Compounding Composition (mass %)
Type
Co
TiC
ZrC
VC
TaC
NbC
Cr 3 C 2
TiN
TaN
WC
Tool
A
7
—
—
—
—
—
—
—
—
Balance
Substrate
B
5.7
—
—
—
1.5
0.5
—
—
—
Balance
C
5.7
—
—
—
—
—
1
—
—
Balance
D
8.5
—
0.5
—
—
—
0.5
—
—
Balance
E
12.5
2
—
—
—
—
—
1
2
Balance
F
14
—
—
0.2
—
—
0.8
—
—
Balance
TABLE 2
Compounding Composition (mass %)
Type
Co
Ni
ZrC
TaC
NbC
Mo 2 C
WC
TiCN
Tool
a
13
5
—
10
—
10
16
Balance
Substrate
b
8
7
—
5
—
7.5
—
Balance
c
5
—
—
—
—
6
10
Balance
d
10
5
—
11
2
—
—
Balance
e
9
4
1
8
—
10
10
Balance
f
12
5.5
—
10
—
9.5
14.5
Balance
TABLE 3
Layer
Constituting Hard
Formation Condition (kPa denotes
Coating Layer
pressure of reaction atmosphere, and
Target
° C. denotes temperature thereof)
Composition
Reaction Gas
Reaction
(atomic
Composition
Atmosphere
Type
ratio)
(volume %)
Pressure
Temperature
TiC
TiC
TiCl 4 : 4.2%, CH 4 :
7
1020
8.5%, H 2 : Balance
TiN
TiN
TiCl 4 : 4.2%, N 2 :
30
900
(First
30%, H 2 : Balance
Layer)
TiN
TiN
TiCl 4 : 4.2%, N 2 :
50
1040
(Other
35%, H 2 : Balance
Layers)
l-TiCN
l-TiC 0.5 N 0.5
TiCl 4 : 4.2%, N 2 :
7
900
20%, CH 3 CN: 0.6%,
H 2 : Balance
TiCN
TiC 0.5 N 0.5
TiCl 4 : 4.2%, N 2 :
12
1020
20%, CH 4 : 4%,
H 2 : Balance
TiCO
TiC 0.5 O 0.5
TiCl 4 : 4.2%, CO:
7
1020
4%, H 2 : Balance
TiCNO
TiC 0.3 N 0.3 O 0.4
TiCl 4 : 4.2%, CO:
20
1020
3%, CH 4 : 3%,
N 2 : 20%, H 2 :
Balance
α-
α-Al 2 O 3
AlCl 3 : 2.2%, CO 2 :
7
1000
Al 2 O 3
5.5%, HCl: 2.2%,
H 2 S: 0.2%, H 2 :
Balance
κ-(Al,
Zr (Value X):
AlCl 3 : 3.7%, ZrCl 4 :
7
950
Zr) 2 O 3 -
0.003
0.03%, CO 2 : 5.5%,
A
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
θ-(Al,
Zr (Value X):
AlCl 3 : 3.6%, ZrCl 4 :
7
800
Zr) 2 O 3 -
0.01
0.1%, CO 2 : 5.5%,
B
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
κ-(Al,
Zr (Value X):
AlCl 3 : 3.53% ZrCl 4 :
7
950
Zr) 2 O 3 -
0.017
0.17%, CO 2 : 5.5%,
C
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
θ-(Al,
Zr (Value X):
AlCl 3 : 3.46%, ZrCl 4 :
7
800
Zr) 2 O 3 -
0.024
0.24%, CO 2 : 5.5%,
D
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
κ-(Al,
Zr (Value X):
AlCl 3 : 3.4%, ZrCl 4 :
7
950
Zr) 2 O 3 -
0.03
0.3%, CO 2 : 5.5%,
E
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
θ-(Al,
Zr (Value X):
AlCl 3 : 3.33%, ZrCl 4 :
7
800
Zr) 2 O 3 -
0.037
0.37%, CO 2 : 5.5%,
F
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
κ-(Al,
Zr (Value X):
AlCl 3 : 3.27%, ZrCl 4 :
7
950
Zr) 2 O 3 -
0.043
0.43%, CO 2 : 5.5%,
G
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
θ-(Al,
Zr (Value X):
AlCl 3 : 3.2%, ZrCl 4 :
7
800
Zr) 2 O 3 -
0.05
0.5%, CO 2 : 5.5%,
H
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
TABLE 4
Target
Compo-
sition
of Ti
Formation Condition
Oxide
Reaction
Type of
Partic-
Reaction
Atmosphere
Ti Oxide
ulates
Gas
Pres-
Temper-
Partic-
(atomic
Composition
sure
ature
Time
ulates
ratio)
(volume %)
(kPa)
(° C.)
(minute)
TiO γ -a
TiO 1.20
TiCl 4 :
30
1020
5
0.5%, CO 2 :
0.2%, Ar:
40%, H 2 :
Balance
TiO γ -b
TiO 1.35
TiCl 4 : 3%,
7
1000
3
CO 2 : 5%,
Ar: 40%,
H 2 : Balance
TiO γ -c
TiO 1.50
TiCl 4 : 3%,
14
1000
10
CO 2 : 10%,
Ar: 50%,
H 2 : Balance
TiO γ -d
TiO 1.60
TiCl 4 : 1%,
7
1000
7
CO 2 : 4.5%,
Ar: 40%,
H 2 : Balance
TiO γ -e
TiO 1.75
TiCl 4 : 1%,
7
950
1
CO 2 : 8%,
Ar: 10%,
H 2 : Balance
TiO γ -f
TiO 1.90
TiCl 4 :
7
900
8
0.2%, CO 2 :
5%, Ar: 5%,
H 2 : Balance
TABLE 5
Tool
Hard Coating Layer (numeral in parentheses denotes target thickness: μm)
Ti Oxide
After Heat-
Substrate
First
Second
Third
Fourth
Fifth
Particulate
Transforming
Type
Symbol
Layer
Layer
Layer
Layer
Layer
Symbol
Treatment
Coated
1
A
TiN (1)
l-TiCN (17.5)
TiN (1)
TiCNO (0.5)
θ-(Al,Zr) 2 O 3 -
TiO γ -c
Transformation
Cermet
B (15)
to α-(Al,Zr) 2 O 3
Tool of
2
B
TiCN (1)
l-TiCN (8.5)
TiCO (0.5)
κ-(Al,Zr) 2 O 3 -
—
TiO γ -e
Transformation
embodiments
A (9)
to α-(Al,Zr) 2 O 3
of Present
3
C
TiN (1)
l-TiCN (4)
TiC (4)
TiCNO (1)
κ-(Al,Zr) 2 O 3 -
TiO γ -d
Transformation
Invention
C (15)
to α-(Al,Zr) 2 O 3
4
D
TiC (1)
l-TiCN (9)
θ-(Al,Zr) 2 O 3 -
—
—
TiO γ -f
Transformation
D (3)
to α-(Al,Zr) 2 O 3
5
E
TiN (1)
l-TiCN (4.5)
TiCO (0.5)
θ-(Al,Zr) 2 O 3 -
—
TiO γ -a
Transformation
B (5)
to α-(Al,Zr) 2 O 3
6
F
TiN (0.5)
l-TiCN (1.5)
TiC (0.5)
TiCNO (0.5)
κ-(Al,Zr) 2 O 3 -
TiO γ -b
Transformation
G (3)
to α-(Al,Zr) 2 O 3
7
A
TiN (1)
l-TiCN (8)
TiCNO (0.5)
κ-(Al,Zr) 2 O 3 -
—
TiO γ -e
Transformation
E (1)
to α-(Al,Zr) 2 O 3
8
a
TiN (1)
TiCN (19)
θ-(Al,Zr) 2 O 3 -
—
—
TiO γ -c
Transformation
D (15)
to α-(Al,Zr) 2 O 3
9
b
TiC (0.5)
l-TiCN (9)
TiCO (0.5)
θ-(Al,Zr) 2 O 3 -
—
TiO γ -b
Transformation
D (10)
to α-(Al,Zr) 2 O 3
10
c
TiN (1)
TiC (1)
TiCN (7)
TiCO (1)
κ-(Al,Zr) 2 O 3 -
TiO γ -f
Transformation
E (15)
to α-(Al,Zr) 2 O 3
11
d
TiN (1)
TiC (1)
l-TiCN (8)
κ-(Al,Zr) 2 O 3 -
—
TiO γ -d
Transformation
C (3)
to α-(Al,Zr) 2 O 3
12
e
TiC (1)
l-TiCN (4)
TiCNO (1)
θ-(Al,Zr) 2 O 3 -
—
TiO γ -c
Transformation
F (5)
to α-(Al,Zr) 2 O 3
13
f
TiCN (0.5)
TiC (2)
TiCNO (0.5)
θ-(Al,Zr) 2 O 3 -
—
TiO γ -a
Transformation
H (1)
to α-(Al,Zr) 2 O 3
TABLE 6
Tool
Hard Coating Layer (numeral in parentheses denotes target thickness)
Substrate
First
Second
Third
Fourth
Fifth
Type
Symbol
Layer
Layer
Layer
Layer
Layer
Conventional
1
A
TiN (1)
l-TiCN (17.5)
TiN (1)
TiCNO (0.5)
α-Al 2 O 3 (15)
Coated
2
B
TiCN (1)
l-TiCN (8.5)
TiCO (0.5)
α-Al 2 O 3 (9)
—
Cermet
3
C
TiN (1)
l-TiCN (4)
TiC (4)
TiCNO (1)
α-Al 2 O 3 (15)
Tool
4
D
TiC (1)
l-TiCN (9)
α-Al 2 O 3 (3)
—
—
5
E
TiN (1)
l-TiCN (4.5)
TiCO (0.5)
α-Al 2 O 3 (5)
—
6
F
TiN (0.5)
l-TiCN (1.5)
TiC (0.5)
TiCNO (0.5)
α-Al 2 O 3 (3)
7
A
TiN (1)
l-TiCN (8)
TiCNO (0.5)
α-Al 2 O 3 (1)
—
8
a
TiN (1)
TiCN (19)
α-Al 2 O 3 (15)
—
—
9
b
TiC (0.5)
l-TiCN (9)
TiCO (0.5)
α-Al 2 O 3 (10)
—
10
c
TiN (1)
TiC (1)
TiCN (7)
TiCO (1)
α-Al 2 O 3 (15)
11
d
TiN (1)
TiC (1)
l-TiCN (8)
α-Al 2 O 3 (3)
—
12
e
TiC (1)
l-TiCN (4)
TiCNO (1)
α-Al 2 O 3 (5)
—
13
f
TiCN (0.5)
TiC (2)
TiCNO (0.5)
α-Al 2 O 3 (3)
—
TABLE 7
Width of Flank Wear (mm)
Cutting Test Result
Cutting
Cutting
Cutting
Cutting
Cutting
Cutting
Condition
Condition
condition
Condition
Condition
Condition
Type
A
B
C
Type
A
B
C
Coated
1
0.18
0.19
0.22
Conventional
1
Usable
Usable
Usable
Cermet
Coated
life of
life of
life of
Tool of
Cermet
3.1
2.9
1.7
Present
Tool
minutes
minutes
minutes
Invention
2
0.16
0.15
0.20
2
Usable
Usable
Usable
life of
life of
life of
2.8
2.4
1.3
minutes
minutes
minutes
3
0.14
0.13
0.16
3
Usable
Usable
Usable
life of
life of
life of
2.0
1.5
1.1
minutes
minutes
minutes
4
0.19
0.25
0.27
4
Usable
Usable
Usable
life of
life of
life of
2.7
3.0
2.0
minutes
minutes
minutes
5
0.23
0.29
0.30
5
Usable
Usable
Usable
life of
life of
life of
3.3
3.3
2.9
minutes
minutes
minutes
6
0.25
0.34
0.41
6
Usable
Usable
Usable
life of
life of
life of
3.9
3.7
3.2
minutes
minutes
minutes
7
0.20
0.23
0.25
7
Usable
Usable
Usable
life of
life of
life of
3.8
3.2
2.4
minutes
minutes
minutes
8
0.17
0.27
0.30
8
Usable
Usable
Usable
life of
life of
life of
2.7
2. 5
2.8
minutes
minutes
minutes
9
0.13
0.16
0.16
9
Usable
Usable
Usable
life of
life of
life of
2.1
1.3
1.5
minutes
minutes
minutes
10
0.11
0.14
0.14
10
Usable
Usable
Usable
life of
life of
life of
1.9
1.1
1.2
minutes
minutes
minutes
11
0.13
0.18
0.19
11
Usable
Usable
Usable
life of
life of
life of
2.3
1.9
2.0
minutes
minutes
minutes
12
0.15
0.21
0.23
12
Usable
Usable
Usable
life of
life of
life of
2.5
2.2
2.5
minutes
minutes
minutes
13
0.21
0.33
0.38
13
Usable
Usable
Usable
life of
life of
life of
3.1
2.9
3.0
minutes
minutes
minutes
(In Table 7, usable life is caused by the chipping generated on the hard coating layer.)
As can be seen apparently from the results shown in Tables 5 to 7, in all the cermet tools 1 to 13 according to the embodiments of the present invention, the heat-transformed α-type (Al, Zr) 2 O 3 layer constituting the upper layer of each hard coating layer has excellent high temperature hardness and heat resistance and high strength, and exhibits excellent chipping resistance due to the heat-transformed α-type structure, thereby showing excellent wear resistance, even in the high-speed intermittent cutting of steel or cast iron with very high mechanical and thermal impacts. However, in all the conventional coated cermet tools 1 to 13, the deposited α-type Al 2 O 3 layers could not resist to severe mechanical and thermal impacts in the high-speed intermittent cutting and thus the chipping is generated in the hard coating layers, thereby shortening the usable life of the conventional cermet cutting tools.
Second Embodiment
Next, using a general chemical vapor deposition reactor, on the surfaces of the tool substrates A to F and the tool substrates a to f equal to those used in the first embodiment, titanium compound layers as lower layers of the hard-coating layers were deposited with combinations and target thicknesses shown in Table 9 under conditions shown in Table 8 (in Table 8, l-TiCN represents formation conditions of TiCN layers having a longitudinal growth crystal structure described in Japanese Unexamined Patent Application Publication No. 6-8010, and the others represent formation conditions of general granular crystal structure). Next, similarly, (Al, Ti) 2 O 3 layers having a κ-type or θ-type crystal structure were deposited with combinations and target thicknesses shown in Table 9 under conditions shown in Table 8. Subsequently, on a surface of each of the (Al, Ti) 2 O 3 layers having κ-type or θ-type crystal structure, a titanium oxide particulates were deposited with a combination shown in Table 9 under conditions shown in Table 4. In this state, heat-transforming treatment was performed in an Ar atmosphere under the following conditions: a pressure of 30 kPa, a temperature of 1100° C., and a predetermined holding duration in a range of 20 to 100 minutes to transform the (Al, Ti) 2 O 3 layers having a κ-type or θ-type crystal structure into (Al, Ti) 2 O 3 layers having an α-type crystal structure. As a result, coated cermet tools 14 to 26 according to the embodiments of the present invention having the heat-transformed α-type (Al, Ti) 2 O 3 layers as upper layers of the hard-coating layers were manufactured, respectively.
Furthermore, in manufacturing the coated cermet tools 14 to 26 according to the embodiments of the present invention, separate test pieces were prepared, and the test pieces were loaded into the same chemical vapor deposition reactor. The test pieces were taken out of the chemical vapor deposition reactor at the time point when the titanium oxide particulates are formed on the surfaces of the test pieces, and compositions (value Y) of the titanium oxide particulates were measured using an Auger Electron Spectroscopy.
For the purpose of comparison, as shown in Table 6, the deposited α-type Al 2 O 3 layers as upper layers of the hard coating layers with the target thicknesses shown in Table 6 were formed-under the conditions shown in Table 8. Then, the conventional cermet tools 1 to 13 were manufactured under the same conditions as the above ones, except that the formation of the titanium oxide particulates and the heat-transforming treatment under the conditions mentioned above were not performed.
The layers constituting of the hard coating layers of the coated cermet tools 14 to 26 according to the embodiments of the present invention and the conventional coated cermet tools 1 to 13 were observed (longitudinal sections of the layers were observed) using an electron probe micro-analyzer (EPMA) and an Auger Electron Spectroscopy. As a result, the former all comprised the Ti compound layer and the heat-transformed α-type (Al, Ti) 2 O 3 layer having substantially the same composition as the target composition, and the Ti oxide particulates deposited on the surfaces before the heat transformation treatment had substantially the same composition as the target composition in the aforementioned observation. On the other hand, it was confirmed that the latter all had the Ti compound layer and the deposited α-type Al 2 O 3 layer having substantially the same composition as the target composition. In addition, the thicknesses of the layers constituting the hard coating layer of the coated cermet tool were measured (the longitudinal sections thereof were measured) using a scanning electron microscope. Here, the thicknesses all exhibited substantially the same average thicknesses (an average of values measured at five points) as the target thicknesses.
Next, in a state in which each of the above-mentioned coated cermet tools was screw-fixed to a tip of a bite made of tool steel with a fixing jig, the coated cermet tools 14 to 26 according to the embodiments of the present invention and the conventional coated cermet tools 1 to 13 were subjected to the following tests:
A dry high-speed intermittent cutting test (normal cutting speed is 250 m/min) of alloy steel under the following condition:
Workpiece: a JIS•SCr420 round bar having four longitudinal grooves equidistantly arranged in the longitudinal direction,
Cutting speed: 450 m/min,
Cutting depth: 1.5 mm,
Feed rate: 0.3 mm/rev,
Cutting time: 5 min;
A dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) of carbon steel under the following condition:
Workpiece: a JIS•S20C round bar having four longitudinal grooves equidistantly arranged in the longitudinal direction,
Cutting speed: 400 m/min,
Cutting depth: 1.5 mm,
Feed rate: 0.3 mm/rev,
Cutting time: 5 min; and
A dry high-speed intermittent cutting test (normal cutting speed is 250 m/min) of cast iron under the following condition:
Workpiece: a JIS•FC300 round bar having four longitudinal grooves equidistantly arranged in the longitudinal direction,
Cutting speed: 500 m/min,
Cutting depth: 1.5 mm,
Feed rate: 0.3 mm/rev,
Cutting time: 5 min,
Then, the width of flank wear of a cutting edge was measured in each test. The measurement results are shown in Table 10.
TABLE 9
Formation Condition (kPa denotes
Layer
pressure of reaction atmosphere, and
Constituting Hard
° C. denotes temperature thereof)
Coating Layer
Reaction
Composition
Reaction Gas
Atmosphere
(atomic
Composition
Pres-
Temper-
Type
ratio)
(volume %)
sure
ature
TiC
TiC
TiCl 4 : 4.2%, CH 4 :
7
1020
8.5%, H 2 : Balance
TiN
TiN
TiCl 4 : 4.2%, N 2 :
30
900
(First
30%, H 2 : Balance
Layer)
TiN
TiN
TiCl 4 : 4.2%, N 2 :
50
1040
(Other
35%, H 2 : Balance
Layers)
l-TiCN
l-TiC 0.5 N 0.5
TiCl 4 : 4.2%, N 2 :
7
900
20%, CH 3 CN: 0.6%,
H 2 : Balance
TiCN
TiC 0.5 N 0.5
TiCl 4 : 4.2%, N 2 :
12
1020
20%, CH 4 : 4%, H 2 :
Balance
TiCO
TiC 0.5 O 0.5
TiCl 4 : 4.2%, CO:
7
1020
4%, H 2 : Balance
TiCNO
TiC 0.3 N 0.3 O 0.4
TiCl 4 : 4.2%, CO:
20
1020
3%, CH 4 : 3%, N 2 :
20%, H 2 : Balance
α-
α-Al 2 O 3
AlCl 3 : 2.2%, CO 2 :
7
1000
Al 2 O 3
5.5%, HCl: 2.2%,
H 2 S: 0.2%, H 2 :
Balance
κ-(Al,
Ti (Value X):
AlCl 3 : 3.27%, TirCl 4 :
7
950
Ti) 2 O 3 -A
0.01
0.03%, CO 2 : 5.5%,
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
θ-(Al,
Ti (Value X):
AlCl 3 : 4.24%, TiCl 4 :
7
800
Ti) 2 O 3 -B
0.015
0.07%, CO 2 : 5.5%,
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
κ-(Al,
Ti (Value X):
AlCl 3 : 3.23%, TiCl 4 :
7
950
Ti) 2 O 3 -C
0.02
0.07%, CO 2 : 5.5%,
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
θ-(Al,
Ti (Value X):
AlCl 3 : 4.19%, TiCl 4 :
7
800
Ti) 2 O 3 -D
0.025
0.11%, CO 2 : 5.5%,
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
κ-(Al,
Ti (Value X):
AlCl 3 : 3.20%, TiCl 4 :
7
950
Ti) 2 O 3 -E
0.03
0.10%, CO 2 : 5.5%,
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
θ-(Al,
Ti (Value X):
AlCl 3 : 4.15%, TiCl 4 :
7
800
Ti) 2 O 3 -F
0.035
0.15%, CO 2 : 5.5%,
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
κ-(Al,
Ti (Value X):
AlCl 3 : 3.17%, TiCl 4 :
7
950
Ti) 2 O 3 -G
0.04
0.13%, CO 2 : 5.5%,
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
θ-(Al,
Ti (Value X):
AlCl 3 : 4.09%, TiCl 4 :
7
800
Ti) 2 O 3 -H
0.05
0.22%, CO 2 : 5.5%,
HCl: 2.2%, H 2 S:
0.2%, H 2 : Balance
TABLE 9
Hard Coating Layer (numeral in
Tool
parentheses denotes target thickness: μm)
Ti Oxide
After Heat
Substrate
First
Second
Third
Fourth
Fifth
Particulate
Transforming
Type
Symbol
Layer
Layer
Layer
Layer
Layer
Symbol
Treatment
Coated
14
A
TiN (1)
l-TiCN (17.5)
TiN (1)
TiCNO (0.5)
θ-(Al,Ti) 2 O 3 -
TiO γ -c
Transformation
Cermet
B (15)
to α-(Al,Ti) 2 O 3
Tool of
15
B
TiCN (1)
l-TiCN (8.5)
TiCO (0.5)
κ-(Al,Ti) 2 O 3 -
—
TiO γ -a
Transformation
embodiments
A (9)
to α-(Al,Ti) 2 O 3
of Present
16
C
TiN (1)
l-TiCN (4)
TiC (4)
TiCNO (1)
κ-(Al,Ti) 2 O 3 -
TiO γ -d
Transformation
Invention
C (15)
to α-(Al,Ti) 2 O 3
17
D
TiC (1)
l-TiCN (9)
θ-(Al,Ti) 2 O 3 -
—
—
TiO γ -f
Transformation
D (3)
to α-(Al,Ti) 2 O 3
18
E
TiN (1)
l-TiCN (4.5)
TiCO (0.5)
θ-(Al,Ti) 2 O 3 -
—
TiO γ -a
Transformation
B (5)
to α-(Al,Ti) 2 O 3
19
F
TiN (0.5)
l-TiCN (1.5)
TiC (0.5)
TiCNO (0.5)
κ-(Al,Ti) 2 O 3 -
TiO γ -b
Transformation
G (3)
to α-(Al,Ti) 2 O 3
20
A
TiN (1)
l-TiCN (8)
TiCNO (0.5)
κ-(Al,Ti) 2 O 3 -
—
TiO γ -c
Transformation
E (1)
to α-(Al,Ti) 2 O 3
21
a
TiN (1)
TiCN (19)
θ-(Al,Ti) 2 O 3 -
—
—
TiO γ -e
Transformation
E (15)
to α-(Al,Ti) 2 O 3
22
b
TiC (0.5)
l-TiCN (9)
TiCO (0.5)
θ-(Al,Ti) 2 O 3 -
—
TiO γ -a
Transformation
D (10)
to α-(Al,Ti) 2 O 3
23
c
TiN (1)
TiC (1)
TiCN (7)
TiCO (1)
κ-(Al,Ti) 2 O 3 -
TiO γ -d
Transformation
E (15)
to α-(Al,Ti) 2 O 3
24
d
TiN (1)
TiC (1)
l-TiCN (8)
κ-(Al,Ti) 2 O 3 -
—
TiO γ -f
Transformation
C (3)
to α-(Al,Ti) 2 O 3
25
e
TiC (1)
l-TiCN (4)
TiCNO (1)
θ-(Al,Ti) 2 O 3 -
—
TiO γ -b
Transformation
F (5)
to α-(Al,Ti) 2 O 3
26
f
TiCN (0.5)
TiC (2)
TiCNO (0.5)
θ-(Al,Ti) 2 O 3 -
—
TiO γ -e
Transformation
H (1)
to α-(Al,Ti) 2 O 3
TABLE 10
Width of Flank
Wear (mm)
Cutting Test Result
Alloy
Carbon
Cast
Alloy
Carbon
Cast
Type
Steel
Steel
Iron
Type
Steel
Steel
Iron
Coated
14
0.12
0.10
0.11
Conventional
1
Usable
Usable
Usable
Cermet
Coated
life of
life of
life of
Tool of
Cermet
1.2
1.1
1.4
embodiments
Tool
minutes
minutes
minutes
of Present
15
0.16
0.14
0.15
2
Usable
Usable
Usable
Invention
life of
life of
life of
1.5
1.4
1.7
minutes
minutes
minutes
16
0.15
0.14
0.15
3
Usable
Usable
Usable
life of
life of
life of
1.5
1.3
1.6
minutes
minutes
minutes
17
0.18
0.16
0.17
4
Usable
Usable
Usable
life of
life of
life of
1.7
1.7
1.9
minutes
minutes
minutes
18
0.20
0.18
0.19
5
Usable
Usable
Usable
life of
life of
life of
2.0
1.9
2.2
minutes
minutes
minutes
19
0.22
0.19
0.20
6
Usable
Usable
Usable
life of
life of
life of
2.8
2.6
2.9
minutes
minutes
minutes
20
0.21
0.18
0.19
7
Usable
Usable
Usable
life of
life of
life of
2.0
1.8
2.2
minutes
minutes
minutes
21
0.13
0.12
0.13
8
Usable
Usable
Usable
life of
life of
life of
1.3
1.2
1.5
minutes
minutes
minutes
22
0.15
0.13
0.14
9
Usable
Usable
Usable
life of
life of
life of
1.5
1.3
1.7
minutes
minutes
minutes
23
0.14
0.12
0.14
10
Usable
Usable
Usable
life of
life of
life of
1.4
1.3
1.5
minutes
minutes
minutes
24
0.19
0.17
0.18
11
Usable
Usable
Usable
life of
life of
life of
1.6
1.4
1.8
minutes
minutes
minutes
25
0.18
0.16
0.17
12
Usable
Usable
Usable
life of
life of
life of
2.0
1.8
2.1
minutes
minutes
minutes
26
0.21
0.20
0.20
13
Usable
Usable
Usable
life of
life of
life of
2.5
2.3
2.7
minutes
minutes
minutes
[In Table 10, usable life is caused by the chipping generated in the hard coating layer]
As can be seen apparently from the results shown in Tables 6, 9, and 10, in all the cermet tools 14 to 26 according to the embodiments of the present invention, the heat-transformed α-type (Al, Ti) 2 O 3 layer constituting the upper layer of each hard coating layer has excellent high temperature hardness and heat resistance, and exhibits excellent chipping resistance, thereby showing excellent wear resistance, even in the high-speed intermittent cutting of steel or cast iron with very high mechanical and thermal impacts. However, in all the conventional coated cermet tools 1 to 13, the deposited α-type Al 2 O 3 layers could not resist to severe mechanical and thermal impacts in the high-speed intermittent cutting and thus the chipping is generated in the hard coating layers, thereby shortening the usable life of the conventional cermet cutting tools.
Third Embodiment
Next, using a general chemical vapor deposition reactor, on the surfaces of the tool substrates A to F and the tool substrates a to f equal to those used in the first embodiment, titanium compound layers as lower layers of the hard-coating layers were deposited with combinations and target thicknesses shown in Table 13 under conditions shown in Table 11 (in Table 11, l-TiCN represents formation conditions of TiCN layers having a longitudinal growth crystal structure described in Japanese Unexamined Patent Application Publication No. 6-8010, and the others represent formation conditions of general granular crystal structure). Next, similarly, (Al, Cr) 2 O 3 layers having a κ-type or θ-type crystal structure were deposited with combinations and target thicknesses shown in Table 13 under conditions shown in Table 11. Subsequently, on a surface of each of the (Al, Cr) 2 O 3 layers having κ-type or θ-type crystal structure, a titanium oxide particulates were deposited with a combination shown in Table 13 under conditions shown in Table 12. In this state, heat-transforming treatment was performed in an Ar atmosphere under the following conditions: a pressure of 30 kPa, a temperature of 1100° C., and a predetermined holding duration in a range of 20 to 100 minutes to transform the (Al, Cr) 2 O 3 layers having a κ-type or θ-type crystal structure into (Al, Cr) 2 O 3 layers having an α-type crystal structure. As a result, coated cermet tools 27 to 39 according to the embodiments of the present invention having the heat-transformed α-type (Al, Cr) 2 O 3 layers as upper layers of the hard-coating layers were manufactured, respectively.
Furthermore, in manufacturing the coated cermet tools 27 to 39 according to the embodiments of the present invention, separate test pieces were prepared, and the test pieces were loaded into the same chemical vapor deposition reactor. The test pieces were taken out of the chemical vapor deposition reactor at the time point when the titanium oxide particulates are formed on the surfaces of the test pieces, and compositions (value Y) of the titanium oxide particulates were measured using an Auger Electron Spectroscopy.
For the purpose of comparison, as shown in Table 6, the deposited α-type Al 2 O 3 layers as upper layers of the hard coating layers with the target thicknesses shown in Table 6 were formed under the conditions shown in Table 11. Then, the conventional cermet tools 1 to 13 were manufactured under the same conditions as the above ones, except that the formation of the titanium oxide particulates and the heat-transforming treatment under the conditions mentioned above were not performed.
The layers constituting of the hard coating layers of the coated cermet tools 27 to 39 according to the embodiments of the present invention and the conventional coated cermet tools 1 to 13 were observed (longitudinal sections of the layers were observed) using an electron probe micro-analyzer (EPMA) and an Auger Electron Spectroscopy. As a result, the former all comprised the Ti compound layer and the heat-transformed α-type (Al, Cr) 2 O 3 layer having substantially the same composition as the target composition, and the Ti oxide particulates deposited on the surfaces before the heat transformation treatment had substantially the same composition as the target composition in the aforementioned observation. On the other hand, it was confirmed that the latter all had the Ti compound layer and the deposited (α-type Al 2 O 3 layer having substantially the same composition as the target composition. In addition, the thicknesses of the layers constituting the hard coating layer of the coated cermet tool were measured (the longitudinal sections thereof were measured) using a scanning electron microscope. Here, the thicknesses all exhibited substantially the same average thicknesses (an average of values measured at five points) as the target thicknesses.
Next, in a state in which each of the above-mentioned coated cermet tools was screw-fixed to a tip of a bite made of tool steel with a fixing jig, the coated cermet tools 27 to 39 according to the embodiments of the present invention and the conventional coated cermet tools 1 to 13 were subjected to the following tests:
A dry high-speed intermittent cutting test (normal cutting speed is 250 m/min) of carbon steel under the following condition:
Workpiece: a JIS•S45C round bar having four longitudinal grooves equidistantly arranged in the longitudinal direction,
Cutting speed: 400 m/min,
Cutting depth: 1.0 mm,
Feed rate: 0.2 mm/rev,
Cutting time: 5 min;
A dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) of alloy steel under the following condition:
Workpiece: a JIS•SCM440 round bar having four longitudinal grooves equidistantly arranged in the longitudinal direction,
Cutting speed: 350 m/min,
Cutting depth: 1.5 mm,
Feed rate: 0.3 mm/rev,
Cutting time: 5 min; and
A dry high-speed intermittent cutting test (normal cutting speed is 300 m/min) of cast iron under the following condition:
Workpiece: a JIS•FC300 round bar having four longitudinal grooves equidistantly arranged in the longitudinal direction,
Cutting speed: 450 m/min,
Cutting depth: 2.0 mm,
Feed rate: 0.25 mm/rev,
Cutting time: 5 min,
Then, the width of flank wear of a cutting edge was measured in each test. The measurement results are shown in Table 14.
TABLE 11
Layer
Formation Condition (kPa denotes
Constituting Hard
pressure of reaction atmosphere, and
Coating Layer
° C. denotes temperature thereof)
Target
Reaction
Composition
Reaction Gas
Atmosphere
(atomic
Composition
Pres-
Temper-
Type
ratio)
(volume %)
sure
ature
TiC
TiC
TiCl 4 : 4.2%, CH 4 :
7
1020
8.5%, H 2 : Balance
TiN
TiN
TiCl 4 : 4.2%, N 2 :
30
900
(First
30%, H 2 : Balance
Layer)
TiN
TiN
TiCl 4 : 4.2%, N 2 :
50
1040
(Other
35%, H 2 : Balance
Layers)
l-TiCN
l-TiC 0.5 N 0.5
TiCl 4 : 4.2%, N 2 :
7
1000
20%, CH 3 CN: 0.6%,
H 2 : Balance
TiCN
TiC 0.5 N 0.5
TiCl 4 : 4.2%, N 2 :
12
1020
20%, CH 4 : 4%,
H 2 : Balance
TiCO
TiC 0.5 O 0.5
TiCl 4 : 4.2%, CO:
7
1020
4%, H 2 : Balance
TiCNO
TiC 0.3 N 0.3 O 0.4
TiCl 4 : 4.2%, CO:
20
1020
3%, CH 4 : 3%, N 2 :
20%, H 2 : Balance
α-
α-Al 2 O 3
AlCl 3 : 2.2%, CO 2 :
7
1000
Al 2 O 3
5.5%, HCl: 2.2%,
H 2 S: 0.2%,
H 2 : Balance
κ-(Al,
Cr (Value X):
AlCl 3 : 2.5%, CrCl 3 :
7
950
Cr) 2 O 3 -
0.005
0.05%, CO 2 : 2.2%,
A
HCl: 3%, H 2 S:
0.1%, H 2 : Balance
θ-(Al,
Cr (Value X):
AlCl 3 : 2.5%, CrCl 3 :
7
800
Cr) 2 O 3 -B
0.012
0.08%, CO 2 : 2.2%,
HCl: 3%, H 2 S:
0.3%, H 2 : Balance
κ-(Al,
Cr (Value X):
AlCl 3 : 2.3% CrCl 3 :
7
950
Cr) 2 O 3 -C
0.02
0.08%, CO 2 : 2.2%,
HCl: 3%, H 2 S:
0.1%, H 2 : Balance
θ-(Al,
Cr (Value X):
AlCl 3 : 2.3%, CrCl 3 :
7
800
Cr) 2 O 3 -D
0.025
0.1%, CO 2 : 2.2%,
HCl: 3%, H 2 S:
0.3%, H 2 : Balance
κ-(Al,
Cr (Value X):
AlCl 3 : 2.2%, CrCl 3 :
7
950
Cr) 2 O 3 -E
0.03
0.1%, CO 2 : 2%,
HCl: 3%, H 2 S:
0.1%, H 2 : Balance
θ-(Al,
Cr (Value X):
AlCl 3 : 2.2%, CrCl 3 :
7
800
Cr) 2 O 3 -F
0.035
0.12%, CO 2 : 2%,
HCl: 3%, H 2 S:
0.3%, H 2 : Balance
κ-(Al,
Cr (Value X):
AlCl 3 : 2.2%, CrCl 3 :
7
950
Cr) 2 O 3 -G
0.04
0.15%, CO 2 : 2%,
HCl: 3%, H 2 S:
0.1%, H 2 : Balance
TABLE 12
Target
Compo-
sition
of Ti
Formation Condition
Oxide
Reaction
Type of
Partic-
Atmosphere
Ti Oxide
ulates
Reaction Gas
Pres-
Temper-
Partic-
(atomic
Composition
sure
ature
Time
ulates
ratio)
(volume %)
(kPa)
(° C.)
(minute)
TiO γ -a
TiO 1.20
TiCl 4 : 0.5%, CO 2 :
30
1020
10
0.2%, Ar: 40%,
H 2 : Balance
TiO γ -b
TiO 1.35
TiCl 4 : 3%, CO 2 :
7
1000
10
5%, Ar: 40%,
H 2 : Balance
TiO γ -c
TiO 1.50
TiCl 4 : 3%, CO 2 :
14
1000
7
10%, Ar: 50%,
H 2 : Balance
TiO γ -d
TiO 1.60
TiCl 4 : 1%, CO 2 :
7
1000
15
4.5%, Ar: 40%,
H 2 : Balance
TiO γ -e
TiO 1.75
TiCl 4 : 1%, CO 2 :
7
950
15
8%, Ar: 10%,
H 2 : Balance
TiO γ -f
TiO 1.90
TiCl 4 : 0.2%, CO 2 :
7
900
20
5%, Ar: 5%,
H 2 : Balance
TABLE 13
Tool
Hard Coating Layer (numeral in parentheses denotes target thickness: μm)
Ti Oxide
After Heat
Substrate
First
Second
Third
Fourth
Fifth
Particulate
Transforming
Type
Symbol
Layer
Layer
Layer
Layer
Layer
Symbol
Treatment
Coated
27
A
TiN (1)
l-TiCN (17.5)
TiN (1)
TiCNO (0.5)
θ-(Al,Cr) 2 O 3 -
TiO γ -d
Transformation
Cermet
B (15)
to α-(Al,Cr) 2 O 3
Tool of
28
B
TiCN (1)
l-TiCN (8.5)
TiCO (0.5)
κ-(Al,Cr) 2 O 3 -
—
TiO γ -b
Transformation
embodiments
A (9)
to α-(Al,Cr) 2 O 3
of Present
29
C
TiN (1)
l-TiCN (4)
TiC (4)
TiCNO (1)
κ-(Al,Cr) 2 O 3 -
TiO γ -a
Transformation
Invention
C (15)
to α-(Al,Cr) 2 O 3
30
D
TiC (1)
l-TiCN (9)
θ-(Al,Cr) 2 O 3 -
—
—
TiO γ -c
Transformation
D (3)
to α-(Al,Cr) 2 O 3
31
E
TiN (1)
l-TiCN (4.5)
TiCO (0.5)
κ-(Al,Cr) 2 O 3 -
—
TiO γ -e
Transformation
E (5)
to α-(Al,Cr) 2 O 3
32
F
TiN (0.5)
l-TiCN (1.5)
TiC (0.5)
TiCNO (0.5)
κ-(Al,Cr) 2 O 3 -
TiO γ -f
Transformation
G (3)
to α-(Al,Cr) 2 O 3
33
A
TiN (1)
l-TiCN (8)
TiCNO (0.5)
κ-(Al,Cr) 2 O 3 -
—
TiO γ -c
Transformation
E (1)
to α-(Al,Cr) 2 O 3
34
a
TiN (1)
TiCN (19)
θ-(Al,Cr) 2 O 3 -
—
—
TiO γ -b
Transformation
D (15)
to α-(Al,Cr) 2 O 3
35
b
TiC (0.5)
l-TiCN (9)
TiCO (0.5)
θ-(Al,Cr) 2 O 3 -
—
TiO γ -f
Transformation
D (10)
to α-(Al,Cr) 2 O 3
36
c
TiN (1)
TiC (1)
TiCN (7)
TiCO (1)
κ-(Al,Cr) 2 O 3 -
TiO γ -a
Transformation
D (15)
to α-(Al,Cr) 2 O 3
37
d
TiN (1)
TiC (1)
l-TiCN (8)
κ-(Al,Cr) 2 O 3 -
—
TiO γ -e
Transformation
C (3)
to α-(Al,Cr) 2 O 3
38
e
TiC (1)
l-TiCN (4)
TiCNO (1)
θ-(Al,Cr) 2 O 3 -
—
TiO γ -c
Transformation
F (5)
to α-(Al,Cr) 2 O 3
39
f
TiCN (0.5)
TiC (2)
TiCNO (0.5)
θ-(Al,Cr) 2 O 3 -
—
TiO γ -d
Transformation
B (1)
to α-(Al,Cr) 2 O 3
TABLE 14
Width of Flank
Wear (mm)
Cutting Test Result
Alloy
Carbon
Cast
Alloy
Carbon
Cast
Type
Steel
Steel
Iron
Type
Steel
Steel
Iron
Coated
27
0.22
0.25
0.24
Conventional
1
Usable
Usable
Usable
Cermet
Coated
life of
life of
life of
Tool of
Cermet
2.5
2.2
2.4
embodiments
Tool
minutes
minutes
minutes
of Present
28
0.18
0.21
0.23
2
Usable
Usable
Usable
Invention
life of
life of
life of
2.3
2.0
2.3
minutes
minutes
minutes
29
0.15
0.17
0.20
3
Usable
Usable
Usable
life of
life of
life of
2.1
1.7
2.0
minutes
minutes
minutes
30
0.25
0.26
0.26
4
Usable
Usable
Usable
life of
life of
life of
2.8
2.6
3.0
minutes
minutes
minutes
31
0.30
0.33
0.35
5
Usable
Usable
Usable
life of
life of
life of
3.2
3.0
3.3
minutes
minutes
minutes
32
0.34
0.36
0.40
6
Usable
Usable
Usable
life of
life of
life of
3.5
3.3
3.6
minutes
minutes
minutes
33
0.26
0.29
0.30
7
Usable
Usable
Usable
life of
life of
life of
3.1
3.9
3.2
minutes
minutes
minutes
34
0.28
0.31
0.34
8
Usable
Usable
Usable
life of
life of
life of
2.8
3.5
2.7
minutes
minutes
minutes
35
0.15
0.17
0.20
9
Usable
Usable
Usable
life of
life of
life of
1.5
2.2
1.6
minutes
minutes
minutes
36
0.13
0.15
0.18
10
Usable
Usable
Usable
life of
life of
life of
1.3
1.0
1.5
minutes
minutes
minutes
37
0.20
0.23
0.24
11
Usable
Usable
Usable
life of
life of
life of
2.3
2.0
2.7
minutes
minutes
minutes
38
0.25
0.28
0.30
12
Usable
Usable
Usable
life of
life of
life of
2.5
2.3
2.9
minutes
minutes
minutes
39
0.34
0.36
0.41
13
Usable
Usable
Usable
life of
life of
life of
3.0
2.8
3.1
minutes
minutes
minutes
[In FIG. 14 , usable life is caused by the chipping generated in the hard coating layer]
As can be seen apparently from the results shown in Tables 6, 13, and 14, in all the cermet tools 27 to 39 according to the embodiments of the present invention, the heat-transformed α-type (Al, Cr) 2 O 3 layer constituting the upper layer of each hard coating layer has excellent high temperature hardness and heat resistance, and exhibits excellent chipping resistance, thereby showing excellent wear resistance, even in the high-speed intermittent cutting of steel or cast iron with very high mechanical and thermal impacts. However, in all the conventional coated cermet tools 1 to 13, the deposited α-type Al 2 O 3 layers could not resist to severe mechanical and thermal impacts in the high-speed intermittent cutting and thus the chipping is generated in the hard coating layers, thereby shortening the usable life of the conventional cermet cutting tools.
As described above, the coated cermet tool according to the embodiments of the present invention exhibits excellent chipping resistance in the high-speed intermittent cutting under particularly severe cutting conditions, as well as in the continuous cutting or the intermittent cutting of various steels, cast iron, etc. under normal conditions, and has an excellent cutting performance for a long time period, so that it is possible to satisfactorily cope with the demands for high performance of a cutting apparatus, labor saving and energy saving in cutting work, and cost reduction. | There is provided a surface-coated cermet cutting tool with a hard-coating layer having excellent chipping resistance. The surface-coated cermet cutting tool is formed by coating, on a surface of a tool substrate made of WC-based cemented carbide or TiCN-based cermet, a hard-coating layer including the following upper and lower layers (a) and (b): (a) as the lower layer, a Ti compound layer having at least one or two of a TiC layer, a TiN layer, a TiCN layer, a TiCO layer and a TiCNO layer, all of which are deposited by chemical vapor deposition, the titanium compound layer having a total average thickness of 3 to 20 μm, and (b) as the upper layer, a heat-transformed α-type Al oxide layer formed by carrying out a heat-transforming treatment in a state that titanium oxide particulates satisfying the composition formula: TiO Y , (where value Y is 1.2 to 1.9 in an atomic ratio to Ti when measured by Auger Electron Spectroscopy) and chemically deposited as a transformation starting material are dispersedly distributed on a surface of an Al oxide layer having a κ-type or θ-type crystal structure deposited by chemical vapor deposition and satisfying the composition formula: (Al 1-X Zr X ) 2 O 3 (where value X is 0.003 to 0.05 in an atomic ratio when measured by an electron probe micro-analyzer (EPMA)) to thereby transform the crystal structure of the Al oxide layer having the κ-type or θ-type crystal structure into an α-type crystal structure, the heat-transformed α-type Al oxide layer having an average thickness of 1 to 15 μm. | 8 |
This is a continuation of application Ser. No. 08/113,159 filed on Aug 27, 1993, now abandoned.
BACKGROUND OF THE INVENTION
This invention is related to Merck case 18727IA, U.S. Ser. No. 07/991,164, filed Dec. 16, 1992, now abandoned, U.S. Ser. No. 08/148,476; and U.S. Ser. No. 08/294,771.
A retrovirus designated human immunodeficiency virus (HIV) is the etiological agent of the complex disease that includes progressive destruction of the immune system (acquired immune deficiency syndrome; AIDS) and degeneration of the central and peripheral nervous system. This virus was previously known as LAV, HTLV-III, or ARV. A common feature of retrovirus replication is reverse transcription of the RNA genome by a virally encoded reverse transcriptase to generate DNA copies of HIV sequences, a required step in viral replication. It is known that some compounds are reverse transcriptase inhibitors and are effective agents in the treatment of AIDS and similar diseases, e.g., azidothymidine or AZT.
This invention relates to an improved process for synthesizing the AIDS antiviral L-738,372, which is a chiral compound of the structure ##STR1##
The substituted quinazoline L-738,372 is an exceptionally potent inhibitor of HIV reverse transcriptase. This activity of the compound makes it useful in the treatment or prevention of AIDS.
The present invention describes an improved synthesis of an intermediate for this compound. A prior method employs a Grignard reagent, which is unsuitable for commercial scale-up. The improved process of the present invention gives higher yields, and is an entirely different approach. In this invention there is a condensation of para-chloroaniline with cyanocyclopropane to give the desired intermediate 4-chloro-2-cyclopropylcarbonylaniline. Alternatively, but less preferably, para-chloroaniline is condensed with chlorobutyronitrile, followed by a second step of ring closure to form 4-chloro-2-cyclopropylcarbonylaniline.
SUMMARY OF THE INVENTION
This invention is concerned with an improved process for introducing the acyl function to the ortho-position of the aromatic amine in preparation of this cyclopropylcarbonylaniline intermediate. The improved process proceeds in higher yield without the use of a Grignard reagent which is incompatible with large scale industrial production. The improved process involves, instead, a condensation of para-chloroaniline with cyanocyclopropane to give the desired cyclopropylcarbonyl compound directly. Alteratively, in a two step sequence, para-chloroaniline is condensed with chlorobutyronitrile, then there is ring closure of the 4-chlorobutyryl group to form the desired cyclopropylcarbonyl compound.
DETAILED DESCRIPTION OF THE INVENTION
The novel process of this invention is illustrated by the reactions of the following scheme: ##STR2## wherein R is ##STR3## or --(CH 2 ) 3 Cl ##STR4## wherein R is ##STR5## or (CH 2 ) 3 Cl; which comprises treating a mixture of boron trichloride and a compound of structural formula 1 ##STR6## in an organic solvent with a compound of formula RCN (2) and an auxiliary Lewis acid selected from aluminum trichloride, indium trichloride, ferric chloride and gallium trichloride at 15°-35° C., followed by heating at about 100°-130° C. for about 3-6 hours, to produce a compound of structural formula: ##STR7##
In one embodiment of this process, the 4-chloroaniline in an organic solvent such as methylene chloride, chlorobenzene, xylene, toluene or tetra-chloroethane is added slowly to a solution of boron trichloride in a similar organic solvent at about -10° C. to about 10° C. After warming to about 15 to 35° C., 4-chlorobutyronitrile is added. An auxiliary Lewis acid such as aluminum trichloride, indium trichloride, ferric chloride or gallium trichloride is then added with stirring and stirring is continued with heating for about 3-6 hours at 100 to 130° C. Stirring for about 4 hours at about 100° C. is preferred.
The intermediate, formed in this process after the addition of the auxiliary Lewis acid, is a compound of the structure ##STR8## based on NMR studies.
In another embodiment of this process, the use of AlCl 3 provides ketone 3 in yields of about 45%. On the other hand, using GaCl 3 under similar conditions increases the yields of 3 to about 75%. Also, use of 2 moles (instead of ! .5 moles) of 4-chloroaniline per mole of nitrile further increases the yield to about 88-93%.
In another embodiment of this process, 4-chloroaniline in an organic solvent is added slowly to a solution of boron trichloride in an organic solvent at between about -20° C. and about 15° C. After warming to between about 15° C. and about 35° C., 4-chlorobutyronitrile (about 0.5 equivalent/equivalent 4-chloroaniline) is added. An auxiliary Lewis acid (about 0.55-0.6 equivalents) is then added with stirring and the stirring is continued at about 80°-140° C. for about 1 to 24 hours, preferably 3 to 6 hours. The organic solvents for this process include halogenated hydrocarbons, such as methylene chloride, 1,1,2,2-tetrachloroethane, 1,2-dichloroethane, or benzene derivatives, such as toluene, xylene, chlorobenzene, or mixture of these solvents. Other solvents may be suitable. The preferred solvent is toluene. The auxiliary Lewis acid is selected from aluminum trichloride, indium trichloride, ferric chloride, gallium trichloride, aluminum tribromide, gallium tribromide, ferric bromide, or indium tribromide. The preferred auxiliary Lewis acid is gallium trichloride.
The most preferred process is for the preparation of a compound of the structural formula: ##STR9## which comprises the steps of
(a) mixing one equivalent of 4-chloroaniline in toluene with about one equivalent of BCl 3 at a temperature range of about -10° to about 10° C., to give a mixture;
(b) warming the mixture to between about 15° and about 35° C.;
(c) adding thereto about 0.5 equivalents of 4-chlorobutyronitrile;
(d) adding about 0.55 equivalents of GaCl 3;
(e) stirring for about 4 hours at about 100° C., to give compound 4.
In the process wherein R is - (CH2)3C1, the next step to prepare the cyclopropylcarbonyl compound 4 comprises treating the purified or crude product 3 in an organic solvent such as THF, DMF or ether with potassium t-butoxide or other alkoxide salts at about room temperature (15°-30° C.). After completion of the reaction (about 30 minutes), it is quenched by the addition of water. ##STR10##
The intermediate 4 is useful in the synthesis of the reverse transcriptase inhibitor in accordance with the following reaction scheme, the steps of which are described in detail below. ##STR11##
As mentioned previously, the ultimate product from the novel process of this invention is useful in the inhibition of HIV reverse transcriptase, the prevention or treatment of infection by human immunodeficiency virus (HIV) and the treatment of consequent pathological conditions such as AIDS. Treating AIDS or preventing or treating infection by HIV is defined as including, but not limited to, treating a wide range of states of HIV infection: AIDS, ARC (AIDS related complex), both symptomatic and asymptomatic, and actual or potential exposure to HIV. For example, the compounds of this invention are useful in treating infection by HIV after suspected past exposure to HIV by e.g., blood transfusion, exchange of body fluids through bites, accidental needle stick, or exposure to patient blood during surgery.
The particular advantage of the compound of this invention is its potent inhibition of HIV reverse transcriptase rendered resistant to other antivirals, such as 3-([(4,7-dichloro- 1,3-benzoxazol-2-yl)methyl]-amino)-5-ethyl-6-methyl -pyridin-2(1H)-one; or 3-[2-1,3-benzoxazol-2yl)ethyl]-5-ethyl-6-methyl-pyridin-2(1H)-one; or AZT.
The ultimate product from the novel process of the present invention is also useful in determining the binding site of other antivirals to HIV reverse transcriptase, e.g., by competitive inhibition. Thus, the ultimate product of the process of this invention is a commercial product to be sold for these purposes.
For the purpose of treating AIDS or ARC, compound 10 may be administered orally, parenterally (including subcutaneous injections, intravenous, intramuscular, intrastemal injection or infusion techniques), by inhalation spray, or rectally, in dosage unit formulations containing conventional non-toxic pharmaceutically acceptable carders, adjuvants and vehicles.
Thus, in accordance with the present invention there is further provided a method of treating and a pharmaceutical composition for treating HIV infection and AIDS. The treatment involves administering to a patient in need of such treatment a pharmaceutical composition comprising a pharmaceutical carrier and a therapeutically effective amount of compound 10.
Compound 10 can be administered orally to humans in a dosage range of 0.1 to 100 mg/kg body weight in divided doses. One preferred dosage range is 0.1 to 10 mg/kg body weight orally in divided doses. Another preferred dosage range is 0.1 to 20 mg/kg body weight orally in divided doses. It will be understood, however, that the specific dose level and frequency of dosage for any particular patient may be varied and will depend upon a variety of factors including the age, body weight, general health, sex, diet, mode and time of administration, rate of excretion, drug combination, the severity of the particular condition, and the host undergoing therapy.
The present invention is also directed to combinations of compound 10 with one or more agents useful in the treatment of AIDS. For example, compound 10 may be effectively administered, whether at periods of pre-exposure and/or post-exposure, in combination with effective amounts of the AIDS antivirals, immunomodulators, antiinfectives, or vaccines.
EXAMPLE
Preparation of ketone 3 with Lewis acid AlCl 3
To a 3-neck, round bottom flask equipped with an overhead stirrer, BCl 3 , (1M solution in CH 2 Cl 2 , 460 ml, 0.46 mol) was added, under N 2 , via addition funnel. After addition, the funnel was removed, under N 2 purge, and replaced with a distillation condenser and trap for removal of methylene chloride. The apparatus was vented through an aqueous NaOH scrubber.
In a separate flask, chlorobenzene (260 ml) was added to 4-chloroaniline, 1, (80.0 g, 0.63 mol). Heating was needed in order to dissolve the aniline completely.
The 4-chloroaniline solution was cannulated into the BCl 3 solution slowly at 0° C. The solution became a thick slurry which was warmed to RT followed by addition of neat 4-chlorobutyronitrile, 2, (37.4 ml, 0.42 mol) with no effect on temperature. Immediately after, solid AlCl 3 , under N 2 , was added at which time an exotherm of approximately 10° C. was observed and the slurry became homogenous. The reaction mixture was then heated at 100° C. and the methylene chloride was distilled. When the distillation was completed, the reaction mixture was heated at reflux (130° C.) for approximately 4 hours, and aged overnight at RT.
The reaction mixture was quenched with equal parts of THF and 1N HCl (300-500 ml) at ca. 25° C. (A cooling bath was used to control the resulting exotherm). A thick slurry formed during the quench which was dissolved by heating to about 60° C. The solution was allowed to cool to RT and was stirred for approximately 1 hour. It was then extracted with methylene chloride (ca 500 mL). The organic layer was washed with 1N HCI, dried over MgSO 4 , filtered and concentrated in vacuo. A 1 H NMR of the crude concentrate showed the desired product, 3, (45% yield) and a trace of 4-chlorobutyronitrile. The crude product was used as such in the following reaction.
Alternate Preparation of Ketone 3 with Lewis acid GaCl 3
To a dry 50 L three neck round bottom flask, equipped with a 10 L dropping funnel, an overhead stirrer, a thermocouple probe, a reflux condenser, a bubbler, a nitrogen inlet and a scrubber, was charged 10.6 L of dry toluene (KF<100 μg/mL) under ice-MeOH cooling. To this solution was added boron trichloride gas (1.42 kg), keeping the temperature under 7° C.
To a 22 L three neck round bottom flask, equipped with a nitrogen inlet and an overhead stirrer, was added dry toluene (10.2 L, KF<100 μg/mL). To this solution was added 2.214 kg of 4-chloroaniline and warmed up to 55° C. to give a homogeneous solution. The solution was cooled to 10°-20° C.
The solution of 4-chloroaniline was transferred into the 10 L dropping funnel and added to the solution of boron trichloride, keeping the temperature at least below 10° C. with a dry ice-acetone bath. The reaction mixture turned into a heavy suspension.
The suspension was stirred at room temperature for 30 minutes. To this suspension was added 4-chlorobutyronitrile (991 mL, 11 mole), in one portion, under a nitrogen atmosphere.
After 30 minutes of stirring, gallium trichloride (2.324 kg) was added to the mixture under nitrogen atmosphere. The resulting exothermic reaction raised the temperature of the mixture to about 40° C. This solution was stirred at 100° C. for 5 hours, giving a biphasic reaction mixture (70-75% yield). The solution was cooled to 40° C. The solution was diluted with toluene (3 L) and DI water (11 L). The organic phase was separated. The pH of the aqueous layer was 0.2. The organic layer was washed with DI water (11 L) to remove 4-chloroaniline. The final organic layer (25 L) contained 70 mg/mL of the product (1800 g; 72% yield). The solution was concentrated under reduced pressure to give 16 L of a 113 mg/mL (0.5 M) solution of the product (KF<170 μg/mL). This solution was used directly in the next step.
Employing the procedures substantially as described above for preparation of ketone 3 but substituting INCl 3 or FeCl 3 for the AlCl 3 and GaCl 3 , similar results are obtained.
Preparation of 4
A solution of the crude product from the previous reaction in THF (820 ml) was treated with t-BuOK (15 1 ml, 0.257 mol) in THF via addition funnel at a moderate rate (small exotherm was observed). The reaction was complete within 30 minutes and was quenched with H 2 O followed by the addition of NaCl to saturate the aqueous layer. The organic layer was washed with 1N HCl, dried over MgSO 4 , filtered, and concentrated in vacuo to obtain 33.5 g (41-44% overall yield when the AlCl 3 procedure was used) of the desired product, 4.
Note: Excess t-BuOK must be added to compensate for the remaining 4-chlorobutyronitrile from the previous reaction when AlCl 3 was used. The latter was converted, under the reaction conditions, to cyclopropyl nitrile which was easily removed in vacuo. Using the GaCl 3 procedure there was no 4-chlorobutyronitrile present.
Preparation of 5
Potassium cyanate (40 g, 0.484 mol) was dissolved in H 2 O (80 ml) and this solution was added to a cold solution (+9° C.) of the cyclopropyl ketone, 4, (39.9 g, 0.20 mol) in acetic acid (800 ml). After the addition was completed, the cooling bath was removed. The reaction was monitored carefully for disappearance of starting material, (4), since prolonged aging resulted in higher level of impurities. The reaction was complete within 1-1.5 hours at which time, H 2 O (3300 ml) was added and the resulting slurry was allowed to stir for 2 hours. The solid was isolated by filtration and the cake was washed with H 2 O (1400 ml) and dried in vacuo (40° C.) to give the desired product, 5, 38.4 g (87% yield). This yield included the 2 impurities at 3.3 min and 6.7 min (HPLC retention times).
The cyclopropyl quinazolinone, 5, (38.3 g) was suspended in hexanes (960 ml) and heated at reflux for 10-15 minutes. After cooling and filtration, 35.7 g were obtained (81% overall yield with 93% recovery). By LC assay, the 6.7-6.9 min impurity peak (the Nacetyl derivative 11) had decreased from 10% A to 1.2% A; them was no effect on the 3.3 min peak.
Preparation of 7
NaI (10.2 g, 68.03 mmol) was dried by heating to +80° C. under high vacuum for 4 hours.
The quinazolinone, 5, (10 g, 45.35 mmol) was azeotropically dried with toluene and then dissolved in DMF (80 ml) in a 3-neck, round bottom flask equipped with a mechanical stirrer and an addition funnel. Additional DMF (20 ml) was used for rinses. The reaction vessel was cooled to 0° C. and LHMDS (55 ml, 55.0 mmol in THF, 1 M) was added via an addition funnel maintaining the temperature below +5° C. After 15-30 minutes, 4-methoxybenzyl chloride, fi, (8 ml, 59.0 mmol) was added followed by NaI (10.2 g, 68.03 mmol). The cooling bath was then removed and the reaction was allowed to warm to RT. The reaction was heated to 60° C. and allowed to age overnight. With approximately 2% A of starting material (5) present, the reaction mixture was cooled to RT, concentrated in vacuo, and the concentrate was flushed with acetonitrile (2×50 ml). Acetonitrile (140 ml) was then added to the concentrate, with stirring, followed by slow addition of water (70 ml). The resulting slurry was allowed to stir for 10 minutes and the product was filtered. The cake was washed with acetonitrile-water (75 ml, 2:1 ) and dried in vacuo (40° C.) giving 7, 11.3 g (73%).
Preparation of 9
To a 3-neck, round bottom flask, THF (32 ml) was added followed by 2-ethynyl pyridine, 8, (800 gl, 7.92 mmol). The solution was cooled to -78° C. and n-BuLi (4.8 ml, 7.63 mmol in hexane, 1 M) was added dropwise maintaining the temperature below -70° C. After the addition was complete, the solution became heterogeneous and was aged for 2 hours at -78° C. The benzylated quinazolinone, 7, (2 g, 5.87 mmol) was added under a N 2 blanket. The reaction mixture was warmed to -15° C. and was aged for 12 hours until less than 1 A%, by LC, of starting material, 7, was present. The reaction mixture was quenched with 1 M citric acid followed by extractive workup using EtOAc and saturation of aqueous layer with NaCl. The organic layer was washed with saturated NaHCO 3 solution, dried over MgSO 4 , filtered and concentrated in vacuo. Hexanes (20 ml) and ethyl acetate (5 ml) were added to the concentrate and the resulting slurry was stirred overnight. After filtration, the cake was washed with hexanesethylacetate (25 ml, 4:1 ) and dried in a vacuum oven to give 2.2 g (86%) of the desired product, 9. The LC purity, using 65:35% to 100.0% acetonitrile:water (in 35 minutes), was 96 A% (uncorrected).
Preparation of 10
A quantity of 70 mg (0.16 mmole) of 9 was treated with a solution of 3.2 ml of trifluoroacetic acid in 4.5 ml of methylene chloride for 96 hours under argon. The solvents were evaporated and the residue was partitioned between CHCl 3 and 10% w/v aqueous Na 2 CO 3 . The organic layer was dried over Na 2 SO 4 , filtered and evaporated to 38 mg of an amorphous solid (73%).
NMR (CDCl 3 ): 0.58-0.72 (m, 1H), 0.73-0.90 (m, 2H), 0.91-1.04 (m, 1H), 1.47-1.60 (m, 1H), 5.85 (s, 1H), 6.78 (d, J=8Hz, 1H), 7.15 (dd, J-8, 2Hz, 1H), 7.20-7.28 (m, 1H), 7.39 (d, J=8Hz, 1H), 7.52 (d, J-2Hz, 1H), 7.63 (td, J=8,2Hz, 1H), 8.58 (d, J=4Hz, 1H), 9.13 (s, 1H). | 4-Chloro-2-cyclopropylcarbonylaniline is prepared by condensation of 4-chloroaniline with 4-chlorobutyronitrile to form a 2-(4-chlorobutyryl)-4-chloroaniline, followed by ring closure of the 4-chlorobutyryl group to a cyclopropylcarbonyl moiety. | 2 |
FIELD OF THE INVENTION
The invention relates to apparatus for removing gases containing dust and other particulate matter evolving from the operation of a coke oven battery by means of a gas collecting arrangement movable from one coking chamber to the next, said arrangement being connected to a removal duct having a stationary collecting main for removing the gases positioned essentially parallel to the path of movement of said gas collecting arrangement, said main being provided at its top side with a full-length slotted longitudinal opening that can be covered by at least one flexible belt and with an enveloping carriage connected to the removal duct and movable parallel to said longitudinal opening, and the carriage being provided with guide rollers for lifting the flexible belt from the collecting main within the outlet region of the removal duct.
DESCRIPTION OF THE PRIOR ART
U.S. Pat. No. 3,729,384 (German OS No. 2,201,963) teaches removing dust-containing gases emitted during pushing coke from coking ovens, by providing a gas-collecting main along the coking side of the coke oven battery, its open top side being covered by a flexible belt made of a heat-resistant material. Arranged on the gas collecting main is a hood jointly movable with the coke guide, said hood having an intake port or a supply line for the dust-containing gases. Rollers are provided inside of the hood for lifting the flexible belt to provide an opening in the gas-collecting main. The flexible belt is thus directly acted upon by the hot exhaust gases that are laterally sucked into the hood. Accordingly, the belt must be manufactured of a heat-resistant material which, in addition, must be wear-resistant. Heat-resistant, wear-resistant belts with a life span of several years necessary for coking operations, which furthermore have the flexibility necessary for this application, are however not available.
A device of the type mentioned at the beginning for removing dust-containing gases emitted during pushing and/or quenching coke from coking chambers, is taught by German OS No. 2,326,630, which provides a cooling device constructed as a bundle of pipes between the dust collecting hood and the connecting carriage for connecting the removal duct with the collecting main. This indeed enables a certain amount of precooling of the hot exhaust gases prior to entry into the collecting main; nevertheless, it requires a heat exchanger of relatively high weight, so that the mobile exhaust device becomes quite heavy. The additional weight of the heat exchanger increases the wheel loads of the machines so that they become inadmissibly high for the majority of existing coke oven batteries, so that expensive reenforcements of foundations and supporting structures become necessary. In the case of newly constructed coke oven batteries, the high weight of the cooling apparatus requires a correspondingly heavy and thus expensive support structure for the driving gear of the machines provided with this device. Furthermore, practice has proven that, particularly when pushing unfinished coking chambers, cooling apparatus consisting of a plurality of pipes becomes coated with a sticky layer due to the condensation of tar mist and other gaseous components of the plunging coke. This drastically reduces the heat exchange between the hot gases and the cooling apparatus, which can result in a destruction of the flexible covering belt. In order to nevertheless enable an exchange of heat to occur, it is necessary to clean the individual pipes (often several hundred of them) at frequent intervals. Maintenance requiring such extensive work, of necessity, places narrow limits on the practical application of such a cooling apparatus to coking plants.
Gases containing dust and particulate matter nevertheless develop not only during pushing and/or quenching of coke from coking chambers, but also in the course of filling the coking chambers with coal. A number of experiments have also been undertaken in this area, in order to achieve an effective removal of the gases that would require practically no maintenance.
It is the object of the invention generally to provide an apparatus of the above-mentioned type in which the action of heat from the hot exhaust gases conveyed through the collecting main onto the flexible covering belt is reduced by simple means to a value permitting the use of a presently commercially available wear-resistant material that is not highly heat-resistant.
SUMMARY OF THE INVENTION
The invention obviates the above-described difficulties by providing a protective device arranged within the collecting main at a distance from the flexible belt and extending at least across the intake cross-section of the collecting main to separate the gas stream in the collecting main from the flexible belt.
According to one embodiment of the invention, cooling tubes are arranged between the flexible belt and the protective device, extending perpendicular to the collecting main, whereby the cooling tubes have blowing outlets for cooling air pointed in the direction of flow of the gases toward the belt.
In that connection it is helpful to have the protective device consist of guide plates or blades arranged along the collecting main at essentially equal distances from each other.
Placing this protective device between the flexible belt and the actual gas-collecting main causes the bottom surface of the flexible belt to be protected from the heat transported in the direction of the belt by the compulsory and also the free convection currents, as well as from the heat radiated by the hot exhaust gases, so that the temperature of the belt can be maintained below that maximum surface temperature permissible for commercially available, non-heat-resistant belts. Thermal shielding is favored by the formation of eddy currents of cooling air emerging from the above-mentioned cooling tubes between the individual guide plates to that heat transfer between the hot exhaust gases and the bottom surface of the belt is prevented. Such protective device renders possible drawing of a stream of exhaust gases at a temperature of ca. 600° C through the gas-collecting main without raising the temperature of the bottom surface of the flexible covering belt to above 150° C. The combination of cooling tubes and guide plates has the advantage that the region close to the belt is acted upon by the cooling air, thereby forming a flowing protective film, so to speak, against the hot gases. In addition, the gas-collecting main as well as the guide plates act throughout the entire length of the exhaust conduit during the relatively short coke pushing operation as a heat reservoir that is cooled during the longer intervals between the individual coke pushing operations by the cold surrounding air flowing through the gas-collecting main.
The effect of the formation of eddy currents between the individual guide plates, or blades, as well as shielding the bottom surface of the flexible belt against heat rays, however, is best achieved if the projection of end guide plate in the intake direction of the gases is the same or greater than half of the distance between two guide plates.
The guide plates may be stationary, nevertheless they may also be mounted on shafts perpendicular to the direction of flow of the gases, said shafts being parallel and movable. In the latter case, it is helpful to have at least one end of each shaft of each guide plate protruding from the collecting main and each connected with an adjustable lever engaging an adjustable crosstie of the enveloping carriage arranged parallel to the collecting main, the crosstie being connected to the enveloping carriage for movement between an operative and an inoperative position by means of a control device. The guide plates or blades over which the air streams, may have a concave surface.
Nevertheless, the guide plates may also be constructed with a support surface profile. Such profiles are suitably hollow so that they can be connected to ventilation means.
For one specific embodiment of the invention, the connecting line between the rollers lifting the belt is inclined against the direction of flow of the gases, and the cooling tubes are arranged along the inner side of the belt within the area of the just-lifted belt, such tubes being provided with the blowing openings for cooling air directed against the belt. This embodiment has an asymmetrically constructed enveloping carriage. Such arrangement provides for a particularly large supply of cooling air at that location at which the covering belt might come in contact with the hot gases.
At the location at which the hot gases are supplied to the collecting main where the flexible belt is lifted up by means of the enveloping carriage, the cooling air emitted from the cooling tubes mixes with the supplied hot gases so that the temperature of the gas mixture flowing in the collecting main is already reduced.
Accordingly, it is apparent that in the closed position of the overlapping guide plates the cooling tubes are positioned within the area formed by the side walls of the collecting main, the protective wall formed by the guide plates, and the flexible belt, so that the air ejected from the cooling tubes flows between the protective wall and the flexible belt. Thus, thw flexible belt is separated from the hot gases over the entire length of the exhaust conduit, so that here also the use of commercially available, wear-resistant non-heat-resistant rubber belts would be possible to cover the gas-collecting main, without having to fear excessive and thus endangering heating of the belts. In general, the pressure prevalent in the exhaust conduit is a reduced pressure compared with that of the environment. This means that the cooling air is automatically sucked from the outside into the cooling tubes. Nevertheless, it is also possible to connect the cooling tubes to conduits for the supply and removal of cooling air, such conduits being located outside of the gas-collecting main; this will ensure the necessary air supply.
The apparatus of the present invention may be used to remove the dust-containing gases emitted during pushing and/or quenching of coke from coking chambers. In that instance it is helpful to have the removal duct of the enveloping carriage connected with a mobile collecting arrangement for the dust-containing gases or vapors accumulating on the coking side of the furnace.
The apparatus of the present invention is just as effective in removing gases containing dust or particulate matter evolving during the filling of coking chambers with coal. In that case it is useful to have the removal ducts of the enveloping carriage connected with a movable collecting arrangement for the dust or particulate matter -- containing gases or vapors accumulating during the filling of a coking chamber.
DESCRIPTION OF THE DRAWINGS
The description refers to the accompanying drawings in which like reference characters refer to like parts throughout the several views, and in which:
FIG. 1 is a plan view of one part of a gas-collecting main covered by a flexible belt;
FIG. 2 is a cross-section along the line II--II of FIG. 3, respectively of FIG. 1;
FIG. 3 is a cross-section along the line III--III of FIG. 2;
FIG. 4 is an enlargement of the area A of FIG. 2;
FIG. 5 is a cross-section along the line V--V of FIG. 6 showing a section of the collecting main at which the enveloping carriage with the removal duct for the gas supply is located;
FIG. 6 is a cross-section along the line VI--VI of FIG. 5;
FIG. 7 is a partial view of the collecting main viewed from the side with the adjustable guide plates;
FIG. 8 is a cross-section along the line VIII--VIII of FIG. 7;
FIG. 9 is a detailed cross-section showing the overlapping guide plates in the collecting main pursuant to the embodiment shown in FIG. 7;
FIG. 10 is a schematic side view of the gas supply location (FIG. 5) with removed connecting duct, and
FIG. 11 is a schematic cross-section showing the connection between the connecting duct of the enveloping carriage and the charging gas collecting conduit of a charging car.
FIG. 12 is a cross-section similar to that of FIG. 11 showing another connection between the connecting duct of the enveloping carriage and the charging gas collecting conduit of a charging car.
FIG. 13 is a plan view of the enveloping carriage with the charging gas collecting conduit of FIG. 12, omitting the remaining parts;
FIG. 14 shows the apparatus of the invention in connection with a hood on the coking side of a coke oven battery as cross-section of the battery;
FIG. 15 is a vertical cross-section through the enveloping carriage of FIG. 16, and
FIG. 16 is a plan view of the enveloping carriage.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, the invention is described with reference to customary apparatus for removing gases containing dust and other particulate matter emitted during the operation of a coke oven battery.
FIGS. 1-4 show that a collecting main 1 has a circular cross-section, whereby one section has been cut out lengthwise and a conduit extension 4 consisting of parallel walls is welded to the longitudinal cut surfaces of the remaining circular segment, said extension ending in horizontal flanges 33 on top of which a flexible belt 2 rests. Shown by dotted lines in FIG. 13 is an enveloping carriage 10 with a removal duct, said carriage running on tracks 34 mounted laterally to the collecting main 1.
Guide blades or plates 3 are provided as a protective device directly beneath the flexible belt 2 covering the collecting main 1, said blades 3 being positioned at equal distances from each other and having a convex shape with respect to the direction of flow of the gases as indicated by the arrow 7. This curvature of the blade causes the gases flowing into the collecting main 1 to be diverted away from the underside of the flexible belt 2. The example illustrated shows that the ratio of the projection of one guide blade in the direction of flow to the distance between two guide blades is very high.
One cooling tube 5 is positioned respectively between each end of the guide blade 3 associated with the flexible belt 2 and the bottom surface of said flexible belt 2, said tube having blowing outlets 8 which may be slots, for example, and which point slightly upwards toward the belt 2 in the direction of flow of the gases. Cooling air is blown through these blowing outlets 8 in the direction of the arrow 9 against the bottom surface of the flexible belt 2. As apparent from FIG. 1, the ends 6 of said cooling tubes 5 are placed outside of the collecting main 1. The cooling tubes 5 are self-priming due to the reduced pressure within the collecting main 1.
FIGS. 5 and 6 show that location of the collecting main 1 at which a removal duct 11 with the enveloping carriage 10 is located. The enveloping carriage 10 has a front roller 13 pivoted on a frame 17, said roller 13 pressing the flexible belt 2 against the top surface 30 of the collecting main 1. By means of a front top roller 14 placed in staggered relation against the direction of flow and in upward direction with regard to the front roller 13, belt 2 is directed upward, whereby the angle of inclination of the belt to the horizontal plane is smaller than 60°. The flexible belt 2 is directed around the removal duct 11 over the front top roller 14 and a back top roller 15, and then steeply downward to a back roller 16, which then presses the flexible belt 2 again against the top surface 33 of the collecting main 1. As concerns its rollers 13-16, the enveloping carriage 10 is constructed asymmetrically in the direction of the gases emerging from the removal duct 11, as shown in FIG. 6 by the arrow 12. The gases emerging from the removal duct 11 then proceed in the direction of an arrow 22 into the collecting main 1, and the sections between the port of the removal duct 11 and those locations at which the flexible belt 2 is lifted away from the collecting main 1, are covered by guards 21. The gases are directed into the interior of the collecting main 1 to flow in the direction 7, by means of guide blades or scoops 3. By means of the cooling air ejected from the cooling tubes in the direction of the arrows 9, simultaneous mixing of the hot gas intake and the cooling air occurs, so that the temperature of the gases conveyed through the collecting main 1 is being lowered due to that mixture.
FIG. 5 shows cooling tubes 18 extending between the front guard 21 and the belt 2 guided between the front roller 13 and the front top roller 14, said tubes 18 being at right angles to said belt 2 and having blowing outlets 19 inclined somewhat toward the bottom surface opposite to the direction of movement of the belt 2, whereby cooling air is blown against the belt 2 and directed through the slot between the covered belt 2 and the guard 21 toward the inside of the collecting main 1, i.e., a particularly large amount of cooling air is provided at that location at which the belt 2 would come in contact with the hot gases supplied by the removal duct 11.
The embodiment shown in FIGS. 7-10 illustrates a protective device consisting of guide plates 3 connected to shafts 23. FIG. 8 shows that the shaft 23 of each guide plate 3 extends across the conduit extension 4 and is journaled in bearings 30. Operation of each shaft 23, thereby adjusting each guide plate 3, is effected by an adjustable lever 24 positioned outside of collecting main 1, said lever 24 being attached to the one end of each shaft 23. FIGS. 7 and 9 show the overlapping guide plates 3 in a closed position. When in that position, the guide plates 3 form a closed protective wall between the flexible belt 2 and the inner space of the collecting main 1. The adjustable levers 24 are fixed to the shafts 23 such that their angle with respect to the guide plates 3 is greater than 90°, i.e., in the closed position of the guide plates 3 illustrated, the adjustable levers 24 are directed diagonally upward. In the case of a spontaneous increase in pressure in the collecting main 1, for example due to a gas explosion, the guide plates 3 are automatically lifted upward so that the pressure can be equalized. It is of course possible to leave a small slot for the emergence of cooling air open also between the guide plates, in contrast to the illustration provided by FIG. 9.
FIG. 10 shows a control device together with the enveloping carriage 10 in side view.
An adjustable crosstie, respectively an adjustable sled 25 is linked to piston rods 27 of control cylinders 28 by means of lugs 26. The control cylinders 28 are attached to the outer wall of the enveloping carriage 10 by means of brackets 29. The adjustable crosstie 25 is arranged such that it is positioned above the adjustable levers 24 when it is in a raised position, so that the enveloping carriage 10 can be moved lengthwise of the gas collecting main 1 without engaging the adjustable levers 24. In the lowered position, the adjustable crosstie 25 presses the adjustable levers 24 coming within its region of contact downward, as apparent from FIG. 10, whereby the guide plates 3 pivot upward, so that the gas emerging from the connecting duct 11 can flow inside the gas collecting main 1 in the direction of the arrows 22 lengthwise of the guide plates 3. Upon raising the adjustable crosstie 25, the guide plates 3 fall back into their starting position due to the force of gravity, so that they form a continuous protective wall in that position.
In similar fashion as shown in FIGS. 7-10, it is possible to pivot support surface profiles in place of guide plates 3, whereby the axes of rotation can be arranged either transversely to the section of on-coming flow or transversely to the section of escaping flow. Nevertheless, the support surface profiles can also be employed in place of the stationary guide scoops of the embodiment shown in FIGS. 1-6.
FIG. 11 shows a hopper car 43 movably arranged on the roof 41 of the coke oven battery, of which one coking chamber 40 is shown in cross-section. A coke oven roof 41 is provided with charging ports 42 with which there are associated charging ducts 44, only one of which is schematically shown in FIG. 11. Each charging duct 44 is surrounded at a radical distance by a charging gas removal hood 45, such that an annlar space exists between the charging duct 44 and the removal hood 45. When the charging duct 44 has been lowered into the charging port 42, the removal hood 45 is placed on the coke oven roof 41 such that it provides a seal. The gases emerging from the charging ports during the charging operation around the charging duct 44 pass through the annular space between said charging duct 44 and the removal hood 45 into a charging gas conduit 46 connected to a charging gas collecting conduit 47 movable in conjunction with the hopper car 43. The charging gas collecting conduit 47 is connected to the removal duct 11 of the enveloping carriage 10 by means of a flange connection 48, so that the charging gases escaping from the coking chamber 40 can be directed into the collecting main 1 as the coking chamber is being filled, without the possibility of escaping into the atmosphere.
In FIG. 12 those parts identical to those of FIG. 11 have been provided with the same reference numerals. FIG. 12 shows a clutch engaging the lower region of the enveloping carriage 10, consisting, as shown in FIG. 13, of an attachment piece 50 fixed to that lateral side of the enveloping carriage 10 which faces the hopper car, and a strap 51 hinged to said attachment piece, the free end of said strap being hinged to a carrier stem 52. The carrier stem 52 is removably connected to two attachment pieces 53, 54 affixed to the wall of the charging gas collecting conduit 47 located transversely to the direction of movement of the enveloping carriage 10.
FIGS. 14-16 show the device of the present invention in connection with a hood 55 overhanging a quenching car 56 and quided at its side opposite a coke oven battery 57 along a support 58 by means of a frame 59. This frame 59 is movably supported along its bottom side by wheels 60 in a track 61 attached to the support 58 and parallel to the coke oven battery. Guide wheels 62 rotatable about vertical axes are located at the top side of the frame 59, said wheels 62 being guided by a pair of guide tracks 63 extending parallel to the coke oven battery. The collecting main 1 is located on said support as is also the movable enveloping carriage 10, its connecting duct 64 being connected with a discharge duct 66 of the hood 55 by means of a connecting flange 65. The reference character 67 designates a junction between the hood and a coke guide 68 movable in familiar fashion along a so-called master gallery 69 of the coke oven battery and serving to push the hot coke from a coking chamber 70 into the quenching car 56. The coke guide 68 is also covered by means of a hood 71 joined to the hood 55 in an air-tight seal by means of a connecting piece 72.
A flexible connection between the hood 55 and the enveloping carriage 10 illustrated in FIGS. 15 and 16 consists of a fork 73 provided at its end with a forked attachment piece 74 linked to one front end of the enveloping carriage 10 through a forked attachment piece 76 by means of a strap 75. This permits dragging the enveloping carriage 10 along with the aid of the hood 55, said hood 55 either being coupled to the coke guide in known fashion for the purpose of such combined movement, or independently movable along the support 58 by means of a drive mechanism associated with the wheels 60 and not illustrated in detail.
Although the invention has been illustrated and described therein with reference to the preferred embodiments thereof, it is understood that the present disclosure is made only as an example and that it is in no way limited to the details of such embodiments and is capable of numerous modifications within the scope of the invention defined by the appended claims. | A gas-collecting arrangement movable from one coking chamber to the next and serving to remove exhaust gases emitted during pushing and/or quenching of coke and during filling of coking chambers with coal, includes a shielding device arranged within the collecting main at a distance from a flexible belt and extending at least across the intake cross-section of the collecting main to separate the gas stream in the main from the flexible belt. | 2 |
PRIORITY
[0001] This application claims the benefit under 35 U.S.C. §119(a) of a United Kingdom patent application filed on Jan. 30, 2009 in the United Kingdom Intellectual Property Office and assigned Serial No. 0901551.2, the entire disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to wireless communication networks. More particularly, although not exclusively, the present invention relates to networks adapted to implement or operate according to the 3 rd Generation Partnership Project (3GPP) Technical Specification (TS) 36.331 version (v) 8.4.0, the entire disclosure of which is hereby incorporated by reference, and/or to User Equipment (UE) for use in such networks.
[0004] 2. Description of the Related Art
[0005] The 3 rd Generation Partnership Project (3GPP) Technical Specification (TS) 36.331 version (v) 8.4.0 specifies a number of conditions, criteria or events in response to which User Equipment (UE) is triggered to send a measurement report to a network, such as an Evolved Universal Mobile Telecommunications System (UMTS) Terrestrial Radio Access Network (E-UTRAN).
[0006] To operate in accordance with the 3GPP TS 36.331 v 8.4.0 specification, the UE is arranged/adapted to report measurement information in accordance with a measurement configuration, which is provided to the UE by the E-UTRAN, that is, the E-UTRAN provides a signal or signals containing the measurement configuration to the UE.
[0007] Generally, the measurement configuration tells the UE, inter alia, the conditions, criteria or events in response to which it should send a measurement report, that is, the measurement configuration tells the UE the “reporting criteria”. Further, the measurement configuration tells the UE what to measure when triggered to send a report. In other words, the measurement configuration tells the UE the measurement objects, which are the objects on which the UE should perform the measurements. Also, the measurement configuration tells the UE the format in which the measurement results should be sent. In other words, the measurement configuration tells the UE the reporting format, including the quantities that the UE should include in the measurement report and associated information, such as the number of cells to report.
[0008] These events, in response to which the UE should send a measurement report, include events A1, A2, A3, A4, A5, B1 and B2 as defined in Table 1 below. Here, “serving” refers to a currently serving cell, e.g., a cell with which the UE is in communication, and “neighbor” refers to a neighboring cell.
[0009] Table 1 shows the current definitions of these events in 3GPP TS 33.331 v 8.4.0. Table 1 defines these events in terms of entering and leaving conditions. The entering conditions define the circumstances under which an event is regarded as occurring, when the event was not previously occurring. In other words, the UE is triggered to send a measurement report when there is a change from the conditions specified in the “entering condition” column not being met to being met.
[0010] The “leaving conditions” specify the conditions under which each event is considered to be no longer occurring. Thus, the UE is triggered to send a measurement report when, after entering an event, the circumstances change and the relevant leaving condition is met.
[0011] In each case, the entering conditions and leaving conditions associated with the various events, which can be regarded as defining the measurement report triggering conditions, are defined using a plurality of parameters or variables including Ms, Mn, Ofn, Ocn, Ofs, Ocs, Hys, Off, Thresh, Thresh1, and Thresh2, where:
[0012] Ms denotes a measurement result of a serving cell,
[0013] Mn denotes a measurement result of a neighboring cell,
[0014] Ofn denotes a frequency specific offset of the frequency of the neighbor cell,
[0015] Ocn denotes a cell specific offset of the neighbor cell,
[0016] Ofs denotes a frequency specific offset of the serving frequency,
[0017] Ocs denotes a cell specific offset of the serving cell,
[0018] Hys denotes a hysteresis parameter for the respective event,
[0019] Off denotes an offset parameter for the respective event,
[0020] Thresh denotes a threshold parameter for the respective event,
[0021] Thresh1 denotes a threshold parameter for the respective event, and
[0022] Thresh2 denotes a threshold parameter for the respective event.
[0023] Further information on these parameters or variables can be found at the end of this description, in an extract from 3GPP TS 36.331 v 8.4.0.
SUMMARY OF THE INVENTION
[0024] An aspect of the present invention is to address at least the above-mentioned problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an aspect of the present invention is to provide new definitions for at least some events, in response to which, User Equipment (UE) is triggered to send a measurement report to a network. The use of these new definitions provides at least one technical advantage over the use of the definitions included in the 3 rd Generation Partnership Project (3GPP) Technical Specification (TS) 36.331 version (v) 8.4.0.
[0025] Another aspect of the present invention is provide trigger measurement reporting by User Equipment (UE) using different criteria or conditions from those previously proposed, so as to provide at least one technical advantage or address at least one problem associated with the related art.
[0026] In accordance with an aspect of the present invention, a UE apparatus for use in a cellular wireless communications network is provided. The apparatus includes a measuring unit for measuring signals received from at least one of a serving cell of the network (e.g., a cell which is currently being used by the UE for communication with, or via, the network) and from neighboring cells, a memory for storing information defining a plurality of conditions for triggering the UE to send a measurement report to the network, the measurement report comprising a result of at least one measurement (e.g., a measurement of a signal received from a serving or neighboring cell) performed by the UE, a determining unit for determining when one of the plurality of conditions is met, and a sending unit for sending, in response to one of the plurality of conditions being met, a measurement report for reception by the network, wherein each of the plurality of conditions is defined by a respective plurality of at least one of parameters and variables. The at least one of the parameters and variables may include a result of a measurement of a signal received from a serving cell, a threshold parameter (e.g., a predetermined value), and at least one offset value associated with at least one of a serving cell and a serving frequency (e.g., a frequency used for transmitting signals from the serving cell to the UE).
[0027] In accordance with another aspect of the present invention, a method of operating UE adapted for use in a cellular wireless telecommunications network is provided. The method includes storing information that defines a plurality of conditions for triggering the UE to send a measurement report to the network, the measurement report comprising a result of at least one measurement (e.g., a measurement of a signal received from a serving or neighboring cell) performed by the UE, determining when one of the plurality of conditions is met, and in response to one of the plurality of conditions being met, send the measurement report for reception by the network, wherein each of the plurality of conditions is defined by a respective plurality of at least one of parameters and variables. The at least one of the parameters and variables may include: a result of a measurement of a signal received from a serving cell, a threshold parameter (e.g., a predetermined value), and at least one offset value associated with at least one of a serving cell and a serving frequency (e.g., a frequency used for transmitting signals from the serving cell to the UE).
[0028] In certain exemplary embodiments, the method further comprises receiving the information from the network.
[0029] In certain exemplary embodiments, the plurality of conditions comprises a condition defined by at least one of:
[0000]
Ms+Ofs+Ocs−Hys>Thresh;
[0000]
Ms+Ofs+Ocs+Hys<Thresh;
[0000]
Ms+Ofs+Ocs+Hys<Thresh;
[0000]
Ms+Ofs+Ocs−Hys>Thresh;
[0000] ( Ms+Ofs+Ocs+Hys<Thresh 1) AND ( Mn+Ofn+Ocn−Hys>Thresh 2);
[0000] ( Ms+Ofs+Ocs−Hys>Thresh 1) OR ( Mn+Ofn+Ocn+Hys<Thresh 2);
[0000] ( Ms+Ofs+Ocs+Hys<Thresh 1) AND ( Mn+Ofn−Hys>Thresh 2); and
[0000] ( Ms+Ofs+Ocs−Hys>Thresh 1) OR ( Mn+Ofn+Hys<Thresh 2),
[0030] and wherein:
[0031] Ms denotes a measurement result of a serving cell,
[0032] Mn denotes a measurement result of a neighboring cell,
[0033] Ofn denotes a frequency specific offset of the frequency of the neighbor cell,
[0034] Ocn denotes a cell specific offset of the neighbor cell,
[0035] Ofs denotes a frequency specific offset of the serving frequency,
[0036] Ocs denotes a cell specific offset of the serving cell,
[0037] Hys denotes a hysteresis parameter for the respective event,
[0038] Off denotes an offset parameter for the respective event,
[0039] Thresh denotes a threshold parameter for the respective event,
[0040] Thresh1 denotes a threshold parameter for the respective event, and
[0041] Thresh2 denotes a threshold parameter for the respective event.
[0042] The measurement result of a serving cell may, for example, be the result of the UE performing a measurement of Reference Symbols (RS) transmitted by the cell. The network configures actual measurement quantity (i.e., tells the UE what to measure), which for EUTRA is RS Received Power or RS Received Quality.
[0043] Similarly, the measurement result of a neighboring cell may be the result of the UE performing a measurement of Reference Symbols (RS) transmitted by the neighboring cell.
[0044] Note, however, that for other radio access technologies, other quantities may apply.
[0045] In accordance with another aspect of the invention, a method of operating user equipment (UE) adapted for use in a cellular wireless telecommunications network is provided. The method includes storing, information that defines a plurality of conditions for triggering the UE to send a measurement report to the network, each condition being associated with a respective event, and the measurement report comprising a result of at least one measurement performed by the UE, determining when one of the plurality of conditions is met; and in response to one of the plurality of conditions being met, sending the measurement report for reception by the network, wherein said plurality of conditions include at least one of:
[0000]
Ms+Ofs+Ocs−Hys>Thresh;
[0000]
Ms+Ofs+Ocs+Hys<Thresh;
[0000]
Ms+Ofs+Ocs+Hys<Thresh;
[0000]
Ms+Ofs+Ocs−Hys>Thresh;
[0000] ( Ms+Ofs+Ocs+Hys<Thresh 1) AND ( Mn+Ofn+Ocn−Hys>Thresh 2);
[0000] ( Ms+Ofs+Ocs−Hys>Thresh 1) OR ( Mn+Ofn+Ocn+Hys<Thresh 2);
[0000] ( Ms+Ofs+Ocs+Hys<Thresh 1) AND ( Mn+Ofn−Hys>Thresh 2);
[0000] and
[0000] ( Ms+Ofs+Ocs−Hys>Thresh 1) OR ( Mn+Ofn+Hys<Thresh 2),
[0046] and wherein:
[0047] Ms denotes a measurement result of a serving cell,
[0048] Mn denotes a measurement result of a neighboring cell,
[0049] Ofn denotes a frequency specific offset of the frequency of the neighbor cell,
[0050] Ocn denotes a cell specific offset of the neighbor cell,
[0051] Ofs denotes a frequency specific offset of the serving frequency,
[0052] Ocs denotes a cell specific offset of the serving cell,
[0053] Hys denotes a hysteresis parameter for the respective event,
[0054] Off denotes an offset parameter for the respective event,
[0055] Thresh denotes a threshold parameter for the respective event,
[0056] Thresh1 denotes a threshold parameter for the respective event, and
[0057] Thresh2 denotes a threshold parameter for the respective event.
[0058] In accordance with another aspect of the present inventions, a UE or other apparatus adapted to operate in accordance with a method as defined by any claim is provided.
[0059] In accordance with yet another aspect of the present invention, a computer program comprising instructions arranged, when executed, to implement a method as claimed in any claim, and machine-readable storage storing such a program is provided.
[0060] In accordance with still another aspect of the present invention, a communication system comprising a communication network and UE, the network being adapted to supply the information to the UE, is provided.
[0061] It will be appreciated that in certain exemplary embodiments:
[0062] a) the network configures the UE to perform measurement of specific quantities;
[0063] b) the network configures the UE to send a measurement report message when certain conditions are met, i.e., the network configures triggering conditions for sending of the measurement report;
[0064] c) certain exemplary embodiments of the present invention relate to event triggered reporting, that is a measurement report is triggered when the quantity fulfils certain conditions (‘the event’);
[0065] d) the events typically involve comparing measured quantities with thresholds or comparing measured quantities of different cells (i.e., serving and neighboring); and
[0066] e) the network may, for various reasons configure offsets, to be applied to the measured quantities. This applies both to serving and neighboring cells.
[0067] It should be noted that offsets may be defined in frequency and cell lists that include both the serving and neighboring cells, i.e., the serving and neighboring cells may be signaled in substantially the same way. As a consequence, these lists may not need to be changed by the network when the UE moves to another cell or frequency.
[0068] In certain exemplary embodiments of the present invention the serving offsets are applied for all event conditions, which, assuming the offsets are relevant not only for the comparison between cells but also for the comparisons to thresholds, avoids the need to reconfigure thresholds when the UE moves to a cell with an offset different from the current serving cell.
[0069] In certain exemplary embodiments, the serving offsets are used to define all event conditions that also use Ms (i.e., a result of a measurement on a serving cell).
[0070] It will be appreciated, that with regard to the conditions/variables mentioned above:
[0071] a) in certain exemplary embodiments there are events, such as A3, where there is a comparison between serving and neighbor cells;
[0072] b) some conditions involve multiple thresholds;
[0073] c) conditions involving comparison may also involve an offset (e.g., the neighbor cell is offset better than the serving cell); and
[0074] d) there may be offsets associated with the neighbor cells as well as the serving cells/frequencies in one or more of the conditions.
[0075] It is possible to distinguish/separate the condition parameters that are related to the measurementObject (i.e., related to the frequencies to be measured) (concerns frequency and cell specific offset) from the parameters that are in the reportConfig (i.e., parameters defined for each condition like threshold, offset, etc.).
[0076] Again, in certain exemplary embodiments of the present invention all conditions affecting the serving cell apply the cell and frequency specific offsets defined for the serving cell/frequency to avoid reconfiguration.
[0077] Certain exemplary embodiments use information defining conditions for events currently specified in 3GPP TS 36.331, but the present invention is not limited to such applications, it has broader application.
[0078] Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0079] The above and other aspects, features and advantages of the certain exemplary embodiments of present invention will become more apparent from the following description taken in conjunction with the accompanying drawings, in which:
[0080] FIG. 1 is a schematic representation of a measurement data model in 3 rd Generation Partnership Project (3GPP) Technical Specification (TS) 36.331 version (v) 8.4.0 according to the related art;
[0081] FIG. 2 is a flowchart illustrating CellsTriggeredList management based on entering/leaving conditions according to an exemplary embodiment of the present invention;
[0082] FIG. 3 illustrates DownLink (DL)/UpLink (UL) imbalance mitigation by the use of cell specific offsets according to an exemplary embodiment of the present invention;
[0083] FIG. 4 is a flowchart illustrating a method according to the related art; and
[0084] FIG. 5 is a flowchart illustrating a method according to an exemplary embodiment of the present invention.
[0085] Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0086] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
[0087] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
[0088] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a component surface” includes reference to one or more of such surfaces.
Measurement Data Model
[0089] The measurement data model in 3 rd Generation Partnership Project (3GPP) Technical Specification (TS) 36.331 version (v) 8.4.0 will be described below with reference to FIG. 1 .
[0090] FIG. 1 is a schematic representation of a measurement data model in 3GPP TS 36.331 v 8.4.0 according to the related art.
[0091] Referring to FIG. 1 , there are two main parts of the measurement data model 100 , namely a measurement object 110 and a reporting configuration 120 , which are linked together by a measurement identity 130 .
[0092] The measurement object 110 describes a set of cells. The set of cells may be described by only denoting a carrier frequency, or by listing specific cells on a certain frequency. A measurement offset can be configured per frequency. In addition, for an Evolved Universal Mobile Telecommunications System (UMTS) Terrestrial Radio Access Network (E-UTRAN) (and not for other Radio Access Technology (RAT) types), a cell specific offset can be configured per cell.
[0093] The reporting configuration 120 lists the characteristics of the measurement. The characteristics of the measurement may include whether the measurement is periodic or event based, and detailed parameters for the measurement. The detailed parameters for the measurement may include thresholds, quantities, etc.
Defined Measurement Events of the Related Art
[0094] 3GPP TS 36.331 v 8.4.0 defines seven events, namely A1, A2, A3, A4, A5, B1 and B2. Rather than having a specific procedural description, such as that disclosed in 3GPP TS 25.331, the entire disclosure of which is hereby incorporated by reference, there is only one description for event based measurement triggering in 3GPP TS 36.331 v 8.4.0. However, for each event, a different “entering condition” (i.e., when a cell is entering the reporting conditions for this event), and a “leaving condition” (i.e., when a cell is leaving the reporting conditions for this event) is defined. The flowchart of this process is described below with reference to FIG. 2 .
[0095] FIG. 2 is a flowchart illustrating CellsTriggeredList management based on entering/leaving conditions according to an exemplary embodiment of the present invention.
[0096] Referring to FIG. 2 , an event is configured in step 202 . In step 204 , it is determined if one or more cells meet the entering condition during a time to trigger. If it is determined at step 204 that one or more cells do not meet the entering condition during the time to trigger, the process returns to step 204 . However, if it is determined at step 204 that one or more cells meet the entering condition during the time to trigger, the process proceeds to step 206 . In step 206 , an entry is created for the measurement in the VarMeasReport variable. In step 208 , concerning cells are included in cellsTriggeredList.
[0097] In step 210 , it is determined if one or more cells meet the leaving condition during a time to trigger. If it is determined at step 210 that one or more cells do not meet the leaving condition during the time to trigger, the process proceeds to step 212 . In step 212 , it is determined if one or additional cells meet the entering condition during a time to trigger. If it is determined at step 212 that one or additional cells do not meet the entering condition during the time to trigger the process returns to step 210 . However, if it is determined at step 212 that one or additional cells meet the entering condition during the time to trigger the process proceeds to step 214 . In step 214 , concerning cells are included in the cellsTriggeredList and the process returns to step 210 .
[0098] Returning to step 210 , if it is determined that one or more cells meet the leaving condition during the time to trigger, the process proceeds to step 218 . In step 218 , concerning cells are removed in cellsTriggeredList. In step 216 , it is determined if the cellsTriggeredList is empty. If it is determined at step 216 that the cellsTriggeredList is not empty the process returns to step 210 . However, if it is determined at step 216 that the cellsTriggeredList is empty the process proceeds to step 220 . In step 220 , the entry for the measurement is removed in VarMeasReport variable. Thereafter, the process returns to step 204 .
[0099] Table 1 provides an overview of the entering and leaving conditions for the different events for event based measurement reporting.
[0000]
TABLE 1
Entering condition
Leaving condition
Event A1
Ms − Hys > Thresh
Ms + Hys < Thresh
(Serving becomes
better than threshold)
Event A2
Ms + Hys < Thresh
Ms − Hys > Thresh
(Serving becomes
worse than threshold)
Event A3
Mn + Ofn + Ocn − Hys > Ms + Ofs + Ocs + Off
Mn + Ofn + Ocn + Hys < Ms + Ofs + Ocs + Off
(Neighbor becomes offset
better than serving)
Event A4
Mn + Ofn + Ocn − Hys > Thresh
Mn + Ofn + Ocn + Hys < Thresh
(Neighbor becomes
better than threshold)
Event A5
Ms + Hys < Thresh 1
Ms − Hys > Thresh 1
(Serving becomes worse
AND
OR
than threshold1 and
Mn + Ofn + Ocn − Hys > Thresh2
Mn + Ofn + Ocn + Hys < Thresh 2
neighbor becomes
better than threshold2)
Event B1
Mn + Ofn − Hys > Thresh
Mn + Ofn + Hys < Thresh
(Inter RAT neighbor becomes
better than threshold)
Event B2
Ms + Hys < Thresh 1
Ms − Hys > Thresh 1
(Serving becomes worse
AND
OR
than threshold1 and inter
Mn + Ofn − Hys > Thresh 2
Mn + Ofn + Hys < Thresh 2
RAT neighbor becomes
better than threshold2)
[0100] For event based reporting, two different offsets are used, namely a frequency offset and a cell specific offset.
[0101] The frequency offset may be configured for a serving frequency (Ofs), a neighboring E-UTRA-frequency (Ofn) or an inter-RAT frequency (Ofn for Code Division Multiple Access (CMDA), Global System for Mobile Communications (GSM) Enhanced Data Rates for GSM Evolution (EDGE) Radio Access Network (GERAN) and Universal Terrestrial Radio Access (UTRA))
[0102] The cell specific offset may be configured for a serving cell (Ocs) or the neighboring intra-freq or inter-freq Evolved-UTRA (E-UTRA) cell (Ofn).
[0103] Due to recent changes, the 3GPP TS 36.331 data model no longer has any serving cell/frequency specific parameter group. The serving cell offset and serving cell frequency offset are merely offsets in an E-UTRA measurement object corresponding to the serving frequency.
[0104] As can be seen in Table 1, Ofn and Ocn are used whenever possible. Ofn is used in all possible events, i.e., whenever Mn is measured, the Ofn is applied. Ocn is used in all possible events, i.e., whenever Mn is a measurement for a neighboring E-UTRA cell, Ocn is applied.
[0105] However this is not true for Ofs and Ocs. These offsets are only used in event A3.
[0106] Herein it is helpful to understand why there are offsets. With respect to cell specific offsets, R2-072721, the entire disclosure of which is hereby incorporated by reference, describes the use of cell specific offsets and the reading of neighboring Broadcast CHannel (BCH). RAN2/58bis, the entire disclosure of which is hereby incorporated by reference, explains why there are cell specific offsets. The usage of cell specific offsets will be described below with reference to FIG. 3
[0107] FIG. 3 illustrates DownLink (DL)/UpLink (UL) imbalance mitigation by the use of cell specific offsets according to an exemplary embodiment of the present invention.
[0108] Referring to FIG. 3 , the usage of cell specific offsets allows the cell coverage area of cells to be adjusted, such as in case of an UL/DL imbalance. If a cell has a large cable loss resulting in a lower Tx power than its neighboring cell, the UL might be better than expected by the Ec/No measurement. Thus, such a cell could be provided with a larger offset so that this cell becomes earlier/remains longer the best cell on that frequency. Offsets can also be used in the case of neighboring cells with different Tx power (e.g., macrocells/femtocells), again to keep the UE longer on the femtocell that would benefit from a better UL due to a smaller cell size.
Frequency Specific Offsets
[0109] Propagation conditions between different frequencies vary. For this reason, when evaluating the quality of a neighboring cell on a certain frequency, a frequency specific Ofn is used in all applicable events. For example, A4 applies the Ofn to the neighboring cell measurement to verify if the quality of the cell is sufficient.
[0110] With regard to related art “solutions”, and specifically with regard to measurements, RAN2 has attempted to limit the actions required to be taken with regard to measurements by the network at intra-frequency and inter-frequency handover as much as possible (see 3GPP TS 36.331, section 5.5.6.1).
[0111] If the neighboring cell list does not need to be adapted (which is typical in LTE), at intra-frequency handover no action is needed and at inter-frequency handover only the measurement gap pattern needs to be setup again. However, this is not completely true for a cell that requires the usage of a different cell specific offset.
[0112] As explained above, the cell specific offset is used to extend/decrease the effective cell coverage area. If it is assumed that a network is using measurement event A2 (e.g., as a trigger for starting inter-RAT measurements), then when the serving cell quality+hysteresis goes below a threshold, the network will be notified by the UE and the network will use this to trigger inter-RAT measurements.
[0113] If two neighboring cells would have significantly different Ocs, it will mean that at the intra-freq handover the threshold should be adapted for the new cell. This is because A2 does not use Ocs, but there is a desire to continue using the same coverage area. This is described below with reference to in FIG. 4 .
[0114] FIG. 4 is a flowchart illustrating a method according to the related art.
[0115] Referring to FIG. 4 , intra-frequency handover is performed in step 402 . In step 404 , a UE autonomously takes almost all necessary actions to continue intra-frequency and inter-frequency measurements. For example, swap intra-frequency and inter-frequency objects so that intra-frequency/inter-frequency measurements can continue. In step 406 , if required, the network reconfigures threshold with RRC reconfiguration procedure. In step 408 , if required, measurement gaps are setup for inter-frequency measurements with RRC reconfiguration procedure.
[0116] Certain exemplary embodiments of the present invention provide a solution in which all evaluations of serving cell quality apply Ocs and Ofs, as shown in Table 2. Table 2 shows proposed entering/leaving conditions for event based measurement reporting.
[0000]
TABLE 2
Entering condition
Leaving condition
Event A1
Ms + Ofs + Ocs − Hys > Thresh
Ms + Ofs + Ocs + Hys < Thresh
(Serving becomes
better than threshold)
Event A2
Ms + Ofs + Ocs + Hys < Thresh
Ms + Ofs + Ocs − Hys > Thresh
(Serving becomes
worse than threshold)
Event A3
Mn + Ofn + Ocn − Hys > Ms + Ofs + Ocs + Off
Mn + Ofn + Ocn + Hys < Ms + Ofs + Ocs + Off
(Neighbor becomes offset
better than serving)
Event A4
Mn + Ofn + Ocn − Hys > Thresh
Mn + Ofn + Ocn + Hys < Thres
(Neighbor becomes
better than threshold)
Event A5
Ms + Ofs + Ocs + Hys < Thresh1
Ms + Ofs + Ocs − Hys > Thresh1
(Serving becomes worse
AND
OR
than threshold1 and
Mn + Ofn + Ocn − Hys > Thresh2
Mn + Ofn + Ocn + Hys < Thresh2
neighbor becomes
better than threshold2)
Event B1
Mn + Ofn − Hys > Thresh
Mn + Ofn + Hys < Thresh
(Inter RAT neighbor becomes
better than threshold)
Event B2
Ms + Ofs + Ocs + Hys < Thresh 1
Ms + Ofs + Ocs − Hys > Thresh1
(Serving becomes worse
AND
OR
than threshold1 and inter
Mn + Ofn − Hys > Thresh2
Mn + Ofn + Hys < Thresh2
RAT neighbor becomes
better than threshold2)
indicates data missing or illegible when filed
[0117] The entering/leaving conditions proposed in Table 2 provide advantages over the related art as described below.
[0118] By also applying Ocs in events, such as A2, this allows continuation of the event after an intra-freq handover without changing the threshold, thus limiting the required amount of signaling from the network at handover. A similar reasoning can be made for events A1, A5 and B2.
[0119] Propagation conditions between different frequencies vary. For this reason, when evaluating the quality of a neighboring cell on a certain frequency, the frequency offset Ofn is used in all applicable events. For example, A4 applies the Ofn to the neighboring cell measurement to verify if the quality of the cell is sufficient.
[0120] Again, to limit changes to threshold, one can also argue here that applying Ofs in events like A1, A2, A5 and B2 is advantageous. If two carriers have a different Ofx, then most likely, a different threshold would be applicable.
[0121] It is true that applying the Ofs in these events is less beneficial than applying the Ocs as proposed in 2.2, since the threshold would only need to be updated at inter-freq events, such as where measurement gaps might need to be activated anyway. Note however, that applying Ocn in the indicated events also makes the resulting entering/leaving conditions consistent. In all cases the applicable Ocx and Ofx are used on the measured Mx.
[0122] The resulting Flow diagram is illustrated in FIG. 5 .
[0123] FIG. 5 is a flowchart illustrating a method according to an exemplary embodiment of the present invention.
[0124] Referring to FIG. 5 , intra-frequency handover is performed in step 502 . In step 504 , a UE autonomously takes almost all necessary actions to continue intra-frequency and inter-frequency measurements. For example, swap intra-frequency and inter-frequency objects so that intra-frequency/inter-frequency measurements can continue. In step 506 , if required, measurement gaps are setup for inter-frequency measurements with RRC reconfiguration procedure.
[0125] Herein, this saves the action of the network having to reconfigure the threshold for the events A1, A2, A5 and B2, thereby reducing the signaling effort at handover. In addition, the event criteria have become more consistent.
[0126] It will be appreciated that exemplary embodiments of the present invention can be realized in the form of hardware, software or a combination of hardware and software. Any such software may be stored in the form of volatile or non-volatile storage such as, for example, a storage device like a ROM, whether erasable or rewritable or not, or in the form of memory such as, for example, RAM, memory chips, device or integrated circuits or on an optically or magnetically readable medium such as, for example, a CD, DVD, magnetic disk or magnetic tape or the like. It will be appreciated that the storage devices and storage media are exemplary embodiments of machine-readable storage that are suitable for storing a program or programs comprising instructions that, when executed, implement exemplary embodiments of the present invention. Accordingly, exemplary embodiments provide a program comprising code for implementing a system or method as claimed in any one of the claims of this specification and a machine-readable storage storing such a program. Still further, such programs may be conveyed electronically via any medium such as a communication signal carried over a wired or wireless connection and exemplary embodiments suitably encompass the same.
[0127] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
[0128] It will be also be appreciated that, throughout the description and claims of this specification, language in the general form of “X for Y” (where Y is some action, activity or step and X is some means for carrying out that action, activity or step) encompasses means X adapted or arranged specifically, but not exclusively, to do Y.
[0129] Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, exemplary embodiment or example of the present invention are to be understood to be applicable to any other aspect, exemplary embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The present invention is not restricted to the details of any foregoing exemplary embodiments. The present invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
[0130] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
[0131] Throughout this specification a number of abbreviations are used. Those abbreviations are defined as follows:
[0132] 1xRTT CDMA2000 1x Radio Transmission Technology
[0133] AM Acknowledged Mode
[0134] ASN.1 Abstract Syntax Notation.1
[0135] ARQ Automatic Repeat Request
[0136] AS Access Stratum
[0137] BCCH Broadcast Control Channel
[0138] BCH Broadcast Channel
[0139] CCCH Common Control Channel
[0140] CCO Cell Change Order
[0141] CP Control Plane
[0142] C-RNTI Cell RNTI
[0143] CSG Closed Subscriber Group
[0144] DCCH Dedicated Control Channel
[0145] DRB (user) Data Radio Bearer
[0146] DRX Discontinuous Reception
[0147] DTCH Dedicated Traffic Channel
[0148] DL Downlink
[0149] DL-SCH Downlink Shared Channel
[0150] ETWS Earthquake and Tsunami Warning System
[0151] E-UTRA Evolved Universal Terrestrial Radio Access
[0152] E-UTRAN Evolved Universal Terrestrial Radio Access Network
[0153] ENB Evolved Node B
[0154] EPC Enhanced Packet Core
[0155] EPS Enhanced Packet System
[0156] FLOOR Mathematical function used to ‘round down’, i.e., to the nearest integer having a lower value
[0157] FDD Frequency Division Duplex
[0158] FFS For Further Study
[0159] GERAN GSM/EDGE Radio Access Network
[0160] GSM Global System for Mobile Communications
[0161] HARQ Hybrid Automatic Repeat Request
[0162] HRPD CDMA2000 High Rate Packet Data
[0163] IE Information element
[0164] IMEI International Mobile Equipment Identity
[0165] IMSI International Mobile Subscriber Identity
[0166] kB Kilobyte (1000 bytes)
[0167] L1 Layer 1
[0168] L2 Layer 2
[0169] L3 Layer 3
[0170] MAC Medium Access Control
[0171] MBMS Multimedia Broadcast Multicast Service
[0172] MBSFN Multimedia Broadcast multicast service Single Frequency Network
[0173] MIB Master Information Block
[0174] N/A Not Applicable
[0175] NACC Network Assisted Cell Change
[0176] NAS Non Access Stratum
[0177] PCCH Paging Control Channel
[0178] PDU Protocol Data Unit
[0179] PDCP Packet Data Convergence Protocol
[0180] PLMN Public Land Mobile Network
[0181] QoS Quality of Service
[0182] RACH Random Access CHannel
[0183] RAT Radio Access Technology
[0184] RB Radio Bearer
[0185] RLC Radio Link Control
[0186] RNTI Radio Network Temporary Identifier
[0187] RRC Radio Resource Control
[0188] RSCP Received Signal Code Power
[0189] RSRP Reference Signal Received Power
[0190] RSSI Received Signal Strength Indicator
[0191] SAE System Architecture Evolution
[0192] SAP Service Access Point
[0193] SI Scheduling Information
[0194] SIB System Information Block
[0195] SI-RNTI System Information RNTI
[0196] SPS Semi-Persistent Scheduling
[0197] SRB Signaling Radio Bearer
[0198] S-TMSI SAE Temporary Mobile Station Identifier
[0199] TA Tracking Area
[0200] TDD Time Division Duplex
[0201] TM Transparent Mode
[0202] TPC-RNTI Transmit Power Control RNTI
[0203] UE User Equipment
[0204] UICC Universal Integrated Circuit Card
[0205] UL Uplink
[0206] UM Unacknowledged Mode
[0207] UL-SCH Uplink Shared Channel
[0208] UP User Plane
[0209] UTRAN Universal Terrestrial Radio Access Network
[0210] It will be appreciated from the preceding text that in exemplary embodiments of the present invention new criteria (comprising combinations of parameters/variables) are used to define entering conditions and leaving conditions associated with particular events, as compared with the criteria defining those conditions in 3GPP TS 36.331 v 8.4.0. For reference, below is an extract from 3GPP TS 36.331 v 8.4.0. It will be appreciated that this extract provides definitions of the various variables and parameters which apply to exemplary embodiments of the present invention defined above. However, the definitions of the entering and leaving conditions for the events in this extract correspond to the related art, and exemplary embodiments of the present invention use new, different criteria as explained above.
[0211] BEGINNING OF EXTRACT OF 3GPP TS 36.331 v 8.4.0
[0000] 5.5.4.2 Event A1 (Serving Becomes Better than Threshold)
The UE shall:
1> apply inequality A1-1, as specified below, as the entry condition for this event;
1> apply inequality A1-2, as specified below, as the leaving condition for this event;
[0000] Ms−Hys>Thresh Inequality A1-1 (Entering condition)
[0000] Ms+Hys<Thresh Inequality A1-2 (Leaving condition)
[0000] The variables in the formula are defined as follows:
Ms is the measurement result of the serving cell, not taking into account any cell individual offset.
Hys is the hysteresis parameter for this event (i.e., hysteresis as defined within the VarMeasurementConfiguration for this event).
Thresh is the threshold parameter for this event (i.e., a1-Threshold as defined within the VarMeasurementConfiguration for this event).
Ms is expressed in dBm in case of RSRP, or in dB in case of RSRQ.
Hys is expressed in dB.
Thresh is expressed in dBm in case Ms is expressed in dBm; otherwise it is expressed in dB.
5.5.4.3 Event A2 (Serving Becomes Worse than Threshold)
The UE shall:
1> apply inequality A2-1, as specified below, as the entry condition for this event;
1> apply inequality A2-2, as specified below, as the leaving condition for this event;
[0000] Ms+Hys<Thresh Inequality A2-1 (Entering condition)
[0000] Ms−Hys>Thresh Inequality A2-2 (Leaving condition)
[0000] The variables in the formula are defined as follows:
Ms is the measurement result of the serving cell, not taking into account any cell individual offset.
Hys is the hysteresis parameter for this event (i.e., hysteresis as defined within the VarMeasurementConfiguration for this event).
Thresh is the threshold parameter for this event (i.e., a2-Threshold as defined within the VarMeasurementConfiguration for this event).
Ms is expressed in dBm in case of RSRP, or in dB in case of RSRQ.
Hys is expressed in dB.
Thresh is expressed in dBm in case Ms is expressed in dBm; otherwise it is expressed in dB.
5.5.4.4 Event A3 (Neighbor Becomes Offset Better than Serving)
The UE shall:
1> apply inequality A3-1, as specified below, as the entry condition for this event;
1> apply inequality A3-2, as specified below, as the leaving condition for this event;
[0000] Mn+Ofn+Ocn−Hys>Ms+Ofs+Ocs+Off Inequality A3-1 (Entering condition)
[0000] Mn+Ofn+Ocn+Hys<Ms+Ofs+Ocs+Off Inequality A3-2 (Leaving condition)
[0000] The variables in the formula are defined as follows:
Mn is the measurement result of the neighboring cell.
Ofn is the frequency specific offset of the frequency of the neighbor cell (equals Ofs for intra-frequency measurements and is included in MeasObjectEUTRA corresponding to the inter frequency as offsetFreq for inter-frequency measurements).
Ocn is the cell specific offset of the neighbor cell. If not configured zero offset shall be applied (included in MeasObjectEUTRA of the serving frequency as parameter cellIndividualOffset for intra-f measurements and included in MeasObjectEUTRA corresponding to the inter frequency as parameter cellIndividualOffset for inter-frequency measurements).
Ms is the measurement result of the serving cell, not taking into account any cell individual offset.
Ofs is the frequency specific offset of the serving frequency (i.e., offsetFreq within the MeasObjectEUTRA corresponding to the serving frequency).
Ocs is the cell specific offset of the serving cell (included in MeasObjectEUTRA of the serving frequency as parameter cellIndividualOffset).
Hys is the hysteresis parameter for this event (i.e., hysteresis as defined within the VarMeasurementConfiguration for this event).
Off is the offset parameter for this event (i.e., a3-Offset as defined within the VarMeasurementConfiguration for this event).
Mn, Ms are expressed in dBm in case of RSRP, or in dB in case of RSRQ.
Ofn, Ocn, Ofs, Ocs, Hys, Off are expressed in dB.
5.5.4.5 Event A4 (Neighbor Becomes Better than Threshold)
The UE shall:
1> apply inequality A4-1, as specified below, as the entry condition for this event;
1> apply inequality A4-2, as specified below, as the leaving condition for this event;
[0000] Mn+Ofn+Ocn−Hys>Thresh Inequality A4-1 (Entering condition)
[0000] Mn+Ofn+Ocn+Hys<Thresh Inequality A4-2 (Leaving condition)
[0000] The variables in the formula are defined as follows:
Mn is the measurement result of the neighboring cell.
Ofn is the frequency specific offset of the frequency of the neighbor cell.
Ocn is the cell specific offset of the neighbor cell.
Hys is the hysteresis parameter for this event (i.e., hysteresis as defined within the VarMeasurementConfiguration for this event).
Thresh is the threshold parameter for this event (i.e., a4-Threshold as defined within the VarMeasurementConfiguration for this event).
Mn is expressed in dBm in case of RSRP, or in dB in case of RSRQ.
Ofn, Ocn, Hys are expressed in dB.
Thresh is expressed in dBm in case Ms is expressed in dBm; otherwise it is expressed in dB.
5.5.4.6 Event A5 (Serving Becomes Worse than Threshold1 and Neighbor Becomes Better than Threshold2)
The UE shall:
1> apply inequality A5-1 and equation A5-2 i.e., both have to be fulfilled, as specified below, as the entry condition for this;
1> apply inequality A5-3 and equation A5-4 i.e., at least one of the two has to be fulfilled, as specified below, as the leaving condition for this event;
[0000] Ms+Hys<Thresh 1 Inequality A5-1 (Entering condition 1)
[0000] Mn+Ofn+Ocn−Hys>Thresh 2 Inequality A5-2 (Entering condition 2)
[0000] Ms−Hys>Thresh 1 Inequality A5-3 (Leaving condition 1)
[0000] Mn+Ofn+Ocn+Hys<Thresh 2 Inequality A5-4 (Leaving condition 2)
[0000] The variables in the formula are defined as follows:
Ms is the measurement result of the serving cell, not taking into account any cell individual offset.
Mn is the measurement result of the neighboring cell.
Ofn is the frequency specific offset of the frequency of the neighbor cell.
Ocn is the cell specific offset of the neighbor cell.
Hys is the hysteresis parameter for this event (i.e., hysteresis as defined within the VarMeasurementConfiguration for this event).
Thresh1 is the threshold parameter for this event (i.e., a5-Threshold1 as defined within the VarMeasurementConfiguration for this event).
Thresh2 is the threshold parameter for this event (i.e., a5-Threshold2 as defined within the VarMeasurementConfiguration for this event).
Mn, Ms are expressed in dBm in case of RSRP, or in dB in case of RSRQ.
Ofn, Ocn, Hys are expressed in dB.
Thresh1 is expressed in dBm in case Ms is expressed in dBm; otherwise it is expressed in dB.
Thresh2 is expressed in dBm in case Mn is expressed in dBm; otherwise it is expressed in dB.
5.5.4.7 Event B1 (Inter RAT Neighbor Becomes Better than Threshold)
The UE shall:
1> for UTRA and CDMA2000, only trigger the event for cells included in the corresponding measurement object;
1> apply inequality B1-1, as specified below, as the entry condition for this event;
1> apply inequality B1-2, as specified below, as the leaving condition for this event;
[0000] Mn+Ofn−Hys>Thresh Inequality B1-1 (Entering condition)
[0000] Mn+Ofn+Hys<Thresh Inequality B1-2 (Leaving condition)
[0000] The variables in the formula are defined as follows:
Mn is the measurement result of the neighboring inter RAT cell.
Ofn is the frequency specific offset of the frequency of the neighbor cell.
Hys is the hysteresis parameter for this event (i.e., hysteresis as defined within the VarMeasurementConfiguration for this event).
Thresh is the threshold parameter for this event (i.e., b1-Threshold as defined within the VarMeasurementConfiguration for this event).
Mn is expressed in dBm or in dB, depending on the measurement quantity of the neighboring inter RAT cell.
Ofn, Hys are expressed in dB.
Thresh is expressed in dBm in case Mn is expressed in dBm; otherwise it is expressed in dB.
5.5.4.8 Event B2 (Serving Becomes Worse than Threshold1 and Inter Rat Neighbor Becomes Better than Threshold2)
The UE shall:
1> for UTRA and CDMA2000, only trigger the event for cells included in the corresponding measurement object;
1> apply inequality B2-1 and inequality B2-2 i.e., both have to be fulfilled, as specified below, as the entry condition for this event;
1> apply inequality B3-3 and inequality B2-4 i.e., at least one of the two has to be fulfilled, as specified below, as the leaving condition for this event;
[0000] Ms+Hys<Thresh 1 Inequality B2-1 (Entering condition 1)
[0000] Mn+Ofn−Hys>Thresh 2 Inequality B2-2 (Entering condition 2)
[0000] Ms−Hys>Thresh 1 Inequality B2-3 (Leaving condition 1)
[0000] Mn+Ofn+Hys<Thresh 2 Inequality B2-4 (Leaving condition 2)
[0000] The variables in the formula are defined as follows:
Ms is the measurement result of the serving cell, not taking into account any cell individual offset.
Mn is the measurement result of the neighboring inter RAT cell.
Ofn is the frequency specific offset of the frequency of the neighbor cell.
Hys is the hysteresis parameter for this event (i.e., hysteresis as defined within the VarMeasurementConfiguration for this event).
Thresh1 is the threshold parameter for this event (i.e., b2-Threshold1 as defined within the VarMeasurementConfiguration for this event).
Thresh2 is the threshold parameter for this event (i.e., b2-Threshold2 as defined within the VarMeasurementConfiguration for this event).
Ms is expressed in dBm in case of RSRP, or in dB in case of RSRQ.
Mn is expressed in dBm or dB, depending on the measurement quantity of the neighboring inter RAT cell.
Ofn, Hys are expressed in dB.
Thresh1 is expressed in dBm in case Ms is expressed in dBm; otherwise it is expressed in dB.
Thresh2 is expressed in dBm in case Mn is expressed in dBm; otherwise it is expressed in dB.
END OF EXTRACT OF 3GPP TS 36.331 v 8.4.0
[0212] While the invention has been shown and described with reference to certain exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents. | A User Equipment (UE) apparatus for use in a cellular wireless communications network, and method for its operation, are provided. The apparatus includes a measuring unit for measuring signals received from at least one of a serving cell of the network and from neighboring cells, a memory for storing information defining a plurality of conditions for triggering the UE to send a measurement report to the network, the measurement report comprising a result of at least one measurement performed by the UE, a determining unit for determining when one of the plurality of conditions is met, and a sending unit for sending, in response to one of the plurality of conditions being met, a measurement report for reception by the network, wherein each of the plurality of conditions is defined by a respective plurality of at least one of parameters and variables. | 7 |
RELATED APPLICATION
This invention is a continuation in part of U.S. patent application Ser. No. 397,030 filed Aug. 22, 1989, now abandoned.
FIELD OF INVENTION
This invention relates to filter fabrics. It specially relates to filter fabrics having a utility for the removal of fine, sub-micron particulate matter from fluid streams, although it is not restricted thereto.
BACKGROUND OF INVENTION
Filter fabrics made from conventional synthetic fibers, non-limiting examples of which are fibers formed from polyesters, polyamides, polyethylene polypropylene and polyacrylonitrile and glass remove particles from a fluid stream initially by a depth filtration mechanism. Such fibers have relatively regular cross-sections of low surface area. Particulate matter in the fluid stream is trapped in the body of the fabric in the interstices between the fibers thereof, to form a cake in the body of the fabric. It is only subsequent to the formation of the body cake that a surface cake builds up, the surface cake then effectively forming the filter medium. The accumulation of the particles inside the fabric creates an appreciable resistance to the flow of fluid through the filter, and correspondingly results in an increase in pressure drop across the filter.
Fabrics which are composed of membranes laminated onto a fibrous substrate considerably reduce entrapment of the particles within the fabric. However, such membranes have an inherently high flow resistance due to the small pore size thereof, and again their use is accompanied by a high pressure drop across the filter.
There has latterly been made available from Lenzing AG an aromatic polyimide fiber known under the trade name P84. Microscopic examination of these fibers indicates them to have an irregular, heavily profiled structure of significantly greater surface area than that of conventional fibers employed in the manufacture of depth filtration filters. These heavily profiled polyimide fibers also have charged surface sites, which generate strong electrostatic fields.
Filter fabrics constructed from HPEC polyimide fibers are found to intercept particulate matter primarily on the surface thereof in a cake filtration mechanism. Fluid flow through such fabric may be gradually restricted, particularly where the feed includes very fine particles. Such particles penetrate the fabric, and since the path resistance tends to be relatively uniform throughout the depth of the fabric, the probability of entrapment is relatively high.
The P84 polyimide fibers are also very expensive, making them cost-prohibitive except for specialty use in very high temperature filtration operations i.e. 200-250 C.
it is an object of this invention to provide filter cloths having improved efficiency.
It is a further object of this invention to provide filter cloths having a high particulate separation efficiency and accompanied therewith a low pressure build-up.
It is another object of this invention to provide filter cloths that are economic.
SUMMARY OF THE INVENTION
In accordance with a principal aspect of this invention, a composite filter fabric comprises cloth having a composite structure comprising a first fabric layer consisting of a non-woven P84 polyimide fiber, and a substrate fabric layer formed from at least one fiber having a relatively regular cross-section and significantly lower surface area than that of said polyimide fabric; wherein the diameter of the fibers of the substrate layer is not less than the diameter of the fibers of the first layer, and wherein the layers are bonded together.
The P84 polyimide fiber forming the first layer has a theoretical structure ##STR1## where n is an integer.
The first layer consists of staple fibers of HPEC polyimide polymer consolidated through entanglement of the fibers, such entanglement being of the character produced by a needle punching operation.
The fibers forming the substrate layer are those commonly used in the formation of depth filtration fabrics, and include without limitation fibers from organic polymers such as polyester, polypropylene, polyethylene, nylon, aromatic polyamides, polyacrylonitrile, polyphenylene sulfide, polytetrafluoroethylene, polybenzimidazole, and inorganic materials including glass, and mixtures thereof.
The diameters of the fibers of the first layer and the substrate layer will desirably be selected in accordance with the nature of the particulate matter to be removed from the fluid stream, especially the particle size distribution thereof, so as to ensure the removal of particulate matter without unnecessarily restricting fluid flow through the filter. It is also a prime consideration that the ratio of the diameters of the fibers be selected such that the pressure drop across the substrate will be less, and preferably substantially less than that across the first layer. Accordingly the composite filter fabrics of the invention may have a permeability substantially greater than that of a fabric having a similar weight and thickness formed from fibers of the first layer only. It will be appreciated that the relative diameters of the fibers is only one factor to be considered, together with the path length through each of the layers and also the degree of consolidation of the layers. Generally speaking the diameter of the substrate fibers will be at least equal to that of the fibers of the first layer. Suitably the ratio of the diameter of substrate fiber to that of the fiber of the first layer will be not less than about 1.5:1; and desirably will be in the range of about 1.5:1 to about 4:1, with a ratio of about 3:1 being preferred. The term "diameter" as used herein relates to the mean cross-sectional dimension of the fibers of the layer.
The substrate layer may be in the form of non-woven fabric, or woven fabric or mixtures thereof.
Desirably the substrate layer comprises a non-woven fabric having a woven fabric such as a scrim entangled therewith, suitably by a needle punching operation.
Also suitably, the first layer of fibers is bonded to the substrate layer by needle punching, preferably so as to entangle some of the fibers of each layer by comminglement with fibers of the other layer, desirably without completely penetrating to the outer side of the other layer. It should be clearly understood that the comminglement of fibers of one layer with those of the other layer is for the purpose of mechanically bonding the layers together, and that from the point of view of the efficiency of filtration, it is desirable that the comminglement be minimized.
The first layer will normally comprise not less than about 5% of the composite filter fabric, expressed on a weight basis. Higher percentages of the first layer fabric will normally be found desirable, particularly where elevated temperature exposure maybe expected, but this will be accompanied by an increase in pressure build-up. Suitably a filter fabric having good all-round filtration characteristics for the removal of fine particulate matter will comprise from about 25 to about 35% by weight of the first layer fabric, with about 30% being preferred.
These foregoing objects and aspects of the invention, together with other objects, aspects and advantages thereof will be more apparent from the following description of a preferred embodiment thereof, taken in conjunction with the following drawings.
IN THE DRAWINGS
FIG. 1 shows in exploded, figurative form the component parts of a preferred, composite filter fabric of the invention;
FIG. 2 is similar to FIG. 1 and shows a substage in the manufacture of the composite filter fabric;
FIG. 3 is similar to FIG. 1 but shows the component parts of the composite filter fabric in their combined form;
FIG. 4 is a flow diagram of the various steps in the manufacture of a preferred composite filter fabric;
FIG. 5 shows comparative test results of a composite filter fabric and a conventional (control) filter fabric, and
FIG. 6 shows in cross-section P84 polyimide fibers of the first layer.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in detail, in particular FIGS. 1-3 thereof, a composite filter fabric is identified therein by the numeral 10.
Filter fabric 10 comprises a first, outer layer 12 which consists essentially of fibers 14 84 polyimide, as previously defined hereinabove, needle punched together at figuratively illustrated sites 16 to form a non-woven fabric 18. Filter fabric 10 further includes a substrate layer 20, which here comprises polyester fibers 22 needle punched together at sites 24 to form a non-woven fabric 26, and a polyester scrim 28. Referring now to FIG. 6, the fiber cross-sections of the P84 polyimide fibers 14 are somewhat irregular, and include a plurality of lobes 30. In comparison fibers used for substrate layer 20 will commonly have a cross-section that is regular in shape, generally round or oval, having a significantly lower ratio of surface area/diameter. The diameter of the P84 fibers is best determined by scanning electron microscope, although a good approximation may be obtained using a digital micrometer and is the circumcircular diameter D of the fibers.
Substrate layer 20 is formed by needle punching non-woven fabric 26 onto scrim 28 at sites 32 so as to generally embed the scrim within the non-woven fabric. Following the formation of substrate layer 20, this layer is bonded to first layer 12 by needle punching fibers from each layer into the other layer. This last recited step is controlled such that the substrate fibers 22 do not penetrate to the outer surface of the first layer, so as not to form a potential low resistance flow path therethrough. The extent of penetration of polyimide fibers 14 into the substrate 20 is commensurate with providing a firm bonding of the layers 12 and 20 together so as to resist disintegration of the filter 10, but penetration is desirably minimized due to the much higher cost of fibers 12, and their providing no effective filtration capacity when embedded into the substrate layer.
Filter fabric 10 is shrunk by heat setting in a hot air chamber at a temperature somewhat more elevated than that to which the fabric 10 will be exposed on a continuous basis during operation. During the heat setting step the filter fabric 10 is desirably tensioned at least across the width thereof to prevent non-uniform shrinkage and a resulting non-uniform outer layer 12.
Following the heat setting step, the outer surface of first layer 12 is exposed to open flame in order to eliminate loose fibers, the presence of which facilitates attachment of particles to the surface of filter cloth 10, making cake removal more difficult during the fabric cleaning cycles.
As a last step in the method, filter 10 is compressed by passage through heated calendering rolls in order to reduce the interstitial spacing between the fibers and control the permeability to desired levels.
A composite filter fabric was formed in accordance with the above method wherein the P84 polyimide fibers had a diameter of 2 denier, and the fabric of the first layer 12 formed therefrom had a weight of 125 g/m 2 . The substrate layer 20 was formed from a 6 denier polyester nonwoven fabric having a weight of 285 g/m 2 needle punched onto polyester spun yarn scrim having a weight of 50 g/m 2 . The composite fabric is usable bn a continuous basis at a temperature of about 150° C, and was heat set at a temperature of 195° C. The permeability of this composite fabric was about 60% greater than that of a non-composite P84 polyimide fabric of comparable weight and thickness.
A further composite filter fabric was formed in accordance with the above method, and was tested for filter efficiency and compared with a conventional polyester filter fabric having a comparable weight and thickness, the characteristics of the two filter fabrics being as given in Table 1.
TABLE 1______________________________________characteristics of composite and control filter fabrics. P84 Polyimide/Polyester PolyesterFabric Construction Composite (Control)______________________________________Weight g/m.sup.2 552 554Thickness mm 1.73 1.65Permeability CFM 44.0 22.9______________________________________
Samples of the two fabrics of Table 1 were compared for particulate removal efficiency and pressure buildup at various particle concentrations and flow rates. The particulate matter consisted of a dust taken from a fluidized bed recirculating type boiler. The particles had a median size of 0.445 microns, with 82.31% of the population below 1 micron. The duration of the runs was 20 hours. The separation efficiency and pressure buildup were measured simultaneously versus time.
The selected particle concentrations were as follows:
1) 11 g/m 3 (5.0 Grains/ft 3 )
2) 110 g/m 3 (50 Grains/ft 3 )
The air flow rates to which both fabrics were subjected were:
1) 1.22 m/min (4 ft/min)
2) 1.52 m/min (5 ft/min)
3) 2.13 m/min (7 ft/min)
The separation efficiencies were found to increase from a lower value and then become invariant after about 10 hours of filtration. However, the separation efficiencies were significantly higher for P84 Polyimide/Polyester fabric than for 100% Polyester fabric at all operating conditions. The lowest value of the separation efficiency recorded for P84 Polyimide/Polyester at the beginning of data acquisition was 98.899%. The equivalent value for 100% Polyester was much lower at 97.721%. Also for HPEC Polyimide/Polyester, the asymptotic values ranged from a minimum of 99.936% to a maximum of 99.992%. The equivalent values for 100% Polyester were significantly lower at 98.605% and 99.918%, respectively. The change in separation efficiency with time for one set of operating conditions is shown in graphical form in FIG. 5, and this typifies the results of all runs.
The pressure buildup increased with time and then became invariant at about the same time as the separation efficiency reached an asymptotic value. For all operation conditions, the pressure buildup remained significantly lower for the P84 Polyimide/Polyester composite fabric.
Table 2 contains the separation efficiency and pressure buildup after 20 hours of filtration for different air flow rates for both 100% Polyester and P84 Polyimide/Polyester fabrics. The results showed that, for the p84Polyimide/Polyester fabric, an increase in the air flow rate from 1.22 m/min to 1.52 m/min resulted in an increase in the separation efficiency recorded. Beyond 1.52 m/min, the separation efficiency remained nearly constant as the air flow rate was increased.
TABLE 2__________________________________________________________________________Effect of Air Flow rate on Separation efficiency and pressure buildupafter 20 hours of filtration SEPARATION EFFICIENCY, % PRESSURE BUILDUP, inches of waterCONC.,AIR FLOW RATE, P84 100% P84 100%g/m.sup.3m/min Polyimide/Polyester Polyester Polyimide/Polyester Polyester__________________________________________________________________________1.22 99.952 99.740 2.6 3.611 1.52 99.989 99.570 2.6 3.9__________________________________________________________________________
Table 2 also shows the effect of air flow rate on the pressure buildup. For the P84 Polyimide/Polyester filter, the pressure buildup did not change appreciably although the separation efficiency increased.
For 100% Polyester filter, the pressure buildup increased with increasing air flow rate.
It will be apparent that many changes may be made to the illustrative embodiment, while falling within the scope the invention and it is intended that all such changes be covered by the claims appended hereto. | Composite filter cloths having a top layer of a heavily profiled, electro-statically charged polyimide fiber and a depth filtration type fabric substrate may be structured to have a higher particulate removal efficiency than that for the substrate layer and a lower pressure drop than that of the top layer. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to automatic gain control (AGC) Loop circuits, usually referred to as AGC loops because automatic gain control necessarily requires a feedback loop of some kind. (There are forward type AGCs that do not require a feedback loop.) AGC loops are used in communication systems to improve receiver operation by varying the gain applied to received signals based upon their detected power. AGC loops are needed in most communication systems because, as a practical matter, received signals are always subject to variations in power. The task of gain control is further complicated by the presence of interfering signals.
Designers of communication receivers face a fundamental choice between first-order AGC loops and second or higher-order AGC loops. The loop “order” is a basic characteristic of feedback control loops in general, not just AGC loops, and refers to the number of mathematical integrators in the loop. First-order loops are less complex and are known for their stability, i.e., their ability to converge on a desired steady-state signal value relatively quickly when there is a change in the received signal strength. For certain received signal conditions, however, first-order loops may not perform as well as desired, and in particular may not react fast enough to large or small received signal changes. First order loops are optimized either for speed or accuracy in performance. In the former case, a large loop bandwidth (equivalent noise bandwidth of the loop) in which the loop can react fast to a change in signal power suffers from poor performance. On the other hand, a first order loop with small loop bandwidth is very slow to react, however, it has a superior performance compared with loops with large bandwidths. For example, in the presence of strong interfering signals, they may tend to clip the interfering signal and thus desensitize the relatively weak desired signal. Second-order and higher-order loops have a theoretically more desirable response characteristic for many applications, but are in general not used because of their potential instability.
Ideally, what is needed is an AGC loop that has the stability of a first-order loop but also has the ability to react rapidly in the presence of large signal changes, interference signals, or in a frequency-hopping communications environment. The present invention is directed to these goals.
SUMMARY OF THE INVENTION
The present invention resides in an automatic gain control (AGC) loop that always operates in a first-order, stable mode, but reacts fast enough to large signals by adapting itself to those signals, and then reverting back to its nominal setting as needed. The AGC loop of the invention relies principally on error-signal power detection techniques that result in selected different gain values being fed to a single-pole loop filter, which operates as a stable first-order loop at all times.
Briefly, and in general terms, the invention may be defined as an automatic gain control (AGC) device for generating amplifier control signals to adjust to a desired level a received communication signal that varies in power, the AGC device comprising a first computational module, for generating a signal representative of the average power of the received communication signal; a second computational module, for generating an error signal representative of the difference between the average power signal generated by the first computational module and a selected power set point; and a third computational module, for generating an amplifier control signal from the error signal. The generated amplifier control signal is responsive to variations in the average power of the received signal.
More specifically, the third computational module comprises a loop gain amplifier for amplifying the error signal; a summing module for combining the amplified error signal with another input signal; and a delay module for receiving the output of the summing module and providing as output the amplifier control signal. The other input signal to the summing module is derived from output of the delay module, and represents the amplifier control signal in an earlier computation cycle.
Preferably, the AGC device further comprises a fourth computational module for controlling the gain of the loop gain amplifier in accordance with the average error signal power. Specifically, the fourth computational module comprises an error signal power determination module; an error signal sign determination module; and a gain decision module receiving input signals from the error signal power determination module and the error signal sign determination module, and selecting a loop amplifier gain based on the inputs received.
Optionally, the AGC device may also comprise a set point selection module, wherein the power set point supplied to the second computational module is automatically selected based on measurements made on the received communication signal.
The invention may also be defined in terms of a method of automatic gain control, comprising the steps of generating a signal representative of the average power of a received communication signal; generating an error signal representative of the difference between the average power signal and a selected power set point; and generating an amplifier control signal from the error signal. Thus, the generated amplifier control signal is responsive to variations in the average power of the received signal.
Preferably, the method also comprises a step of controlling the gain of the loop gain amplifier in accordance with average error signal power. Specifically, the step of controlling the gain of the loop gain amplifier comprises determining the average power of the error; determining the algebraic sign of the average power of the error signal; and selecting, based on the error signal power the error signal algebraic sign, determination module, a loop amplifier gain.
In defining the invention in this summary and in the claims below, the expression “signal representative of the average power” and similar expressions are used. The term “representative of” is intended to encompass signals that are directly proportional to the power, or those that are directly proportional to some mathematical function of the power, such as the square of the power. For processing convenience, as will become apparent from the detailed description that follows, the square of the power is used in the presently preferred embodiments of the invention. Also in this summary and in the claims, the term “AGC device” is used with the intent of encompassing implementations in software, programmable hardware, or integrated or discrete circuitry.
It will be appreciated from this summary that the present invention represents a significant advance in the field of automatic gain control circuits and devices. In particular, the AGC device of the invention has the stability advantages of a first-order control loop, but still adapts rapidly to large input signal variations. Other aspects and advantages of the invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a conceptual block diagram of a receiver that includes the automatic gain control (AGC) loop of the present invention.
FIG. 2 is block diagram of a first order AGC loop
FIG. 3 is an expanded block diagram of the AGC loop, depicting the technique of the invention as it relates to adaptively changing the loop filter gain in accordance with the nature of the error signal.
FIG. 4 is a block diagram showing how a variable AGC set-point feature may be incorporated into the AGC loop of the invention.
FIG. 5 is a graph of an in-phase input signal used in simulation of AGC loop operation.
FIG. 6 is a graph showing the in-phase signal of FIG. 5 after adjustment by the AGC loop of the invention.
FIG. 7 is a graph showing the AGC error signal corresponding to FIGS. 5 and 6 .
FIG. 8 is a graph showing the output of the AGC loop filter, corresponding to FIGS. 5-9 .
DETAILED DESCRIPTION OF THE INVENTION
As shown in the drawings, the present invention pertains to automatic gain control (AGC) circuits or loops. As briefly discussed above, first-order AGC loops are preferably used in communication receivers because of their known stability of operation. First-order AGC loops do not, however, normally react fast enough to large signal inputs, and therefore do not provide appropriate gain control in some communication applications.
In accordance with the present invention, a relatively simple, first-order AGC loop is provided with enhanced capability to adapt to large input and error signals and then to readapt to its nominal settings when the need for a more rapid response has passed. The invention will be described in the context of a typical communications receiver, which is conceptually illustrated in FIG. 1 .
The receiver is shown as including a front-end analog section with amplifying, filtering and mixing stages. Specifically, the front end of the receiver is shown as including a first low noise amplifier (LNA) indicated by reference numeral 10 and designated LNA 1 , which receives an incoming radio frequency (RF) signal on line 12 , an image reject filter 14 coupled to the output of LNA 1 , and a first mixer 16 connected to receive the output of the filter and having a second input to which a local oscillator signal LO 1 is applied. The output of the first mixer 16 is further processed by another filter 18 , a second low noise amplifier 20 designated LNA 2 , a second mixer 22 to which a second local oscillator signal LO 2 is applied, another filter 24 , and finally a third low noise amplifier 26 designated LNA 3 . It will be understood, of course, that there is nothing novel in this analog front end architecture and nothing critical to the invention in the use of two mixer stages for downconversion of the received RF input signals to an intermediate frequency (IF) signal such as the one output from the third low noise amplifier 26 . Note also that the invention is not restricted to the use of LNAs at this point; the LNAs could be replaced by a variable gain amplifier (VGA).
The conceptual receiver illustrated in FIG. 1 further includes a digital module, including an analog-to-digital converter (ADC) 28 , the digital output of which is connected to two parallel digital mixers 30 and 32 , which have as additional inputs the in-phase and quadrature components of a digital local oscillator signal. The outputs of the digital mixers 30 and 32 are further processed by digital lowpass filters 34 and 36 , respectively, which provide digital in-phase (I) and quadrature (Q) output signals on lines 38 and 40 , respectively, for further processing by other components (not shown) downstream from the receiver.
To control the gain of the signals on lines 38 and 40 , these signals are also coupled to an AGC loop 42 , which generates appropriate amplifier control signals on lines 44 , which are fed back to the low noise amplifiers 12 , 20 and 26 . The structure of the AGC loop 42 will now be discussed in more detail with reference to FIG. 2 .
The AGC loop 42 obtains I and Q output signals from the digital low pass filters 34 and 36 on lines 38 and 40 , respectively. At this point in processing, it is assumed that the I and Q digital data streams have been decimated to a data rate convenient for further processing. The decimated I and Q signals are separately squared in squaring circuits 50 and 52 , respectively, added together in a summing circuit 54 , and then further processed in a computation module 56 that generates a signal that is a measure of the input power. Further details of module 56 are discussed below.
The measure of input power is input to a summer 58 , which also receives a set-point input signal on line 60 . The summer 58 output, on line 62 , is amplified by a loop amplifier 64 , which applies a loop gain of μ to the difference between the set-point signal and the measure of input power. There is no amplification since μ is must be less than 1. The loop amplifier 64 provides an output on line 66 to another summer 68 , and the output of the summer 68 is connected, in turn, to a loop delay circuit 70 , which interjects a delay of one sample time this process is called a running sum and serves to estimate the desired gain needed to amplify or attenuate the received signal. The delay circuit 70 output is fed back over line 72 to provide a second input to the summer 68 .
The output signal from the delay circuit 70 of the AGC loop is also coupled through line 74 to a gain decision and hysteresis block 76 , which determines the adjustments, if any, to made to the gains of the low noise amplifiers 12 , 20 and 26 ( FIG. 1 ). Finally, a control signal distribution 78 distributes control signals to the low noise amplifiers, as indicated by lines 44 . Further details of the AGC loop are shown in FIG. 3 , in which the same reference numerals as in FIGS. 1 and 2 are used to refer to identical components.
As shown in FIG. 3 , the computational module 56 ( FIG. 2 ) for computing a measure of input power has two subcomponents, indicated as blocks 56 A and 56 B. In block 56 A, an integrate-and-dump function is performed on the incoming I and Q signals, as expressed by:
1
N
∑
n
=
1
N
-
1
I
2
(
t
-
nT
)
+
Q
2
(
t
-
NT
)
where n refers to the sample number in a series of samples, N denotes the total number of samples in the summation performed, t denotes time from the start of a block of samples, and T is the time interval between samples.
In block 56 B, the following function is performed on the output of block 56 A: 10 log 10 (.)
The need for performing the logarithm operation arises from the nature of a typical low-noise amplifier gain characteristic, which can be modeled as an exponential voltage gain amplifier (VGA) type of function of the form 10 (.)/10 . The logarithm is also used to compress the input signal power and allow the loop to react fast to power changes. The output of block 56 B provides a measure of the rms (root mean square) input power, designated r n , for reasons that are made more apparent from the following mathematical relationships. More precisely, the output of block 56 B provides signals proportional to the square of the rms input power, i.e., r n 2 .
The state space relation of the AGC loop may be expressed by the following equation:
ν n+1 =ν n +μe n =ν n +μ[P d −10 log 10 ( E{ 10 2ν n /10 r n 2 })], where:
ν n is the state at the output of summer 68 ,
μ is the loop gain,
e n is the error signal output from summer 58 ,
P d is the set point signal on line 60 , and
E represents an expected value operator, in this case performed by the integrate and dump function in box 56 A.
The expectation operator serves as a lowpass filter to remove the effect of zero-mean white noise in the input signal. The above equation may be expressed differently as:
ν n+1 =ν n +μ( P d −2ν n −10 log 10 ( {circumflex over (r)} n 2 ))=(1−2μ)ν n +μ( P d −10 log 10 ( {circumflex over (r)} n 2 ))
where
r ^ n 2 = E { r n 2 }
is the rms input power.
In the event that the I and Q signals resemble white Gaussian noise, the envelope r n 2 has a Rayleigh distribution. The distribution becomes Rician in the presence of a dominant narrowband signal.
The following discussion pertains to the steady state response of the AGC loop and stability considerations. During steady state operation, the mean of the error e n is zero and ν n+1 =ν n =ν. The expression immediately above then becomes:
ν=(1−2μ)ν+μ( P d −10 log 10 ( {circumflex over (r)} n 2 )).
Solving for ν in yields:
v
=
P
d
-
10
log
10
(
r
⋒
n
2
)
2
.
This equilibrium point is pivotal in computing the instantaneous dynamic range of the AGC loop. If we let χ n be the perturbation around the equilibrium point during steady state, then
ν+χ n+1 =(1−2μ)(ν+χ n )+μ( P d −10 log 10 ( {circumflex over (r)} n 2 ))
Simplifying this relation yields:
χ n+1 =(1−2μ)χ n −2μν+μ( P d −10 log 10 ( {circumflex over (r)} n 2 ))
Substituting for ν.results in:
χ
n
+
1
=
(
1
-
2
μ
)
χ
n
-
2
μ
P
d
-
10
log
10
(
r
⋒
n
2
)
2
+
μ
(
P
d
-
10
log
10
(
r
⋒
n
2
)
)
=
(
1
-
2
μ
)
χ
n
The above relation can be further expressed as:
χ n+1 =(1−2μ) n χ 0
In order for the AGC loop to be stable, this expression must converge to zero as n approaches infinity, thus imposing the relation:
1
-
2
μ
<
1
⇒
{
μ
>
0
μ
<
1
In the above discussion, it is assumed that the AGC loop has the same attack and decay time. Attack and decay time refers to the rate at which the AGC reacts to sudden increases and decreases, respectively, in the input signal. It is well known from control theory that the attack or decay time constant is inversely proportional to the loop gain μ.
An important aspect of the invention is that the AGC loop is modified to include measurement of error signal energy, and that the average error signal energy is used to select an appropriate loop gain μ. To this end, the AGC loop of the invention also includes an error signal energy detector block ( FIG. 3 ), connected between summer 58 and summer 68 , that includes an integrate-and-dump block, connected to an output of summer 58 by line 62 , that averages the error signal, a sign block, connected to an output of the integrate-and-dump block, that determines the sign of the average of the error signal, and a gain and switch block, connected to a second output of the integrate-and-dump block and an input to summer 68 by line 66 , to effect appropriate switching of the loop gain μ. Averaging of the error signal energy in the integrate-and-dump block is effected by an integrate-and-dump operation that may be expressed as:
e
avg
2
(
n
)
=
∑
n
=
0
N
-
1
e
2
(
t
-
nT
)
If the average error energy exceeds a certain threshold Γ, this implies that a sudden increase or decay in the incoming signal energy has taken place, and the AGC is controlled to use a large loop filter gain to compensate more rapidly for the change in received signal magnitude. This mode is referred to as the coarse AGC mode. The coarse AGC loop exhibits a low loop signal-to-noise ration (SNR) to allow for fast tracking of the input signal. If the error signal energy is less than the threshold Γ, then the loop filter gain remains at its original low setting. This mode is known as the fine AGC mode. The loop exhibits a high SNR at this slower tracking speed. Therefore, the attack and decay time can change depending on the input signal condition if it is desired to change the loop behavior accordingly.
The sign of the average error signal is expressed as:
sign
{
e
avg
(
n
)
}
=
{
1
sign
{
∑
m
=
0
M
-
1
e
(
t
-
m
)
}
≥
0
-
1
sign
{
∑
m
=
0
M
-
1
e
(
t
-
m
)
}
<
0
In this expression, M is a programmable parameter that indicates the number of samples taken in the averaging process. The sign of the average error is used to indicate whether the AGC loop is in attack mode (positive average error) or decay mode (negative average error). The sign determination is made in the sign block ( FIG. 3 ) and transmitted to a threshold detector and decision mechanism block, which is connected to the second output of the integrate-and-dump block and line 80 . Based on the sign of the average error (which determines whether the AGC mode is attack or decay) and on the comparison of the average error with the threshold (which determines whether the AGC mode is coarse or fine), the decision mechanism in the threshold detector and decision mechanism block generates a loop gain selection signal on line 80 , which results in the selection of one of four gain values by a multiplexer 82 . The four gain values are μ dc , μ af , μ ac and μ df , where the subscripts d and a refer to the decay and attack modes, respectively, and the subscripts c and f refer to the coarse and fine modes, respectively. Selection of the loop gain can be expressed by the relation:
μ
=
{
μ
a
,
f
e
avg
2
(
n
)
<
Γ
,
sign
{
e
avg
(
n
)
}
<
0
μ
d
,
f
e
avg
2
(
n
)
<
Γ
,
sign
{
e
avg
(
n
)
}
≥
0
μ
a
,
c
e
avg
2
(
n
)
≥
Γ
,
sign
{
e
avg
(
n
)
}
<
0
μ
d
,
c
e
avg
2
(
n
)
≥
Γ
,
sign
{
e
avg
(
n
)
}
≥
0
In effect, the magnitude of the average error signal is used to determine the magnitude of the loop gain, and the sign of the average error signal is used to determine whether the gain needs to be increased or decreased, based on whether the AGC is in attack or decay mode. It will be readily appreciated that the principle of the invention is not limited to use of a single threshold to determine the loop gain. One could also employ multiple thresholds and choose from a larger number of gain values.
A further optional feature of the AGC loop of the invention is the ability to provide a variable set point P d depending on the difference between the signal energy or power, derived as previously described, and the signal energy after passing through a channel filter. If this difference is greater than a preselected threshold, a higher value of P d is chosen. The scheme for varying the set point is depicted in FIG. 4 . The digital input signals are passed through a channel filter 90 , the output of which is processed in blocks 92 A and 92 B in much the same way that the original input signals are processed in blocks 56 A and 56 B. In other words, the signal energy at the output of the channel filter 90 is estimated using an integrate-and-dump function:
1
GN
∑
n
=
t
N
-
1
I
c
2
(
t
-
nT
)
+
Q
c
2
(
t
-
NT
)
where G is a gain adjustment and the subscript c refers to input signals passed through the channel filter. This estimated signal energy is input to a summer 94 , the other input of which receives the estimated signal energy of the original signal, not passed through the channel filter 90 . The summer 94 generates a difference signal given by:
E
Δ
=
1
N
∑
n
=
t
N
-
1
I
2
(
t
-
nT
)
+
Q
2
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As in any AGC implemented with discrete gain steps, a hysteresis is often necessary when switching a gain stage on and off. Gain stages farthest away from the antenna are turned on first in order to minimize the noise figure of the receiver. Once a gain stage is switched on or off, the AGC loop may not switch it back off despite a drop or increase in the signal level until a certain power threshold is surpassed. Failure to present adequate hysteresis results in AM-modulating the received signal. The important point to note is that the fixed point implementation of the loop must be designed such that the quantized levels are much smaller than the required gain steps, which is normally the case.
FIG. 5 is a graph showing the magnitude changes in a sample input signal, including a first step change (reduction) in magnitude and, a short time later, another step change, also reducing the magnitude. Although not apparent from the figure, which plots magnitude on a linear scale, the second change is much greater than the first in signal power (dB) terms, specifically 10 dB for the first change versus 40 dB for the second.
FIG. 6 plots the in-phase signal after it has been adjusted by the AGC loop of the invention. Adjustment for the second step change is achieved in approximately the same time as adjustment for the first step change, even though the second step change was a much bigger reduction in signal power. The reason for the fast reaction to the greater step change is that the second change produced an average power change that exceeded the selected threshold, and resulted in the AGC loop switching to its coarse mode of operation. This is apparent from the plot of the AGC error signal in FIG. 7 . The error signal spikes to a very large value at the time of the second step change and then quickly readjusts to a lower value. Finally, FIG. 8 shows the corresponding changes in the output of the AGC control loop.
It will be appreciated from the foregoing that the present invention represents a significant advance in the field of automatic gain control technology. In particular, the invention provides an AGC loop that has the stability advantages of first-order control loops, but is still able to react rapidly to sudden changes in received signal power. It will also be appreciated that, although an embodiment of the invention has been described in detail for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. In particular, it should be noted that, because signals in the AGC loop are processed in digital form, most of the components and modules of the AGC loop are conveniently implemented in the form of software or some form of programmable hardware (firmware). The invention is not, however, limited to such implementations. Accordingly, the invention should not be limited except as by the appended claims. | An automatic gain control device and a related method for its operation, using a first-order control loop for adjusting a received communication signal to compensate for variations in received signal power. The device bases its adjustments on a measure of the average received root-mean-square (rms) signal power and, in its preferred form, adjusts a loop gain adaptively to react rapidly to large input signal variations. The loop gain is adjusted based on measurement of the average power of an error signal and on the sign of the error signal power. Optional features include an automatically adjustable power set point. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application relates to and claims priority from U.S. Provisional Patent Application Ser. No. 60/506,217, filed Sep. 26, 2003, and is incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
The present invention relates generally to input/output circuits, and more particularly, to buffer circuits capable of fast translation between core and external signals.
BACKGROUND OF THE INVENTION
Conventional I/O buffers can include circuitry (typically in the I/O portion of an integrated circuit) to provide fast translation between core and external signals. Core signals may have lower voltage differential signaling levels, for example between 0 and 1 V, whereas external output signals may have higher voltage signaling, for example ranging between 0 and 3.3 V.
FIG. 1 illustrates a conventional translation scheme in conventional I/O buffer 10 . Core differential signals X/XB are provided to gates of transistors N 1 /N 2 , respectively. The drains of N 1 and N 2 are coupled to nodes D and B, respectively. The external signal output OUT is provided from node B in this example. In accordance with the state of the input differential signals X/XB, therefore, either N 1 or N 2 will turn on, pulling either node D or B toward Vss, respectively. Nodes D and B are further respectively coupled to the gates of P 2 and P 1 . Accordingly, if D is pulled toward Vss (having a value of about 0 V, for example) by action of N 1 and signals X/XB, P 2 will turn on, pulling node B (and thus external signal OUT) toward Vdd (having a value of about 3.3 V, for example). Conversely, if node B is pulled toward Vss (and thus external signal OUT) by action of N 2 and signals X/XB, P 1 will turn on, pulling D toward Vdd, and further turning off P 2 .
One problem with the conventional approach is that transistors with sufficient voltage ratings to tolerate the higher voltage output usually have high threshold voltages. Transistors with low threshold voltage and high breakdown voltage are either not available or are a costly process option. When X/XB are core differential signals having a maximum signaling value of about 1V, N 1 and N 2 are only driven weakly by signals X/XB because of the threshold voltage being so high. The result is slow responsiveness, which is a problem in, for example, applications where fast translation is desired.
SUMMARY OF THE INVENTION
The present invention relates to a circuit for providing fast translation from differential signals at the lower core voltage to higher voltage signals external to the core. In accordance with an aspect of the invention, an I/O buffer includes low voltage devices for receiving core input signals, a cascode stage for setting a bias between the input devices and an output stage, and an output stage including a current mirror for providing a translated external output. Another aspect of the invention further includes a feedback path to cut off the current mirror to prevent static current and a keeper device to maintain an output level after cut off of the current mirror.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures, wherein:
FIG. 1 illustrates a conventional I/O buffer;
FIG. 2 illustrates an I/O buffer for providing fast translation between input core differential signals and an external output signal according to the present invention; and
FIG. 3 illustrates another embodiment of an I/O buffer in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail with reference to the drawings, which are provided as illustrative examples of the invention so as to enable those skilled in the art to practice the invention. Notably, the figures and examples below are not meant to limit the scope of the present invention. Moreover, where certain elements of the present invention can be partially or fully implemented using known components, only those portions of such known components that are necessary for an understanding of the present invention will be described, and detailed descriptions of other portions of such known components will be omitted so as not to obscure the invention. Further, where an embodiment is described with singular components, the invention is not limited thereto, and it should be understood that plural components can be substituted therefor unless expressly stated otherwise herein. Still further, the present invention encompasses present and future known equivalents to the known components referred to herein by way of illustration.
An example implementation of a fast translation I/O buffer 20 in accordance with the present invention is illustrated in FIG. 2 . As shown in FIG. 2 , N 1 and N 2 have been replaced with N 1 ′ and N 2 ′ which are low-voltage devices capable of responding faster to changes in low-voltage core differential signals X/XB. The problem of the commonly available lower threshold core devices having too low of a breakdown voltage tolerance is addressed by transistors N 3 and N 4 (comprising cascode stage 22 ), which protect the drains of N 1 ′ and N 2 ′ from overvoltage. As further shown in this illustrative example, N 3 is coupled between the sources of N 1 ′ and P 1 at node C and transistor N 4 is coupled between the sources of N 2 ′ and P 2 at node A. Transistors N 3 and N 4 have threshold voltages similar to transistors P 1 and P 2 , in accordance with the desired external signaling voltage levels of OUT. The gates of transistors N 3 and N 4 are coupled to a bias voltage Vbias which is sufficiently high to overcome the higher threshold voltages of these devices.
As further shown in FIG. 2 , in the output stage current mirror comprised of transistors P 1 and P 2 , the gate of P 1 is further coupled to node D. As is still further shown in this example, the output stage is further comprised of driver INV 1 which is coupled to node B between P 2 and N 4 and provides external signal OUT.
In operation, depending on the differential state of X/XB, either transistor N 1 ′ or N 2 ′ will more reliably and responsively pull either node C or A, respectively, toward Vss. Because N 3 and N 4 are supplied the same bias voltage at their gates, the node pulled more toward Vss will cause the respective transistor N 3 or N 4 to be turned on, pulling either node D or B, respectively, more toward Vss. This causes either P 1 or P 2 to pull the other node toward Vdd.
For example, where X/XB is high/low, for example 1V/0V, respectively, node A is pulled toward Vss by N 2 ′ turning on, causing the voltage difference between Vbias and node A to exceed the threshold voltage of N 4 . Meanwhile, N 1 ′ turns off, keeping the voltage at node C too close to Vbias and preventing N 3 from turning on. Because N 4 turns on, however, node B is pulled toward Vss, which is inverted by INV 1 , and so external signal OUT is driven high. Meanwhile, transistor P 2 , having its gate coupled to node D, stays off because N 3 stays off by action of N 1 ′ and the bias voltage supplied to the gate of N 3 .
Conversely, where X/XB is low/high, respectively, node C is pulled toward Vss by N 1 ′ turning on, causing the voltage difference between Vbias and node C to exceed the threshold voltage of N 3 . Meanwhile, N 2 ′ turns off, keeping the voltage at node A too close to Vbias and preventing N 4 from turning on. Because N 3 turns on, however, node D is pulled toward Vss. Meanwhile, transistor P 2 , having its gate coupled to node D, turns on, pulling node B toward Vdd, which is inverted by INV 1 , and so external signal OUT is driven low. Meanwhile, N 4 stays off by action of N 2 ′ and the bias voltage supplied to the gate of N 4 .
By virtue of the present invention, therefore, including the lower voltage devices N 1 ′ and N 2 ′, and biased devices N 3 and N 4 , the buffer 20 of FIG. 2 is able to provide faster and more reliable translation between core and external signals.
Although the buffer 20 in FIG. 2 provides advantages over the prior art, certain issues remain. For example, in a differential input state where XB is high and X is low, N 1 and N 3 turn on, causing node D to be pulled toward Vss and P 1 and P 2 to conduct. But, as P 1 conducts, node D is also pulled toward Vdd, causing excessive current and power to be consumed.
Another embodiment of the invention is illustrated in FIG. 3 . As shown in FIG. 3 , this embodiment of the invention further includes a feedback transistor N 5 coupled between transistor N 3 and node D, and keeper transistor P 3 , having its source coupled to node B and its gate coupled to the output OUT. The gate of N 5 is also coupled to the output OUT.
By virtue of this arrangement, for example, in the input differential signaling state when X is low and XB is high, node C is driven toward Vss, causing N 3 to turn on. Meanwhile, if the output OUT was previously in the high state (opposite of what needs to be signaled now), N 5 will be turned on, and node D will be pulled low, causing P 2 to conduct and pull node B toward Vdd. This will cause the output signal OUT to be driven low as desired, thus driving node E low. This situation causes P 3 to turn on, keeping node B pulled toward Vdd and shutting off N 5 , thus removing the path of static current in the XB signal path, which static current was a problem in the previous embodiment.
Although the present invention has been particularly described with reference to the preferred embodiments thereof, it should be readily apparent to those of ordinary skill in the art that changes and modifications in the form and details may be made without departing from the spirit and scope of the invention. It is intended that the appended claims include such changes and modifications. | In accordance with an aspect of an input/output device for providing fast translation between differential signals from a core of an integrated circuit and higher voltage signals that are external to the core, an I/O buffer includes low voltage devices for receiving core input signals, a cascode stage for setting a bias between the input devices and an output stage, and an output stage including a current mirror for providing a translated external output. Another aspect of the invention further includes a feedback path to cut off the current mirror to prevent static current and a keeper device to maintain an output level after cut off of the current mirror. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a gas combustion-powered apparatus, and more specifically to a gas combustion-powered fastener-driving apparatus having a collapsible combustion volume for displacing a gas volume within a combustion chamber.
[0002] Gas combustion devices are known in the art. A practical application of this technology is found in combustion-powered fastener driving tools. One type of such tools, also known as IMPULSE brand tools for use in driving fasteners into workpieces, is described in commonly assigned patents to Nikolich, U.S. Pat. Re. No. 32,452, and U.S. Pat. Nos. 4,522,162, 4,483,473, 4,483,474, 4,403,722, 5,197,646, and 5,263,439, all of which are incorporated by reference herein. Similar combustion powered nail and staple driving tools are available commercially from ITW-Paslode of Vernon Hills, Ill. under the IMPULSE brand.
[0003] Such tools incorporate a generally pistol-shaped tool housing enclosing a small internal combustion engine. The engine is powered by a canister of pressurized fuel gas, also called a fuel cell. A battery-powered electronic power distribution unit produces a spark for ignition, and the engine also includes a reciprocating piston with an elongated, rigid driver blade disposed within a single cylinder body. When a work contact element is pressed against a workpiece, a fuel-metering valve introduces a specified volume of fuel into a combustion chamber of the engine.
[0004] Upon pulling a trigger switch, which causes the spark to ignite a charge of gas in the combustion chamber, the piston and the driver blade are shot downward to impact a positioned fastener and drive it into a workpiece. The piston then returns to its original, or “ready,” position through differential gas pressures within the cylinder. Fasteners are fed magazine-style into a nosepiece, where the fasteners are held in a properly positioned orientation for receiving the impact of the driver blade. The charge of gas is a combustible fuel/air mixture, and the combustion in the chamber causes an acceleration of the piston/driver blade assembly and a resulting penetration of the fastener into the workpiece if the fastener is present in the nosepiece.
[0005] Combustion pressure in the chamber is an important consideration because such pressure affects the amount of force with which the piston may drive the fastener. Combustion pressure increases the more rapidly the fuel/air mixture within the combustion chamber can be ignited. The fuel/air mixture in the combustion chamber may be more rapidly ignited when the mixture is in a turbulent state. The ability to rapidly complete processes ancillary to this combustion operation of the tool is another important consideration. Such ancillary processes include: inserting the fuel into the combustion chamber; mixing the fuel and air within the chamber; and removing, or scavenging, combustion by-products remaining in the chamber after a combustion event.
[0006] One known method of scavenging the residual combustion by-products between combustion events is by dilution. Dilution scavenging is performed by sending fresh air flowing through the combustion chamber between combustion events to displace combustion by-products. An example of dilution scavenging is described in commonly assigned, copending application Ser. No. ______ (Attorney Docket No. 13696), which is incorporated by reference herein. A fan is located within the combustion chamber to create the turbulence for a more rapid, higher-energy combustion, and also to drive fresh air through the combustion chamber between combustion events. Although this process is effective to achieve rapid, high-energy combustions and scavenging, the scavenging is not always performed efficiently. Typically, a volume of air required to scavenge the combustion by-products after a combustion event is equal to approximately two and one half times the volume of the combustion chamber itself.
[0007] Another known method of scavenging, which is more efficient than the dilution method, is the displacement method. Displacement scavenging is performed by eliminating, or otherwise effectively reducing to zero, the volume within the combustion chamber itself, thereby removing all air within the volume, including that containing combustion by-products. Examples of displacement scavenging are described in patents to Cotta, U.S. Pat. No. 4,721,240, and to Gschwend, U.S. Pat. No. 5,181,495.
[0008] Cotta requires the displacement of moveable parts at the front of the combustion chamber toward a rear wall of the chamber. Displacement is thus performed by the movement of a second piston assembly through the combustion chamber in a direction opposite to the piston in the piston chamber. The second piston displaces the entire volume of gas from the combustion chamber, but does not actually reduce the volume to zero. Although reasonably efficient, the complexity of this configuration greatly increases the cost of the tool. The cost and complexity are both significantly increased by the number of extra components required for the second piston assembly, as well as a host additional electrical components (motors, batteries, control circuits, etc.) to operate the complex construction.
[0009] Gschwend displaces the combustion chamber volume by requiring that a moveable section at the rear of the combustion chamber move toward the front of the chamber to mostly collapse the chamber from behind, and reduce its volume to near zero. Force from an operator in back of the tool moves the moveable section to toward the front of the combustion chamber, thereby having the moveable section operate like Cotta's piston, but only in the reverse direction. Gschwend also separates the combustion chamber into first volume and a second combustion volume by use of a divider plate configured as a multiple-volume system, as is known in the art, to increase the energy of combustion.
[0010] To operate the tool as a multiple volume system though, Gschwend requires a complicated system of collapsing guide rods throughout the moveable section and the divider plate between the volumes. The tool's trigger also must be located at an awkward position at the rear of the tool where the operator must be positioned to push the moveable section toward the front of the tool, thereby making the tool itself cumbersome to operate. And similar to Cotta's tool as well, this tool is significantly complex, and requires a great deal of additional electrical and mechanical components to guide the opposing structures of the combustion chamber together and apart at appropriate timings.
[0011] There is a need therefore for a commercially available combustion gas fastener-driving tool having a simplified construction that reduces the need for expensive mechanical and electrical components in its construction. Such expensive components limit the availability of cordless combustion gas technology to a range of high cost applications only. A simplified single or multiple combustion volume construction, which can achieve substantially the same performance as the higher cost tools, would greatly extend the availability of combustion gas technology to more affordable, lower cost applications.
SUMMARY OF THE INVENTION
[0012] The above-listed concerns are addressed by the present gas combustion-powered apparatus, which features a simplified solid chamber structure for igniting a combustible gas to drive a piston. A combustion volume is defined between the piston and a moveable wall of a combustion chamber, and an ignition device ignites the combustible gas in or into the combustion volume to drive the piston. Turbulence is created within the combustion volume to increase the speed and energy of combustion in a single volume by either the movement of the moveable wall, or by a high speed fuel injected into the combustion chamber shortly prior to ignition, or in a second volume by a high speed flame jet exiting the first volume.
[0013] More specifically, the present invention provides a gas combustion-powered apparatus includes a driveable piston chamber housing a piston and a combustion chamber having a generally flat wall assembly and a cup-shaped wall defining at least one combustion volume therebetween. The cup-shaped wall is moveable in relation to the piston chamber, and has a generally flat portion opposing, and generally parallel to, the generally flat wall assembly. An ignition source is in operable relationship to the combustion volume, which can ignite a combustible gas within the combustion volume. The piston forms at least a portion of the generally flat wall assembly when the piston is in an undriven state.
[0014] In a gas combustion-powered apparatus, the simplified structure of the present invention is effective for generating high-energy combustion to drive a piston, and for a broader cost range of applications than other types of combustion-powered devices. The present invention is also effective in either single-, or multiple-volume combustion apparatuses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a vertical schematic sectional view of an embodiment of the present gas combustion-powered apparatus;
[0016] FIG. 2 is vertical schematic sectional view illustrating an operation of the apparatus shown in FIG. 1 ;
[0017] FIG. 3 is a partial sectional schematic view of the apparatus shown in FIG. 1 ;
[0018] FIG. 4 illustrates an alternative configuration of the apparatus illustrated in FIG. 1 ;
[0019] FIG. 5 is a vertical schematic sectional view of another embodiment of the present gas combustion-powered apparatus;
[0020] FIG. 6 is vertical schematic sectional view illustrating an operation of the apparatus shown in FIG. 5 ;
[0021] FIG. 7 is an expanded partial sectional view illustrating the moveable plug structure of the embodiment shown in FIG. 5 ;
[0022] FIG. 8 is an alternative configuration of the apparatus illustrated in FIG. 5 ;
[0023] FIG. 9 is a vertical schematic sectional view of still another embodiment of the present gas combustion-powered apparatus;
[0024] FIG. 10 illustrates an operation of the apparatus illustrated in FIG. 9 ; and
[0025] FIG. 11 illustrates a further operation of the apparatus illustrated in FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring now to FIGS. 1-4 , a combustion-powered apparatus is generally designated 10 , and includes a combustion chamber 12 in communication with a piston chamber 14 . Such an apparatus 10 is preferably intended for use in a combustion-powered tool of the type described above and disclosed in the patents incorporated by reference herein. Both of the chambers 12 and 14 are preferably rigid metal bodies, but may also be formed from other strong, combustion-resistant solid materials as are known in the art. The piston chamber 14 houses a piston 16 and driver blade 18 within a main body 20 , which is preferably generally cylindrical.
[0027] When the piston 16 is in a “ready” position prior to firing, as best seen in FIG. 1 , a generally flat surface 22 of the piston substantially aligns with outer surface 24 of a flanged end 26 of the piston chamber 14 to create a substantially continuous and generally flat wall assembly 28 . A piston stop 30 , which is preferably one or more protrusions, or a continuous ring, around an inner surface 32 of the main body 20 of the piston chamber 14 , is preferably positioned near the flange outer surface 24 against which the piston 16 aligns. Air is preferably prevented from flowing between the piston 16 and the piston chamber inner surface 32 by a piston seal 34 . The piston seal is preferably an o-ring around an outer circumference 36 of the piston 16 , but may also be any type of combustion-resistant seal known in the art.
[0028] The flat wall assembly 28 , together with a cup-shaped wall 38 , defines the combustion chamber 12 . Referring now to FIG. 1 , the combustion chamber 12 is shown in a fully closed, or “collapsed,” position. The cup-shaped wall 38 includes a generally flat rear surface 40 that opposes, and is generally parallel to, the flat wall assembly 28 , and a continuous sleeve body 42 joining to an outer periphery 44 of the flat rear surface. The cup-shaped wall 38 is preferably formed as single piece, or as several pieces solidly joined together, and is slidingly moveable in a direction A about the piston chamber flanged end 26 . A chamber seal 46 preferably prevents air from flowing between the flanged end 26 and an internally extending portion 48 of the sleeve body 42 when the cup-shaped wall 38 is in a fully opened position, as best seen in FIG. 3 . The sleeve body 42 is preferably cylindrical, but may be of any shape to conform to a shape of the flanged end 26 , and the flat rear surface 40 .
[0029] Although moveable, the cup-shaped wall 38 is preferably held in the fully closed position by a first pawl 50 . The first pawl 50 is configured as well known in the art to be preferably located directly, or by a linkage, in association with a housing (not shown) of the tools described above. The first pawl 50 is preferably also a beveled rod, or any solid shape known in the art which is moveable to hold the cup-shaped wall 38 firmly. When in the fully closed position, the flat rear surface 40 of the cup-shaped wall 38 approaches very near to, or contacts, the flat wall assembly 28 , which includes the flange outer surface 24 and the piston flat surface 22 . When the cup-shaped wall 38 is in the fully closed position therefore, there is preferably no effective volume of air between the flat rear surface 40 and the flat wall assembly 28 .
[0030] Referring now to FIG. 2 , a work contact element 52 is pressed against a workpiece (not shown), pushing the work contact element in the direction A. The work contact element 52 is connected directly to the cup-shaped wall 38 , but is more preferably operably linked to the cup-shaped wall by a first spring 54 . A first end 56 of the first spring 54 is connected to a first stop 58 located on the work contact element 52 , and a second end 60 of the first spring is connected to an extending portion 62 of the cup-shaped wall 38 . The movement of the work contact element 52 and the first stop 58 in the direction A compresses the first spring 54 to create pressure against the cup-shaped wall 38 , which is still held in place by the first pawl 50 . A second spring 64 is similarly compressed between a second stop 66 and an extending portion 68 of the piston chamber 14 . The compression of the second spring 64 moves the work contact element 52 back to its original ready position when released from the workpiece. The extending portion 68 also preferably serves as a guide for the moving work contact element 52 .
[0031] Referring now to FIG. 3 , when a trigger (not shown) is activated, the pawl 50 retracts in the direction B, thereby allowing the pressure from the compressed first spring 54 to rapidly move the cup-shaped wall 38 in the direction A to the fully opened position, thereby creating a combustion volume between the flat wall assembly 28 and the open cup-shaped wall. In this embodiment, fuel is preferably injected from a fuel line 70 into the combustion volume through a fuel port 72 when the trigger releases the first pawl 50 . However, fuel may also be injected at any time while the flat wall assembly 28 and the rear surface 40 of the cup-shaped wall are still moving apart. A suitable fuel is MAPP gas of the type used in combustion-powered fastener driving tools, but may also be any of a number of known combustible fuels practiced in the art. As the cup-shaped wall 38 moves in the direction A, a vacuum pressure from the opening combustion volume draws air into the combustion chamber 12 along and through an unsealed periphery 74 between the cup-shaped wall 38 and the piston chamber 14 . The vacuum pressure also facilitates holding of the piston 16 against the piston stop 30 .
[0032] The rapid movement of the cup-shaped wall 38 toward the fully opened position creates turbulence within the combustion chamber 12 and the opening combustion volume therein. The turbulence in turn mixes the fuel and the air in the volume. Ideally, when the cup-shaped moving wall 38 reaches its fully opened position, but before the turbulence with the volume subsides, an ignition source 76 (which is preferably a spark plug) ignites the turbulent air/fuel mixture within the combustion chamber 12 . The turbulence within the combustion chamber 12 also increases the speed at which the air/fuel mixture ignites, thereby also increasing the combustion pressure. The rapid increase in combustion pressure drives the piston 16 in the direction C, which in turn drives the driver blade 18 to drive the fastener into the workpiece.
[0033] Excess combustion pressure in the piston chamber 14 is expelled through an exhaust port 78 , and the piston 16 comes to a stop against a resilient member 80 after the piston passes the exhaust port in the direction C. Although the resilient member 80 is preferred to act as a brake for the piston 16 , air pressure between the piston and a generally closed end 82 of the piston chamber 14 may also be utilized to provide a braking force for the piston. Additionally, when the cup-shaped wall 38 reaches its fully opened position, by a linkage with the tool housing and trigger (not shown) similar to that of the first pawl 50 , a second pawl 84 moves in the direction D to contact the cup-shaped wall and fixedly hold it in the fully opened position, and thus also fixedly sealing the piston chamber flanged end 26 to the internally extending sleeve portion 48 at the chamber seal 46 .
[0034] As residual gas within the combustion chamber 12 and the piston chamber 14 cools, a vacuum develops in the chambers, which closes a valve 86 over the exhaust port 78 , and draws the piston 16 back to the initial ready position aligning with the flange outer surface 24 ( FIG. 1 ). When the trigger is released, the second pawl 84 retracts in the direction B, thereby allowing the vacuum to also pull the cup-shaped wall 38 toward its initial fully closed position. As the cup-shaped wall 38 closes, the volume within the combustion chamber 12 is effectively reduced to zero, and all of the residual combustion gases from the volume are expelled through the unsealed periphery 74 ( FIG. 1 ). Additionally, force from the compressed second spring 64 causes a catch 88 on an end 90 of the work contact element 52 to pull the cup-shaped wall 38 toward the initial fully closed position after the second pawl 84 retracts, and after the work contact element is removed from the workpiece.
[0035] Referring now to FIG. 4 , an alternative configuration of the apparatus 10 is configured without the first pawl 50 . This alternative configuration is otherwise identical to the configuration shown in FIG. 1 , except for the positioning of the fuel line 70 and fuel port 72 along the flanged end 26 of the piston chamber 14 . According to this configuration, the turbulence in the combustion chamber 12 is created by injecting the fuel into the combustion volume as a high-speed fuel jet. The present inventors have discovered that, when properly configured within the combustion volume, the high-speed fuel jet will have sufficient energy to create the necessary turbulence to produce a rapid, high-energy combustion. The fuel jet itself thus serves as the mixing element for the fuel and the air. The air still is drawn into the combustion chamber 12 through the unsealed periphery 74 as the cup-shaped wall 38 is pushed open. Mixing occurs as the air is entrained into the jet as the jet courses through the open combustion chamber 12 .
[0036] To maximize the mixing effect, the fuel line 70 and fuel port 72 should be positioned at the flanged end 26 of the piston chamber 14 to fire the jet of fuel in a direction E toward the flat rear surface 40 of opened cup-shaped wall 38 , and more preferably toward a center point 92 of the flat rear surface. The ignition source 76 should also be located ideally on the flanged end 26 , and generally in the same plane as the fuel port 72 and the piston surface 22 , but at a maximum distance from the fuel port along the flanged end. By this preferred configuration, the fuel jet travels a maximum distance from the fuel port 72 toward the center 92 of the rear surface 40 , and then toward the ignition source 76 before igniting. This extended distance allows for better mixing of the fuel with air in the combustion volume.
[0037] Also according to this configuration, the first spring 54 is preferably eliminated, and the cup-shaped wall 38 can be directly fixed to the work contact element 52 , thereby moving to the fully opened position directly when the work contact element is placed against the workpiece. The fuel need not be injected when the combustion chamber 12 opens, but instead is preferably introduced into the already-open chamber whenever firing is desired. Ideally then, when the trigger is activated, the second pawl 84 moves in the direction D to lock the cup-shaped wall 38 into the fully opened position, as described above ( FIG. 3 ), the fuel jet is injected into the combustion volume, and the ignition source 76 ignites the resultant fuel/air mixture. The ignition source 76 is preferably timed to allow the fuel jet sufficient time to travel across the combustion volume before ignition occurs. The remaining sequence of operation for this alternative configuration is as described above for FIGS. 1-3 .
[0038] According to these embodiments of the present invention, a combustion volume is created from a simplified construction of an expanding collapsible chamber by moving apart two generally opposing walls of the chamber. Turbulence for a rapid combustion is thus created by one of two methods described above. According to the first method, components of the chamber move apart immediately prior to igniting the fuel/air mixture, to expand the combustion volume. The turbulence created by the moving components is adequate to produce the rapid combustion needed for a practical tool if ignition occurs early enough. According to the second method though, a fuel jet both creates the turbulence, and also is the mixing element for the air and fuel. Both turbulence generation methods produce adequate fuel/air mixtures for rapid, high-energy combustions.
[0039] Referring now to FIGS. 5-8 , a combustion-powered apparatus is generally designated 100 , but features of the apparatus 100 that are the same as those described above with reference to FIGS. 1-4 are identified by the same numerical designations.
[0040] The apparatus 100 includes a combustion chamber 102 in communication with a piston chamber 104 , and is formed of materials as described above with respect to the apparatus 10 . The piston chamber 104 is preferably cylindrical, and is located partially within the combustion chamber 102 , which is also preferably cylindrical and has a larger outer diameter than the piston chamber, however, non-cylindrical shapes are also contemplated. A moveable plug 106 is located within the combustion chamber 102 . In this embodiment, the combustion chamber 102 is preferably a rigid structure, and does not move relative to the piston chamber 104 .
[0041] The moveable plug 106 includes a generally flat base portion 108 , which preferably is shaped as a round disk having an outer periphery 110 , which generally corresponds to an inner wall 112 of the combustion chamber 102 . Connected to the base portion 108 is a generally ring-shaped wall 114 , which has a ring inner wall 116 that preferably corresponds to an outer wall 118 of the piston chamber 104 , and a ring outer wall 120 that generally corresponds to the inner wall 112 of the combustion chamber 102 . As best seen in FIG. 7 , the ring-shaped wall 114 has a height H that preferably corresponds to a length L of a portion 122 of the piston chamber 104 which is located within the combustion chamber 102 . In this embodiment, the flat base portion 108 and the ring-shaped wall 114 together preferably form a cup shape similar to the cup-shaped wall 38 of the apparatus 10 ( FIGS. 1-4 ). The cup-shaped portion 108 , 114 of the plug 106 therefore functions, with respect to the portion 122 of the piston chamber 104 , similarly to the function of the cup-shaped wall 38 with respect to the piston chamber 14 of the apparatus 10 ( FIGS. 1-4 ).
[0042] Connected to the base portion 108 , and on a side 124 of the base portion opposite to the ring-shaped wall 114 , is a stem portion 126 . The stem portion 126 is preferably centered relative to the base portion 108 , and preferably generally aligns with the driver blade 18 of the piston 16 . The stem portion preferably extends through an opening 128 in a rear wall 130 of the combustion chamber 102 , and is fixedly attached to an attaching member 132 , which in turn is operably linked to the work contact element 52 directly, by spring tension, or other linking methods known in the art. Although the moveable plug 106 is preferably formed from separate and/or hollow pieces, the base portion 108 , the ring-shaped wall 114 , and the stem portion 126 are more preferably formed together as a single, solid piece, and of generally rigid, combustion-resistant materials as are known in the art.
[0043] The base portion 108 and the ring-shaped wall 114 have a cup-like shape, and move and function in relation to the piston chamber 104 similarly to the way the cup-shaped wall 38 moves and functions in relation to the piston chamber 14 of the apparatus 10 , as described above. As best seen in FIG. 5 , the moveable plug 106 is fixedly held in the fully closed, or ready, position by a pawl 134 , which is associated or linked with a tool housing (not shown) similar to the pawls 50 , 84 described above. In this embodiment, when the moveable plug 106 is fully closed, a single mixing volume Vm is defined within the combustion chamber 102 between the side 124 of the base portion 108 and the rear wall 130 of the combustion chamber. All other volume of air within the combustion chamber 102 , but outside of the dimensions of the mixing volume Vm, is effectively reduced to zero. As the work contact element 52 is pushed against the workpiece, a first spring 136 , which connects the attaching member 132 to the work contact element at a first spring stop 138 , is stretched to create a pulling tension against the attaching member in the direction A.
[0044] Referring now to FIG. 6 , activation of the trigger releases the pawl 134 in the direction B, and the pulling tension from the first spring 136 rapidly moves the plug 106 in the A direction toward the rear wall 130 of the combustion chamber 102 . This movement of the plug 106 is preferably terminated when the side 124 of the base portion 108 contacts a resilient stop 140 at the fully open position of the plug. In addition to acting as a brake for the movement of the plug 106 , the resilient stop 140 is preferably a hollow cylinder, which also preferably serves as a guide for the movement of the stem portion 126 through the hollow cylinder, as well as a seal against potential airflow into the mixing volume Vm through the opening 128 . When the moveable plug 106 reaches its fully open position, the mixing volume Vm partially collapses, and first and second combustion volumes V 1 and V 2 respectively are created within the combustion chamber 102 , which now contains at least three separate and distinct volumes.
[0045] When the plug 106 is fully open, the first and second combustion volumes V 1 and V 2 together contain approximately the amount of volume by which the mixing volume Vm is reduced. In other words, the distinct volumes within the combustion chamber 102 preferably generally satisfy the equation V 1 +V 2 +Vm open =Vm closed . Although the mixing volume Vm is not entirely collapsed in this configuration, the present inventors contemplate that the moveable plug 106 and chambers 102 , 104 are configurable so that the resilient stop 140 is alternatively removed, and the base portion 108 then will open all of the way to the rear wall 130 of the combustion chamber 102 . The formula described above would then still be satisfied as Vm open becomes equal to zero.
[0046] The first combustion volume V 1 is preferably annular, and the second combustion volume V 2 is cylindrical. A diameter of the cylindrical volume V 2 will then preferably be approximately equal to an inner diameter of the annular volume V 1 . The cylindrical volume V 2 also ideally conforms to the shape of the cylindrical portion 122 of the piston chamber 104 located within the combustion chamber 102 . The mixing volume Vm is basically cylindrical, but can also be considered annular when movement of the plug 106 is effected by the central inclusion of the stem portion 126 through the mixing volume Vm. One skilled in the art, however, will be aware that movement of the plug 106 may instead be operably linked to the movement of the work contact element 52 , without the inclusion of the stem portion 126 , through many other linkage methods known in the art, without departing from the present invention.
[0047] As best seen in FIG. 5 , when the work contact element 52 is pressed against the workpiece, fuel is preferably injected into the mixing volume Vm of the combustion chamber 102 through a first fuel port 142 , to mix with air in the mixing volume. Although fuel is preferably injected at this time, it can also be injected at any time prior to movement of the moveable plug, such as in coordination with an activation of the trigger. As described above, the trigger activation will also preferably move the pawl 134 in the direction B to release the attaching member 132 to begin a rapid movement of the moveable plug in the direction A.
[0048] Referring now to FIG. 6 , as the first combustion volume V 1 and the second combustion volume V 2 begin to open and expand, the fuel/air mixture in the mixing volume Vm is drawn into the combustion volume V 2 through a fuel valve 144 located in the base portion 108 , and then from the combustion volume V 2 into the combustion volume V 1 through at least one combustion port 146 located in the ring-shaped wall 114 . The fuel valve 144 is preferably a reed valve, but may be any type of valve known in the art which allows one-way communication from the mixing volume Vm into the combustion volume V 2 . The combustion port 146 is ideally located on the ring-shaped wall 114 at a location that is a maximum distance on the wall 114 from the ignition source 76 . Vacuum pressure, caused by the expansion of the combustion volumes V 1 and V 2 , will then fill the two combustion volumes with the fuel/air mixture. The vacuum and rapid expansion of the combustion volumes V 1 and V 2 will also create a sufficient turbulence within both of the combustion volumes V 1 and V 2 to provide a rapid, high-energy combustion when the fuel/air mixture is ignited.
[0049] Referring now to FIG. 7 , the chambers 102 , 104 and the ring-shaped wall 114 are configurable to allow even greater airflow between the several volumes within the combustion chamber, to provide additional filling, mixing, and turbulent properties to the several volumes. The ring-shaped wall 114 is preferably formed to include an extending portion 148 on the ring inner wall 116 which approaches, but does not contact, the portion 122 of the piston chamber 104 inside the combustion chamber 102 . In this preferred configuration, when the plug 106 reaches the fully opened position, the extending portion 148 will contact a combustion seal 150 , thereby sealing airflow between the two combustion volumes V 1 and V 2 , except for the combustion port 146 . The combustion seal 150 is preferably an o-ring located around an outermost periphery 152 of the piston chamber portion 122 , but may be any type of combustion-resistant seal known in the art. The air/fuel mixture in the second combustion chamber V 2 then flows around the combustion seal 150 and across the ring inner wall 116 into the first combustion chamber V 1 while the plug 106 is moving, but is blocked when the plug reaches the fully opened position. This increased airflow further increases turbulence in the first combustion volume V 1 shortly prior to ignition.
[0050] To further increase the turbulence in V 1 caused by the structure of the moving plug 106 , a recess 154 is preferably provided on the inner wall 112 of the combustion chamber 102 , and located in the vicinity of the ring-shaped wall 114 when the plug 106 is in the fully closed position. The recess 154 thus allows additional airflow between the combustion chamber inner wall 112 and the outer wall 120 of the ring-shaped wall 114 . A first ring seal 156 is preferably located on the ring outer wall 120 opposite to the extending portion 148 of the ring inner wall 116 . Airflow is then sealed between the ring outer wall and the combustion chamber inner wall 112 when the first ring seal 156 moves past the recess 154 and the plug 106 reaches the fully opened position.
[0051] Before the first ring seal 156 passes the vicinity of the recess 154 , however, the ring outer wall 120 and the combustion chamber inner wall 112 are configurable to allow additional airflow between the mixing volume Vm and the first combustion volume V 1 while the plug 106 is moving, but before first ring seal contacts the combustion chamber inner wall. A second ring seal 158 is optionally included on the ring outer wall 120 , and near the base portion 108 , to prevent any direct airflow between the mixing volume Vm and the first combustion volume V 1 by having the second ring seal be always in contact with the combustion chamber inner wall 112 away from the recess 154 , and regardless of whether the plug 106 is in the fully opened or fully closed positions. The present inventors contemplate that it may desirable in some circumstances to prevent direct airflow into the first combustion volume V 1 from the mixing volume Vm.
[0052] Referring now to FIG. 6 , activation of the trigger causes the pawl 134 to move in the direction B, thereby allowing the plug 106 to rapidly move in the direction A. The moving plug 106 reduces the mixing volume Vm and opens first and second combustion volumes V 1 and V 2 respectively. The fuel/air mixture in the mixing volume Vm flows into combustion volumes V 1 and V 2 , and a spark from the ignition source 76 ignites the fuel/air mixture in the first combustion volume V 1 , and preferably when the plug 106 reaches the fully opened position and turbulence within the combustion volume V 1 still exists from the movement of the plug. A flame front of the ignited fuel/air mixture then progresses through dual arcs of the annular combustion volume V 1 , until reaching combustion port 126 . The moving flame front passes through the combustion port 126 and into the second combustion volume V 2 as an ignited gas jet, thereby also igniting the fuel/air mixture within the volume V 2 . The ignited gas jet also creates turbulence in the volume V 2 , and in addition to the turbulence caused by movement of the plug 106 .
[0053] As the air/fuel mixture in the second combustion volume V 2 is ignited, the increased pressure in the volume V 2 rapidly pushes the piston 16 and driver blade 18 to drive the fastener into the workpiece. Similarly to the operation of the apparatus 10 described above, excess pressure in the piston chamber 104 is exhausted through the exhaust port 78 as and after the piston 16 passes the exhaust port. As the gas remaining within the piston chamber 104 and combustion volumes V 1 and V 2 cools, a vacuum develops which acts to pull the piston 16 back to the initial ready position. When the tool 100 is removed from the workpiece, the work contact element 52 is returned to its original ready position as well by compression force of a second spring 160 , which is ideally compressed between a second spring stop 162 located on the work contact element 52 , and either of the combustion chamber 102 or the piston chamber 104 .
[0054] The combination of the return movement of the work contact element 52 to its ready position, together with the vacuum created in the combustion volumes V 1 and V 2 from the cooling gas, causes the plug 106 to move to its original closed position, thereby collapsing both of the combustion volumes V 1 and V 2 , while also effectively scavenging the remaining combustion gases from both combustion volumes as well. The movement of the plug 106 to its fully closed position also reduces the pressure in the mixing volume Vm, which in turn draws fresh air into the volume Vm through an air check valve 164 . The air check valve 164 is preferably a reed valve, but can be any combustion-resistant one-way valve as is known in the art. When the trigger is released, the pawl 134 moves in the direction D to lock the attaching member 132 near the combustion chamber 102 ( FIG. 5 ), in preparation for a next combustion/firing cycle.
[0055] Because the mixing volume Vm is not utilized in the actual combustion (the air/fuel mixture in the volume Vm is not ignited), it is not an important consideration for combustion purposes to displace the entire volume Vm, or scavenge its unignited contents. The present inventors do contemplate, however, that other considerations may make it desirable to completely displace the mixing volume Vm ( FIGS. 9-11 , below). The present inventors also contemplate that it may be preferable in some circumstances to inject the fuel into the mixing chamber Vm at this time (trigger release), which will also be in preparation for the next cycle.
[0056] Referring now to FIG. 8 , an alternative configuration of the apparatus 100 uses a fuel jet, similar to that described above for the tool 10 ( FIG. 4 ), to generate turbulence in the combustion volume V 1 immediately prior to ignition. The present inventors have discovered that, for this configuration, only a moderate amount of turbulence is required in the first combustion volume V 1 to rapidly and sufficiently ignite the air/fuel mixture drawn into the volume. A second fuel port 166 is preferably located along the combustion chamber 102 , to allow a high-speed fuel jet to be injected directly into the first combustion volume V 1 . The second fuel port 166 is preferably located on the combustion chamber 102 in the same plane as, but at a maximum distance from, the ignition source 76 , to allow a maximum amount of mixing of air and gas throughout the volume V 1 before the fuel/air mixture reaches the ignition source. Except for the addition of the second fuel port 166 , and the elimination of the pawl 134 and the spring 136 , this alternative configuration is preferably the same as that shown in FIGS. 5-7 .
[0057] For this configuration, the attaching member 132 is connected directly to the work contact element 52 , thereby opening the first and second combustion volumes to the fully opened position when the work contact element 52 is pressed against the workpiece. For this particular configuration then, the fuel jet is preferably injected upon activation of the trigger, and the ignition source 76 is timed to spark after a brief delay to allow the air and fuel to fill and mix in both combustion volumes. The air/fuel mixture enters the second combustion volume V 2 through the combustion port 146 from the first combustion volume V 1 , or through the fuel valve 144 from the mixing volume Vm, or both.
[0058] When the mixing volume Vm is used as an air/fuel mixture source for the second combustion volume V 2 , fuel is preferably injected into the mixing volume Vm through the first fuel port 142 , when the work contact element 52 opens the plug 106 to the fully opened position. The present inventors also contemplate, however, that because no fuel is actually required in the mixing chamber Vm for combustion, the first fuel port 142 may be entirely eliminated from the structure, leaving the mixing volume Vm as a source for fresh air only into the combustion volumes V 1 , V 2 , and the second fuel port 166 as the only fuel source for the three volumes. In this configuration, it is also preferable to eliminate the second ring seal 158 from the structure in order to allow direct airflow between the mixing volume Vm and the first combustion volume V 1 while the combustion volume V 1 is expanding.
[0059] For this configuration, the first combustion volume V 1 , into which the fuel is injected, is defined between a preferably flat portion 168 of the ring-shaped wall 114 and an opposing region 170 of the combustion chamber 102 . The flat portion 168 is preferably generally parallel to both the base portion 108 and the opposing region 170 , and located on an end of the ring-shaped wall 114 opposite to the base portion 108 . The opposing region 170 also preferably defines the plane in which the ignition source 76 and the fuel port 166 are preferably located. The moveable flat portion 168 thus performs, with respect to the opposing region 170 , similarly to how the flat rear surface 40 ( FIG. 4 ) performed with respect to the flat wall assembly 28 of the apparatus 10 . Turbulence is created in the combustion volume V 1 by the unignited fuel jet, in a manner similar to the configuration shown in FIG. 4 .
[0060] Once the air/fuel mixture in the first combustion volume V 1 is ignited, the flame front travels rapidly across the annular volume V 1 and into the second combustion volume V 2 through the combustion port 146 as a high-energy flame jet. Directing a separate, unignited fuel jet into the second combustion volume V 2 is not an important consideration because the high-energy flame jet itself from the first combustion volume V 1 is a sufficient source of turbulence to create an adequate high-energy combustion in the volume V 2 , which then resultantly fires the piston 16 . For the second combustion volume V 2 therefore, the ignited high-energy flame jet performs the turbulence function of the unignited fuel jet into the first combustion volume V 1 . The rest of the operation of this configuration of this embodiment is as described above with respect to FIGS. 5-7 (without the use of the fuel jet as the turbulence source).
[0061] Referring now to FIGS. 9-11 , a combustion-powered apparatus is generally designated 170 , but features of the apparatus 170 that are the same as those described above with reference to FIGS. 1-8 are identified by the same numerical designations.
[0062] The apparatus 170 includes a combustion chamber 172 in communication with the piston chamber 104 . The piston chamber of the apparatus 170 is preferably the same as that of the apparatus 100 , described above ( FIGS. 5-8 ). Preferably, no portion of the piston chamber 104 is located within the combustion chamber 172 , and the flat surface 22 of the piston 16 is preferably in the general plane of an annular wall 174 of the combustion chamber when in the ready position. The combustion chamber 172 is preferably cylindrical and does not move relative to the piston chamber 104 .
[0063] A moveable cup 176 moves relative to both the combustion chamber 172 and the piston chamber 104 . The moveable cup includes a generally flat plate 178 and a ring wall 180 attached to flat portion along one entire edge 182 of the ring wall. The ring wall 180 is preferably tubular, and has a cylindrical diameter slightly larger than the outer wall 118 of the piston chamber 104 . The flat plate 178 is generally parallel to the annular wall 174 , and includes an annular portion 184 that extends from the ring wall 180 toward an inner wall 186 of the combustion chamber 172 . The inner wall 186 is also preferably a tube, and the annular portion 184 is configured to have an outer periphery 188 slightly smaller than a diameter of the inner wall. A mixing seal 190 , which is preferably a combustion-resistant o-ring, prevents airflow between the outer periphery 188 of the flat plate 178 and the inner wall 186 .
[0064] As best seen in FIG. 9 , when in the ready position, a volume of air between the flat plate 178 and both the annular wall 174 and the piston flat surface 22 is practically zero. The mixing volume Vm is therefore defined within the combustion chamber 172 between the flat plate 178 and a rear wall 192 of the combustion chamber. The rear wall 192 is preferably generally flat, and also generally parallel to both the annular wall 174 and the plate 178 . The moveable cup 176 is preferably held in the ready position by a spring 194 attached to both a fixed portion 196 of the apparatus 170 and an extension 198 of the ring wall 180 . The ring wall extension 198 is preferably also a tube formed together with, or attached to, the ring wall 180 , but may also be a single rod, or a plurality of rods.
[0065] When in the ready position, fuel is preferably injected into the mixing volume Vm through a fuel valve 200 located on the inner wall 186 of the combustion chamber 172 , to mix with air that enters the mixing volume Vm through a first air intake port 202 . A first air check valve 204 prevents backflow through the air intake port 202 .
[0066] Referring now to FIG. 10 , when a work contact element 206 is pressed against the workpiece, the work contact element pushes the ring wall extension 198 in the direction A, thereby moving the moveable cup 176 toward the rear wall 192 of the combustion chamber 172 , and effectively reducing to zero the mixing volume Vm when in the fully opened position. The fuel/air mixture from the mixing volume Vm enters the first combustion volume V 1 through a second air intake port 208 and a one-way second air check valve 210 , and into the second combustion volume V 2 through a third air intake port 212 and a one-way third air check valve 214 .
[0067] A flange 216 is located on the ring wall 180 between the ring wall and the ring wall extension 198 , and generally conforms to the shape of the ring wall, but extends outward from either side of the ring wall. When the moveable cup 176 is in the fully opened position, the flange 216 contacts a first purging seal 218 and a second purging seal 220 , to close airflow through a first purging opening 222 between the annular wall 174 of the combustion chamber 172 and the ring wall 180 , and through a second purging opening 224 between the ring wall and the outer wall 118 of the piston chamber 104 , respectively. The first and second purging seals 218 , 220 are preferably constructed similarly to the seals described above.
[0068] In this embodiment, when the moveable cup is in the fully opened position, the combustion chamber is divided into two effective combustion volumes V 1 and V 2 , and the third mixing volume Vm is effectively eliminated. Also in this embodiment, the annular first combustion volume V 1 preferably surrounds the cylindrical second combustion volume V 2 instead of the piston chamber 104 , and both combustion volumes align along their respective planar borders parallel to the annular wall 174 and the rear wall 192 of the combustion chamber 172 . And except for this different structural placement, the combustion volumes V 1 and V 2 otherwise function the same as described above with respect to the apparatus 100 .
[0069] When in the fully opened position, activation of a trigger (not shown) causes a spark from the ignition source 76 to ignite the fuel/air mixture in the first combustion volume V 1 . The ignition source is preferably located on the annular wall 174 of the combustion chamber 172 . The ignited flame front travels through the first combustion volume V 1 until reaching, and exiting through, a combustion port 226 . The combustion port 226 may be located on the ring wall 180 to directly connect the first and second combustion volumes V 1 and V 2 , but more preferably the combustion port is located on the annular portion 184 of the flat plate 178 facing the rear wall 192 of the combustion chamber 172 . The present inventors further contemplate that, for some circumstances, it may also be preferable to inject fuel directly into the first combustion volume V 1 from the fuel valve 200 , and particularly if and when there is a significant delay between the movement of the moveable cup to the fully opened position, and the activation of the trigger.
[0070] When the combustion port 226 is located on the annular portion 184 , a combustion recess 228 is preferably formed in the rear wall 192 of the combustion chamber 172 to create a path for the high-energy flame jet to travel. The third air intake port 212 is therefore preferably located near the combustion recess 228 and the combustion port 226 such that the combustion recess can provide a continuous path for the flame jet to travel from the first combustion volume V 1 through the combustion port 226 into the combustion recess 228 , and then from the combustion recess 228 through the third air intake port 212 into the second combustion volume V 2 to ignite that volume as well. To allow for a maximum distance for the flame front to travel, it is preferable that the combustion port 226 , the combustion recess 228 , and the third air intake port 212 be located at a distance farthest away from the ignition source 76 . The present inventors also contemplate that it can be advantageous to locate the second air intake port 208 , where the most airflow turbulence is created, on the annular portion 184 nearest the ignition source 76 , and to located the first air check valve 204 within the combustion recess 228 to allow a maximum displacement of the mixing volume Vm.
[0071] Similar to with the apparatus 100 , described above, the flame jet into the second combustion volume V 2 provides both the desired turbulence and ignition of the air/fuel mixture within that volume to create a high-energy combustion. This combustion in the second combustion volume V 2 then drives the piston 16 in the direction C, as best seen in FIG. 11 .
[0072] Referring now to FIG. 11 , excess ignited gas exits the piston chamber 104 through the exhaust port 78 , and the combustion by-products within the piston chamber and the combustion volumes V 1 and V 2 cool. The cooling gases within the apparatus 170 create a vacuum effect that pulls the piston 16 back toward the combustion chamber 172 . The relative volumes of the piston chamber 104 and the second combustion volume V 2 are preferably configured so as to allow the vacuum effect to fully return the piston 16 to the original, ready position (best seen in FIG. 10 ) without requiring separate, mechanical tension on the piston. As the work contact element 206 is removed from the workpiece, tension from the spring 194 moves the moveable cup 176 back to its original, ready position as well (best seen in FIG. 9 ) for the next combustion event. Residual combustion by-products within the two combustion volumes are purged through the first and second purging openings 222 and 224 that reappear as the flange 216 moves in the direction C.
[0073] According to this embodiment of the present invention, the need for pawls can be entirely eliminated, and the need for springs reduced to a minimum. This embodiment provides a “cup within a cup” (moveable cup within a combustion chamber) configuration which gives all of the advantages described above for multiple-volume apparatuses, but at the same time also allows for the significantly more compact geometry closer to that of single volume apparatuses.
[0074] Utilization of moveable plugs and or cup-shaped walls therefore, allow combustion-powered tools according to the present invention to adapt the turbulence generation methods, described above for a single-volume combustion chamber, to multiple-volume combustion apparatuses. The present invention can thus be adapted to both lower- and higher-energy combustion-powered fastener-driving operations. Furthermore, although the present invention has been described in relation to single-, dual-, and triple-volume combustion apparatuses, those skilled in the art will know that the basic principles of the present invention may be utilized in combustion apparatuses employing any number of volumes in their structure, with departing from the present invention.
[0075] Those skilled in the art are further apprised that combustion apparatuses, such as in the present invention, may also be effectively employed in other devices which drive a piston, or devices that may be powered by combustion in general. While particular embodiments of the combustion-powered apparatus of the present invention have been shown and described, it will also be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects, and as set forth in the following claims. | A gas combustion-powered apparatus includes a piston chamber housing a driveable piston, and a combustion chamber having a generally flat wall assembly and a cup-shaped wall defining at least one combustion volume therebetween. The cup-shaped wall is moveable in relation to the piston chamber, and has a generally flat portion opposing, and generally parallel to, the generally flat wall assembly. An ignition source is in operable relationship to the combustion volume, which can ignite a combustible gas within the combustion volume. The piston forms at least a portion of the generally flat wall assembly when the piston is in an undriven state. | 1 |
FIELD OF THE INVENTION
The present invention relates to a micro-controller unit and, more particularly, to a micro-controller unit for accessing external memory having different access time using a microcode.
DESCRIPTION OF THE PRIOR ART
In general, an embedded application is used to control. Once hardware is decided, a method for controlling it is decided and the method is implemented by programs. Accordingly, such program as well as its size is different according to hardware.
A typical micro-controller unit (hereinafter, referred to as MCU) includes an internal memory such as a code memory for storing microcodes and a data memory for storing data. However, the internal memory of MCU alone may not carry out the large-size embedded application. In that case, an additional external memory may be used to carry out the large-size embedded application.
Accordingly, the MCU includes a memory management unit (hereinafter, referred to as MMU) for controlling read/write operations of the external memory and provides an instruction that enables the MCU to access the external memory.
In addition, the MMU of MCU should have flexibility, that is, ability to accessing the various external memory devices having various characteristics, one of which is the access time.
FIG. 1 is a block diagram illustrating a conventional MCU for accessing the external memory using a handshake method. Referring to FIG. 1, the MCU includes a data path 10 , a microcode ROM 12 , a MMU 14 and a bus unit 16 . In case of accessing the external memory, the MMU 14 outputs an external memory request signal REQUEST to the bus unit 16 . The bus unit 16 generates a memory access bus cycle signal BUS CYCLE in repose to the signal REQUEST to access the external memory 18 . After accessing the external memory, the bus unit 16 outputs a signal READY to the MMU 14 to inform that it is already ready to send the accessed data and the accessed data are then transmitted to the data path 10 .
In the conventional mechanism to be described above, since the access to the external memory is operated through the MMU 14 and the bus unit 16 , the operation of accessing the external memory is separated from the internal operation of MCU. Therefore, the MCU may have the high flexibility. However, since the additional hardware such as the MMU and the bus unit is needed and the number of microcodes for internal controls is increased, problems may occur in that the size of the circuit becomes larger.
FIGS. 2 and 3 are timing charts illustrating basic read and write cycles of the external memory, respectively.
Referring to FIGS. 2 and 3, in order to satisfy a various access time of external memory devices having various read/write cycles, an address latch enable signal ALE, a read enable signal RD# and a write enable signal WR# should appropriately be extended according to the specification of the external memory. Where a Port 1 is used as an address/data sharing bus and a Port 2 is used as an address bus.
Referring to FIG. 4, an operation of the conventional MCU using the handshake method will be described in details. An instruction for accessing the external memory is “MOVX” and the instruction is operated according to a microcode.
In case of the MOVX instruction, a microcode program counter 20 for increasing a program counter value one by one generates a signal ACTIVE to a MMU 14 , and then stops increasing the program counter value. When a handshake operation between MMU 14 and the bus unit 16 is completed, the MMU 14 outputs a resuming signal RESUME to the microcode program counter 20 . The microcode program counter 20 restarts to increase the program counter value in response to the resuming signal RESUME and sequentially outputs addresses of a next microcode to the microcode ROM 12 .
Consequently, the MCU operation is simplified by separately processing a complicated function through the MMU and the bus unit. However, when a small-size MCU is used as the embedded controller processing a simple operation, hardware such as the MMU and the bus unit is needless and the total stability may be degraded.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a micro-controller unit for accessing an external memory using a microcode, thereby scaling down the chip size and improving a stability of the circuit.
In accordance with an aspect of the present invention, there is provided the micro-controller unit for accessing an external memory according to the characteristics of the external memory, comprising: a ROM storing a series of codes including sequence, address latch enable, read enable and write enable fields, wherein the ROM outputs one of codes in response to a counting value and a program counting determining means for determining the counting value in response to the sequence field of the outputted code from the ROM and for outputting the counting value to the ROM.
In accordance with another aspect of the present invention, there is provided a micro-controller unit for accessing an external memory according to the characteristics of the external memory, comprising: a) a first storage means for storing microcodes; b) a programmable memory means for storing cycle extension data of a address latch enalbe signal and a wait signal and for selectively outputting the cycle extension data as an offset value to a microcode program counting means in response to a sequence field from the first storage mean; and c) the microcode program counting means for increasing a program counter value in response to the offset value from the programmable memory means and for outputting an increased program counter value to the first storage means when the offset value is received from the programmable memory means.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent from the following description of the preferred embodiments given in connection with the accompanying drawings, in which:
FIG. 1 is a block diagram illustrating a conventional MCU;
FIGS. 2 and 3 are timing charts illustrating read and write cycles of external memory, respectively;
FIG. 4 is a block diagram illustrating a conventional MCU for accessing an external memory using MMU;
FIG. 5 is a block diagram illustrating a MCU in accordance with the present invention;
FIG. 6 is a block diagram illustrating a memory type program block in FIG. 5;
FIGS. 7A and 7B are flow charts illustrating MCU for accessing an external memory; and
FIG. 8 is a timing chart of an extended memory cycle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be described in detail referring to the accompanying drawings.
The present invention provided a MCU capable of accessing an external memory having a different access time using a microcode. The microcode comprises a sequence field, an address latch enable field, a read enable field and a write enable field. Here, the sequence field is used as a select signal of a memory type program block and the address latch enable field is used to extend an address latch enable cycle. The read and write enable fields are used to extend a read and write cycle, respectively.
FIG. 5 is a block diagram of MCU according to the present invention. Referring to FIG. 5, a memory type program block 22 outputs a value stored in internal registers as an offset value ADD VALUE in response to a sequence field signal SEQUENCE FIELD from a microcode ROM 12 . A microcode program counter 20 receives the offset value ADD VALUE and increases the program counter value and then outputs a next microcode address corresponding to the added program counter value. The microcode ROM 12 stores microcodes for accessing the external memory.
The memory type program block 22 stores characteristic values of the external memory in response to internal program register enable signals of ALE program resister enable signal and WAIT program register enable signal, wherein the values are programmed by a user. In addition, the stored values are outputted as an offset value ADD VALUE is response to a sequence field signal SEQUENCE FIELD. Here, the offset value is used to calculate a next program counter value in the microcode program counter 20 .
In normal operation, the microcode program counter 20 increases the program counter value one by one. However, in case where the microcode program counter 20 receives the offset value ADD VALUE from the memory type program block 22 , the microcode program counter 20 calculates the next microcode program counter value by adding the offset value ADD VALUE to a current program counter value and outputs the next microcode program counter address corresponding to the increased value to the microcode ROM 21 .
FIG. 6 is a block diagram illustrating the memory type program block in FIG. 5 . Referring to FIG. 6, an ALE program register 26 stores ALE cycle extension data in response to an ALE program register enable signal, wherein the cycle extension data are programmed according to a characteristic of the external memory by a user. A wait program register 28 stores read or write cycle extension data in response to a WAIT program register enable signal, wherein the cycle extension data are programmed according to a characteristic of the external memory by a user. A multiplexer 24 selectively outputs the data stored in the ALE program register 26 and the WAIT program register 28 and ‘0’ in response to the sequence field signal SEQUENCE FIELD from the microcode ROM 21 . Here, the data of the WAIT program register 28 is commonly used to extend the cycle of the read enable signal RD# and the write enable signal WR#.
Referring to FIGS. 7A, 7 B and 8 , an operation of the MCU for accessing the external memory is described in details.
Here, “MOVX reg, address” is an instruction that represents that data corresponding to an external memory address (address) are read out and written to an internal register (reg). It is assumed that an ALE cycle can be extended by one cycle and a WAIT cycle can be extended from one to three cycles.
The microcode ROM 12 comprises microcodes for below-mentioned operations in following order.
Loading an external memory address into an external address bus and setting the address latch enable signal ALE and the read enable signal RD# to “0” (at step 31 );
Setting the address latch enable signal ALE to “0” (at step 32 );
Setting the address latch enable signale ALE to pb “ 0 ” (at step 34 );
Setting the address latch enable signal ALE to “1” and setting the read enable signal RD# to “0” (at step 35 );
Setting the read enable signal RD# to “0” (at step 37 );
Setting the read enable signal RD# to “0” (at step 38 );
Setting the read enable signal RD# to “0” (at step 39 );
Setting the read enable signal RD# to “1” (at step 40 ).
First, in executing the MOVX instruction, the microcode program counter 20 outputs an address corresponding to the start address of the instruction and the step 31 is operated so that the address latch enable signal (ALE) and the read enable signal (RD#) are disabled.
Next, with the increase of the program counter by one, the step 32 is operated so that the address latch enable signal ALE is enabled.
Next, a value stored in ALE program register 26 is outputted as an offset value ADD VALUE in response to a sequence field signal SEQUENCE FIELD. At this time, in case where the value of the ALE program register 26 is “0”, the offset value ADD VALUE becomes “0”. Therefore, the steps 34 and 35 are sequentially operated so that the address latch enable signal ALE is extended by one cycle and the read enable signal RD# is then enabled.
In case where a value of ALE program register 26 is “1”, the offset value ADD VALUE becomes “1”. Therefore, the program counter value is added to the offset value ADD VALUE and the increased value is outputted. The step 34 is skipped and the step 35 is operated, thus the address latch enable signal ALE is not extended. Simultaneously, the read enable signal RD# is enabled.
Sequentially, a value stored in WAIT program register 27 is outputted as an offset value ADD VALUE in response to a sequence field signal SEQUENCE FIELD.
In case where the value of the WAIT program register 27 is “0”, the offset value ADD VALUE becomes “0”. Therefore, the microcode program counter is increased one by one. Therefore, the steps 37 , 38 , 39 and 40 are sequentially operated, so that the read enable signal RD# is set to “0” during three cycles and then is disabled. Consequently, the read enable signal RD# is extended by three cycles.
In case where the value of the WAIT program register 27 is “1”, the offset value ADD VALUE becomes “1”. Therefore, the microcode program counter is added to the offset value ADD VALUE and an increased value is outputted. Therefore, the microcodes 37 is skipped and the microcodes 38 , 39 and 40 are sequentially operated, so that the read enable signal RD# is set to “0” during two cycles and is disabled. Consequently, the read enable signal RD# is extended by two cycles.
In case where the value of the WAIT program register 27 is “2”, the offset value ADD VALUE becomes “2”. Therefore, the microcode program counter is added to the offset value and an increased value is outputted. Therefore, the microcodes 37 and 38 are skipped and the microcodes 39 and 40 are sequentially operated, so that the read enable signal RD# is set to “0” during one cycles and then is disabled. Consequently, the read enable signal is extended by one cycle.
In case where the value of the WAIT program register 27 is “3”, the offset value ADD VALUE becomes “3”. Therefore, the microcode program counter is added to the offset value and an increased value is outputted. Therefore, the microcodes 37 , 38 and 39 are skipped and the microcode 40 is operated, so that the read enable signal RD# is not extended.
Here, when the value of the ALE program register 26 is ‘1’, the address latch enable signal ALE is not extended. Therefore, the basic value of the ALE program register 26 should be “1”. In the similar manner, when the value of the WAIT program register 27 is ‘3’, the read enable signal RD# is not extended. Therefore, the basic value of the WAIT program register 27 should be “1”. At this time, the programmed values in the ALE program register 26 and the WAIT program register 27 is not consistent with the extending values. If an inverter is inserted at the output terminal of the ALE and WAIT program register 26 and 27 , respectively, the programmed values are consistent with the extending values.
Although the read cycle extension is described, the write cycle extension is also preferably embodied.
While the present invention has been described with respect to certain preferred embodiments only, other modifications and variation may be made without departing from the spirit and scope of the present invention as set forth in the following claims. | A micro-controller unit for accessing external memory having different access time using a microcode. The micro-controller unit for accessing an external memory according to the characteristics of the external memory includes a first storage device for storing microcodes, a programmable memory for storing cycle extension data of a address latch enable signal and a wait signal and for selectively outputting the cycle extension data as an offset value to a microcode program counter in response to a sequence field from the first storage device and the microcode program counter for increasing a program counter value in response to the offset value from the programmable memory and for outputting an increased program counter value to the first storage device when the offset value is received from the programmable memory. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
The present application claims priorities to Japanese Patent Application No. 2009-173617 filed on Jul. 24, 2009 and Japanese Patent Application No. 2010-135182 filed on Jun. 14, 2010, the entire disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a Ti-based brazing filler material, which is mainly used for brazing and soldering Ti or Ti-based alloy, and method for producing the Ti-based brazing filler material.
2. Description of Related Art
Titanium has features such as high specific strength (i.e., strength with regard to specific weight), high corrosion resistance, and high biocompatibility, and Ti alloys such as Ti-6Al-4V alloy have been used for various aerospace instruments, medical instruments, and the like. Ag-based or Al-based brazing filler materials have been conventionally and widely used for brazing such Ti alloys. Ag-based or AI-based brazing filler materials, however, have problems of resulting in low joint strength or insufficient corrosion resistance.
To these problems, Ti-based brazing filler materials have been developed. In particular, for the purpose of lowering the melting point, addition of Zr, Cu, Ni, and the like has been developed and put to practical use. These Ti-based brazing materials have a joint strength comparable to the base material as well as good corrosion resistance. For example, as disclosed in Japanese Patent Laid-Open Publication No. S59-220299 (Patent Literature 1), there was proposed an alloy in which Ni, Cu and Ag are added into Ti—Zr-based alloy. In addition, as disclosed in Japanese Patent Laid-Open Publication No. S59-126739 (Patent Literature 2), there was proposed an alloy in which various elements are added into an alloy comprising Ti, Zr, Hf and Cu.
The above-mentioned brazing filler materials comprising these alloys can be used for brazing Ti or Ti alloy or ceramics and the like, but are difficult to produce in ribbon form due to poor workability. It was therefore proposed that a brazing filler material be produced by liquid melt-spun ribbon production method, in which a molten alloy is ejected to the surface of cooling rolls which are rotating at a high speed.
On the other hand, some base materials to be brazed have complicated shapes and, in terms of latitude of the shape of the brazing filler material, it is also demanded, other than a ribbon, to produce a paste by mixing a powder and a binder. In this respect, melt-spun ribbons as disclosed in above-mentioned Patent Literatures 1 and 2 are difficult to meet this demand, and thus it is essential that a brazing filler material is powdered. Brazing filler materials in powder form are mainly categorized into two types as shown below.
One of the types is obtained by a mixing method, in which pure metal powders of individual elements, which constitutes an alloy to be a brazing filler material, are mixed in given proportions. The other type is obtained by producing an alloy to be a brazing filler material through atomizing method and the like, in which the brazing filler material consists of an alloy powder having a single composition. These two methods are applicable to conventional alloys such as Ni-based or Cu-based brazing filler materials, but are difficult to apply to Ti-based brazing filler materials as having a problem peculiar to Ti-base.
The problems peculiar to Ti-base are such that, in the mixing method, (1) an active metal powder such as Ti or Zr is oxidized; (2) it is difficult for alloying to proceed when jointing; and that, in atomizing method, (3) contamination occurs from the crucible when melting. For the problem of the above (1), for example, the section of background art of Patent Literature 2 describes that “active metal powder such as Ti and Zr tends to be easily oxidized to form an oxide on the surface of the powder, and this oxide remains in the joint part to become a factor for lowering credibility after jointing.”
For the above problem (2), for example, paragraph [0003] of Japanese Patent Laid-Open Publication No. 2009-90304 (Patent Literature 3) describes that “The paste for jointing before heating is a mere mixture of active metal powder and a metal powder having a composition as the balance, and has problems that alloying before heating does not proceed sufficiently so that the strength tend to be insufficient.” For the above problem (3), for example, the third paragraph in the introduction of “Denki Seikou” Vol. 74, No. 4, pages 227-232 (Non-Patent Literature 1) describes that “it is concerned that a reaction occurs between melting crucible and a molten titanium alloy to contaminate the titanium alloy powder from the material constituting the crucible.
[Citation List]
[Patent Literature]
[PTL 1] Japanese Patent Laid-Open Publication No. S59-220299
[PTL 2] Japanese Patent Laid-Open Publication No. S59-126739
[PTL 3] Japanese Patent. Laid-Open Publication No. 2009-90304
[PTL 4] Japanese Patent Laid-Open Publication No. H4-220198
[Non Patent Literature]
[NPL 1] “Denki Seikou” Vol. 74, No. 4, pages 227-232
SUMMARY OF THE INVENTION
However, none of the above patent literatures provides an example which alleviates the above problems (1) and (2). For the above problem (3), there is seen a method for melting by use of a special crucible as disclosed in paragraph [0021] of Patent Literature 3 or Table 3 of Non-Patent Literature 1, but improvement effect is not necessarily sufficient. There is also seen a method for melting by use of a high frequency coil and a water-cooled copper crucible as disclosed in Non-Patent Literature 1, but the equipment is peculiar. Further, Japanese Patent Laid-Open Publication No. H4-220198 (Patent Literature 4) proposes a single-composition alloy powder prepared by atomizing method, but it is unclear whether the above problem (3) has been solved.
The inventors has now found that a Ti-based brazing filler material in powder form to solve the above problems (1) to (3) at low cost is obtained by mixing a Zr-containing alloy powder comprising one or two of Cu and Ni and Ti powder or Ti-containing alloy powder (these powders are called herein as “Ti-based powder”) in a given proportion. That is, the inventors has found that it is possible to provide a Ti-based brazing filler material in powder form, which can achieve good brazing and can exhibit excellent effects in the production of aerospace instruments, medical instruments, frames of glasses, heat-exchangers made from titanium.
Therefore, the object of the present invention is to provide a Ti-based brazing filler material in powder form, which can achieve good brazing and can exhibit excellent effects in the production of aerospace instruments, medical instruments, frames of glasses, heat-exchangers made from titanium.
According, to an aspect of the invention, there is provided a Ti-based brazing filler material comprising in mixture:
a Zr-containing alloy powder comprising 30 to 90% by mass of one or two of Cu and Ni, the balance being Zr and unavoidable impurities; and
a Ti-based powder comprising 0 to 50% by mass of one or two of Cu and Ni, the balance being Ti and unavoidable impurities,
wherein the Ti-based brazing filler material has a weight ratio of the Zr-containing alloy powder to the Ti-based powder of 8:2 to 4:6.
According to another aspect of the invention, there is provided a method for producing a Ti-based brazing filler material, the method comprising the steps of:
providing a Zr-containing alloy powder comprising 30 to 90% by mass of one or two of Cu and Ni, the balance being Zr and unavoidable impurities and a Ti-based powder comprising 0 to 50% by mass of one or two of Cu and Ni, the balance being Ti and unavoidable impurities; and
mixing the Zr-containing alloy powder and the Ti-based powder to a weight ratio of the Zr-containing alloy powder to the Ti-based powder of 8:2 to 4:6.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is explained in detail below. It is noted that “%” indicates herein “% by mass” unless otherwise defined.
The most important feature of the present invention resides in not simply mixing pure metal powders but mixing the Zr-containing alloy powder and the Ti-based powder. For example, when a Ti—Zr—Cu—Ni-based brazing filler material is produced by simply mixing pure metal powders, as in the above problem (1), these powders form a stiff oxide on the surface so that a reaction with the other metal powder in the surroundings be inhibited, as Ti and Zr are active metals. As a result, the brazing filler material is not molten well to leave a defect in the brazed part.
In addition, the melting points of each pure metal are as high as 1670° C. for Ti, 1855° C. for Zr, 1084° C. for Cu, and 1455° C. for Ni, and it is therefore necessary to lower the melting point by reacting with the other metal powders in the surroundings. Furthermore, an investigation of the oxygen level in the commercially available pure metal powders of Ti and Zr indicated that Ti powder contains 0.05 to 0.5 mass % of oxygen while Zr powder was not easily available and is carried with the liquid into which the powder is immersed due to possibility of explosion. When dried, its oxygen level in the Zr powder reached several %.
In view of the above, a device is needed especially for Zr powder, although it is an active metal as well. Thus, we decided not to use a Zr powder as a pure metal but to use a Zr-containing alloy in which the Zr level is lowered. This has made it possible to significantly prevent oxidization of the powder as well as to lower the melting point of Zr, which has the highest melting point among the constituting elements.
This is extremely effective to the problems (1) and (2). Moreover, it has also been found that a mixed powder of the Zr-containing alloy powder and the Ti-based powder provides unexpected effect as shown below. That is, there has been seen an effect that brazing the mixed powder of the Zr-containing alloy powder and the Ti-based powder leads to better reaction with the Ti powder being a mixing component, compared with the mixed powder using a Zr-free alloy powder and a Ti-based powder. The mechanism of this phenomenon is uncertain, but it is assumed that Zr, which has a higher affinity to oxygen than Ti, reduces the oxide on the surface of the Ti powder being an active metal, so that it can break the stiff oxide film on the surface of the Ti powder to facilitate the reaction with metal Ti. This is effective to the problem (2). Accordingly, it is the most important feature in the present invention to mix the Zr-containing alloy powder and the Ti-based powder.
On the other hand, in brazing filler materials in ribbon form, a brazing material formed by laminating ribbons of pure Ti, pure Cu and pure Ni, such as Ti—Cu—Ni laminated foil as described in paragraph [0004] of Patent Literature 3. In the case of laminated foils, however, it is considered that Ti can react with other elements even without containing an element having a function of reducing Ti-oxide, such as Zr, since the area where the respective pure metals contact with each other is large, unlike a mixed powder.
The second feature of the present invention is to limit the Cu and Ni content in the composition of the Zr-containing alloy powder. Cu and Ni both have an effect of significantly lowering the melt temperature by alloying with Zr having the highest melting point among the elements constituting the brazing material of the present invention. This is effective against the problem (2). Limiting the total amount makes it possible to achieve a low melt temperature while exhibiting an effect which is considered to be a reduction effect of the Ti-oxide by Zr. In addition, limiting the total amount of Cu and Ni leads to limitation of the Zr amount, and thus makes it possible to prevent contamination from the crucible upon production by atomizing method. This is very effective against the problem (3).
The third feature of the present invention is to limit the mixing ratio of the Zr-containing alloy powder to the Ti-based powder. When the mixing ratio of any one of the Zr-containing alloy powder to the Ti-based powder is too high, there may microscopically generate a region consisting of the powder with a higher mixing ratio even after mixing the powders. In this region, no reaction occurs between the powders with the both compositions, causing a defect in brazing or non-uniformity in composition after the brazing, and deteriorating the joint strength and the corrosion resistance. Therefore, limiting the mixing ratio of the both powders to a given proportion facilitate the alloying of the brazing part. This is very effective against the problem (2). The present invention has solved the conventional problems (1) to (3) effectively at low cost by combining the above features.
The Zr-containing alloy powder to be used in the present invention comprises 30 to 90%, preferably 40 to 80%, more preferably 50 to 75%, of one or two of Cu and Ni, the balance being Zr and unavoidable impurities. In the Zr-containing alloy powder, Cu and Ni have an effect of lowering the melt temperature of this powder and the brazing material as a whole and, when this powder is produced by atomizing method, also have an effect of lowering the oxygen level. The total amount of Cu and Ni of less than 30% reduces the effect of lowering the melt temperature of the brazing material as a whole and, when this powder is produced by atomizing method, also reduces the effect of reducing the oxygen level. On the other hand, the total amount of Cu and Ni exceeding 90% deteriorates reactivity with the Ti powder due to a reduced amount of Zr.
The Ti-based powder to be used in the present invention comprises 0 to 50% of one or two of Cu and Ni, the balance being Ti and unavoidable impurities. In other words, the Ti-based powder to be used in the present invention may be not only a Ti powder but also a Ti-containing alloy powder comprising one or two of Cu and Ni in an amount that exceeds 0% and is less than 50%. Containing more than 50% of one or two of Cu and Ni in the Ti-containing alloy powder may cause a melting failure when brazing or deteriorate uniformity. In consideration of the prices of the commercially available powders, it is preferred that the Ti-based powder does not contain Cu and Ni.
The Ti-based brazing material according to the present invention comprises the Zr-containing alloy powder and the Ti-based powder in mixture. That is, the Zr-containing alloy powder is an essential powder for facilitating the reaction with the Ti powder and attaining good brazing. It is necessary that these powders are mixed together.
The weight ratio of the Zr-containing alloy powder to the Ti-based powder in the Ti-based brazing material according to the present invention is 8:2 to 4:6, preferably 7:3 to 5:5, more preferably 6.5:3.5 to 5.5:4.5. When the weight ratio of the Zr-containing alloy powder to the Ti-based powder far exceeds the above range to get too close to any one of the powders, any one of the powders agglomerates in a microscopic region, where a brazing defect occurs.
EXAMPLES
The present invention is explained in detail below with reference to examples.
Example 1
A Zr-containing alloy powder having a composition as shown in Table 1 was prepared by pulverizing a melt-spun ribbon or gas-atomizing. After preparation of the powder, the powder was screened through a sieve having an opening size of 150 μm to prepare a powder having a size of 150 μm or less. Also, as a Ti powder and a Zr powder (comparative powder with regard to the Zr-containing alloy powder), commercially available Ti powder and Zr powder which have been screened to a size of 150 μm or less were also prepared. The oxygen level was measured on the Zr-containing alloy powder to obtain a result as shown in Table 1.
The Zr-containing alloy powder and the Ti powder were mixed in a mixing ratio as shown in Table 1 to prepare a mixed powder as a Ti-based brazing material. In order to evaluate the brazing properties on the mixed powder thus obtained, a lump of pure Ti with a size of 20 mm square was perforated to form an opening with a diameter of 10 mm. The opening was filled with the mixed powder and was heated in vacuum to 950° C. for brazing.
The cross-section of this specimen was observed and evaluated for existence/absence of a melting failure and uniformity of the brazing material in accordance with the following criteria:
<Existence/Absence of Melting Failure>
C: Melting failure over the entire surface
B: Melting failure in part
A: No melting failure
<Uniformity of Brazing Material>
C: Non-uniformity over the entire surface
B: Non-uniformity in part
A: Uniformity
In addition, since the Zr-containing alloy powder was able to melt at a temperature of 1350° C. or lower when preparing a melt-spun ribbon or a powder, the melt temperature of the Zr-containing alloy powder has been significantly lowered from 1855° C. of that of pure Zr. “Melting failure” used herein refer to a condition where the powders are melted insufficiently to leave some powders, while “uniformity” used herein refers to a condition where a solidified layer has a composition uniformly mixed together after melting and solidifying the mixed powders. This means that a trace of the composition of the original powders (one of the mixed powders) being left locally is regarded as non-uniformity.
TABLE 1
Composition of
Zr-containing
Oxygen level in
Mixing ratio of
Mixing
alloy powder
Production Method of
Zr-containing
Zr-containing
ratio of Ti
Brazing properties
(mass %)
Zr-containing alloy
alloy powder
alloy powder
powder
of mixed powder
No.
Cu
Ni
Zr
powder
(mass %)
(wt. ratio)
(wt. ratio)
Melting failure
Uniformity
Note
1
30
0
bal.
atomizing
0.20
8
2
B
B
Present
2
60
0
bal.
atomizing
0.12
7
3
A
A
Invention
3
90
0
bal.
atomizing
0.02
5
5
B
B
Examples
4
0
30
bal.
atomizing
0.18
6
4
A
B
5
0
60
bal.
ribbon pulverization
0.04
5
5
A
A
6
0
90
bal.
atomizing
0.01
4
6
B
B
7
20
15
bal.
atomizing
0.18
5
5
B
B
8
20
30
bal.
atomizing
0.10
4
6
A
B
9
20
60
bal.
atomizing
0.07
6
4
A
A
10
10
30
bal.
atomizing
0.12
5
5
A
B
11
30
30
bal.
atomizing
0.08
6
4
A
A
12
40
30
bal.
ribbon pulverization
0.02
6
4
A
A
13
20
0
bal.
atomizing
1.80
5
5
B
C
Comp.
14
0
20
bal.
atomizing
1.30
7
3
C
C
Examples
15
10
10
bal.
ribbon pulverization
0.10
6
4
C
C
16
30
0
bal.
atomizing
0.20
9
1
C
C
17
20
30
bal.
atomizing
0.10
3
7
C
C
18
95
0
bal.
atomizing
0.01
5
5
B
C
19
0
95
bal.
atomizing
0.01
4
6
B
C
20
0
0
bal.
commercially
3.10
5
5
C
C
available powder
21
100
0
bal.
atomizing
0.01
5
5
B
C
22
0
100
bal.
atomizing
0.01
5
5
C
C
23
50
50
bal.
atomizing
0.01
5
5
C
C
Note:
Underlined figures are outside the conditions as required in the present invention.
In Table 1, Nos. 1 to 12 are present invention examples, while Nos. 13 to 23 are comparative examples.
As shown in Table 1, in sample No. 13, the total content of Cu and Ni was less than 30% in view of 20% of Cu and no inclusion of Ni in the composition of the Zr-containing alloy powder, thus leading to a result that, for brazing properties of the mixed powder, a melting failure partially occurred and, for uniformity of the brazing material, non-uniformity over the entire surface was observed. In sample No. 14, the total of Cu and Ni was less than 30% in view of 0% of Cu and 20% of Ni as opposed to sample No. 13, thus leading to a result that, for brazing properties of the mixed powder, a melting failure occurred over the entire surface and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed.
In sample No. 15, the total content of Cu and Ni was less than 30% in view of 10% of Cu and 10% of Ni in the composition of the Zr-containing alloy powder, thus leading to a result that, for brazing properties of the mixed powder, a melting failure occurred over the entire surface and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed. In sample No. 16, the proportion of the Zr-containing alloy powder in the mixing ratio of the Zr-containing alloy powder to the Ti powder is high while that of the Ti powder is low, thus leading to a result that, for brazing properties of the mixed powder, a melting failure occurred over the entire surface and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed.
In sample No. 17, the proportion of the Zr in the mixing ratio of the Zr-containing alloy powder to the Ti powder is low while that of Ti is high as opposed to sample No. 16, thus leading to a result that, for brazing properties of the mixed powder, a melting failure occurred over the entire surface and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed. In sample No. 18, the content of Cu exceeds 90% in view of 95% of Cu and 0% of Ni in the composition of the Zr-containing alloy powder, thus leading to a result that, for brazing properties of the mixed powder, a melting failure partially occurred and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed.
In sample No. 19, the content of Ni exceeds 95% in view of 0% of Cu and 95% of Ni in the composition of the Zr-containing alloy powder as opposed to sample No. 18, thus leading to a result that, for brazing properties of the mixed powder, a melting failure partially occurred and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed. In sample No. 20, Cu and Ni are not contained in view of 0% of Ni and 0% of Cu in the composition of the Zr-containing alloy powder, thus leading to a result that, for brazing properties of the mixed powder, a melting failure occurred over the entire surface and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed.
In sample No. 21, the content of Cu exceeds 95% in view of 100% of Cu and no inclusion of Ni, thus leading to a result that, for brazing properties of the mixed powder, a melting failure partially occurred and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed. In sample No. 22, the content of Ni exceeds 95% in view of 0% of Cu and 100% of Ni as opposed to sample No. 21, thus leading to a result that, for brazing properties of the mixed powder, a melting failure occurred over the entire surface and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed.
In sample No. 23, the content of both Cu and Ni exceeds 95% in view of 50% of Cu and 50% of Ni, thus leading to a result that, for brazing properties of the mixed powder, a melting failure occurred over the entire surface and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed. In contract, it is understood that sample Nos. 1 to 12, which satisfy the conditions as required in the present invention, were excellent in both of brazing properties of the mixed powder and uniformity of the brazing material.
While Example 1 is an example directed to the mixed powder of the Zr-containing alloy powder and the Ti powder, a similar effect can be obtained even by using, instead of the Ti powder, a Ti-containing alloy powder comprising one or two of Cu and Ni in an amount that exceeds 0° h and is not more than 50° A), the balance being Ti and unavoidable impurities. An Example where such a Ti-containing alloy powder was used instead of the Ti powder is shown below.
Example 2
A Zr-containing alloy powder and a Ti-containing alloy powder as a Ti-based powder as shown in Table 2 were prepared and then subjected to evaluation of brazing properties. Preparation of the powders, classification and evaluation were conducted in the same manner as in Example 1.
TABLE 2
Zr-containing alloy powder (mass %)
Ti-containing alloy powder (mass %)
Brazing
Mixing
Mixing
properties of
Oxygen
Ratio
Oxygen
Ratio
mixed powder
Production
level
(wt.
Production
level
(wt.
Melting
No.
Cu
Ni
Zr
method
(mass %)
ratio)
Cu
Ni
Ti
method
(mass %)
ratio)
failure
Evenness
Note
24
60
0
bal.
atomizing
0.20
8
0
5
bal.
atomizing
0.09
2
A
A
Present
25
60
0
bal.
atomizing
0.20
7
10
0
bal.
ribbon
0.12
3
A
A
Invention
pul-
Examples
verization
26
0
30
bal.
atomizing
0.18
6
15
15
bal.
atomizing
0.05
4
A
B
27
0
30
bal.
atomizing
0.18
4
30
20
bal.
atomizing
0.03
6
A
B
28
0
90
bal.
atomizing
0.01
5
0
5
bal.
atomizing
0.09
5
B
B
29
0
90
bal.
atomizing
0.01
6
30
30
bal.
atomizing
0.03
4
B
C
Comp.
30
0
30
bal.
atomizing
0.18
9
15
15
bal.
atomizing
0.05
1
C
C
Examples
31
20
30
bal.
atomizing
0.10
3
0
5
bal.
atomizing
0.09
7
C
C
Note:
Underlined figures are outside the conditions as required in the present invention.
In Table 2, Nos. 24 to 28 are present invention examples, while Nos. 29 to 31 are comparative examples.
In sample No. 29, the content of Cu and Ni is high, thus leading to a result that, for brazing properties of the mixed powder, a melting failure partially occurred and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed. In sample No. 30, the proportion of the Zr-containing alloy powder in the ratio of the Zr-containing alloy powder to the Ti-containing alloy powder is high while the proportion of the Ti-containing alloy powder is low, thus leading to a result that, for brazing properties of the mixed powder, a melting failure occurred over the entire surface and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed.
In sample No. 31, the Zr proportion in the ratio of the Zr-containing alloy powder to the Ti-containing alloy powder is low while the Ti proportion is high as opposed to sample No. 30, thus leading to a result that, for brazing properties of the mixed powder, a melting failure occurred over the entire surface and, for uniformity of the brazing material, non-uniformity over the entire surface was also observed. In contract, it is understood that sample Nos. 24 to 28, which satisfy the conditions as required in the present invention, were excellent in both of brazing properties of the mixed powder and uniformity of the brazing material. | A Ti-based brazing filler material comprising in mixture a Zr-containing alloy powder comprising 30 to 90% by mass of one or two of Cu and Ni, the balance being Zr and unavoidable impurities and a Ti-based powder comprising 0 to 50% by mass of one or two of Cu and Ni, the balance being Ti and unavoidable impurities, wherein the weight ratio of the Zr-containing alloy powder to the Ti-based powder is 8:2 to 4:6. This Ti-based brazing filler material can achieve good brazing and can exhibit excellent effects in the production of aerospace instruments, medical instruments, frames of glasses, heat-exchangers made from titanium. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for the dry treatment of a fabric, comprising: a first enclosure for a stock of in-coming fabric, said enclosure being capable of maintaining said fabric generally disposed in open width form; a second enclosure for a stock of exiting fabric, said enclosure being capable of maintaining said fabric generally disposed in open width form; first means for causing a gradual in-feed of fabric in said first enclosure; second means for providing a gradual removal of fabric from said second enclosure; a passage of flattened section allowing the cloth to pass therethrough in open width form between said first and second enclosures; alternately operating pneumatic means for moving the fabric from one of said enclosures to the other; and control means which when activated cause reversal of said alternate operation.
REFERENCE TO THE PRIOR ART
The currently known apparatus of this type afford a large number of advantages, since during the treatment the fabric is not subjected to mechanical tensions or harmful chafing, since the fabric is moved practically without contact with the walls of the passage, thanks to the air drive in one direction or the other.
Nevertheless, in these known apparatus down times are produced each time there is to be a change of direction, whereby the treatment requires a certain duration. Furthermore, these commonly known apparatus are very voluminous, whereby they require very large spaces for their installation.
SUMMARY OF THE INVENTION
It is an object of the invention to overcome these drawbacks, while maintaining the recognized advantages of the known apparatus. This object is achieved with an apparatus of the type described at the beginning which is characterized by comprising: a space; a rotary cylindrical drum disposed in said space; drive means for said drum, adapted to cause the drum to rotate alternately in both directions and associated with said control means; ad in that said passage comprises a first portion, communicating said first enclosure with said space, and a second portion communicating said second enclosure with said space, allowing the fabric that enters in said space through one of said portions to leave said space through the other portion after partially wrapping said rotary cylindrical drum.
BRIEF DESCRIPTION OF THE DRAWING
Further advantages and features of the invention will be appreciated from the following description in which, without any limiting nature, there is described a preferred embodiment of the invention, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic cross section view of the apparatus of the invention, in the longitudinal direction thereof.
FIG. 2 is a schematic cross section view on the line II--II of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus of the present invention comprises a first enclosure 2 for receiving an in-coming fabric 4 from the outside and which is fed into the enclosure 2 by conventional means not forming part of the invention, such as an in-feed bridge 6, a fabric centering means 8, a regulating roll 10 and a set of rolls 12 comprising a drive roll. The fabric is fed in gradually, i.e. slowly and preferably continuously, as indicated later on.
A stock 16 of in-coming fabric may be formed in the enclosure 2 and particularly on the bottom 14 thereof (to be referred to later on) and the dimensions of the enclosure are such that the fabric is disposed in open width form.
The apparatus comprises a second enclosure 18, having a bottom 20 (to which further reference will also be made later on), on which a stock 22 of exiting fabric may be formed; in this case also, the dimensions of the enclosure 18 are such as to maintain the fabric disposed in open width form. The fabric is drawn out of the apparatus by conventional means which do not form part of the present invention either, such as a transport apron 24, a fabric centering means 26 and a folder 28 or other fabric take-up means. Preferably the exiting fabric passes through a cooling means 30, to which a flow of air is applied. The removal of the fabric also takes place gradually, i.e. slowly and preferably continuously.
The fabric 4 moves from the first enclosure 2 to the second enclosure 18 through a passage of flattened section, suitable for containing the fabric in open width form. According to the invention, this passage comprises a first portion 32a and a second portion 32b, which are preferably generally vertical and mutually parallel. Each of these portions is formed as a nozzle and receives a current of air capable of hauling the cloth along. The air enters the first portion 32a alternately through oppositely orientated ports 34 or 36, so that when the air flows in through the ports 34 the fabric is driven into the first enclosure 2, while when blown in through the ports 36 the fabric is drawn out of the first enclosure 2.
In a similar fashion, the air enters the second portion 32b alternately through oppositely orientated ports 38 or 40, so that when the air flows in through the ports 40 the fabric is driven into the second enclosure 18, while when blown in through the ports 38 the fabric is drawn out of the second enclosure 18.
There is a conventional mechanism, also outside the scope of the present invention, which alternately: either simultaneously opens the ports 34 and 38, closing the ports 36 and 40, or simultaneously opens the ports 36 and 40, closing the ports 34 and 38.
Both portions 32a and 32b communicate with a generally closed space 42 in which there is a rotary cylindrical drum 44; the drum 44 is so arranged as to allow the fabric entering in the space 42 through either of the portions 32a or 32b to leave the same space through the other portion 32b or 32a, after partly wrapping the drum. The drum 44 may also rotate in either direction and it is driven by a motor 46.
The outer surface of the rotary cylindrical drum 44 is preferably provided with a plurality of longitudinal reliefs 46, which may be continuous or discontinuous and preferably said reliefs 46 are arranged substantially on generating lines of the drum 44.
The apparatus also comprises a fan 48, driven by the motor 50, which generates the required air; known alternately operating pneumatic means (such as gates, dampers and the like not shown) direct the air provided by the fan 48 (as described above) to flow alternately through the ports 34 and 38 or through the ports 36 and 40. There is also provided the unit 51 for heating the air used in the treatment. There are, furthermore, control means which when activated cause reversal of said alternate operation.
The drum 44 is preferably perforated on the outer surface thereof and the interior thereof is in (direct or indirect) communication with the fan 48 through passages 49, which may be regulated with a valve 53. The air flowing axially into the drum 44 and out through the said perforations contributes to move the fabric along and furthermore has a flattening effect on the fabric.
There is also preferably provided a rotor 52 to receive the fabric from one of the portions 32a or 32b. The rotor 52 is air permeable and is adapted to receive the fabric entering in the enclosures 2 and 18 from the space 42, without retaining it. Since the fabric is blown in with a substantial air pressure, it is advantageous to prevent the fabric from impacting against the bottom of the enclosures and the rotor 52 furthermore allows the fabric to be piled in each enclosure in an orderly fashion and the formation of tangles which may seriously hinder a free passage of the fabric through the portions 32a and 32b. A description of this rotor is to be found in ES-P-2011141 (application no. 8803076).
The invention contemplates the existence of a single rotor 52 for both portions 32a and 32b, such that the rotor may oscillate between two positions which are respectively situated at a level below the portions 32a and 32b and substantially opposite the lower open ends of these portions. There is a geared motor 54 for driving the rotor 52 and appropriate means allowing it to oscillate.
At least one (and preferably both) of the bottoms 14 and 20 of the enclosures 2 and 18 is a weighing platform, i.e. is sensitive to the weight of the fabric deposited thereon. Furthermore, each bottom 14, 20 is associated with a weight control device 56, 57 which, in turn, is associated with the said control means.
Finally, the apparatus may also comprise an automatic filter 58 for dust and lint removal and a fan 60 for exhausting the moist air and the products removed by the filter 58.
For the operation of the apparatus, the fabric is first fed manually through the in-feed bridge 6, fabric centering means 8, regulating roll 10 and set of rolls 12, with the drive roll forming part of the roll set 12 being switched on for a short period of time, whereby a sufficient length of fabric is deposited on the bottom 14 of the first enclosure 2. Through side openings not shown, the leading edge of the fabric is fed by hand up to the lower open end of the portion 32a of the passage connecting both enclosures 2 and 18. When the fan 48 is switched on, with the ports 36 open, the fabric is caused to rise towards the space 42 where the fabric is wrapped round the top portion of the drum 44 and fed downwards through the portion 32b, whereby the second stock of fabric starts to be formed in the enclosure 18; subsequently the fabric is led to the outside of the apparatus through the apron 24, fabric centering means 26, folder 28 and cooling means 30.
Thereafter a substantial length of fabric is fed in until the in-coming stock is formed. With the pneumatic means (with the ports 36 and 40 open) and the drum 44, the fabric is moved until the exiting stock 22 is formed. Obviously, during this stage, the drum 44 (as seen in FIG. 1) rotates in a clockwise direction. The fabric in-feed means to the first enclosure 2 and the fabric exiting means from the second enclosure 18 are activated.
When the second stock 22 reaches a certain weight (a fact usually coinciding with a substantial exhaustion of the in-coming stock 16), the weighing platform and the control device 57 reverse the cloth flow. Therewith, the air ceases to blow through the ports 36 and 40 and flows through the ports 34 and 38. The drum 44 reverses its rotation and the rotor 52 swings to place itself below the first portion 32a. Naturally the fabric is now fed from the second enclosure 18 to the first enclosure 2.
When the stock formed again in the first enclosure 2 reaches the preset weight, the flow is reversed again and the whole operation is repeated until the fabric treatment has terminated.
The inclusion of the drum 44 provides a notable acceleration in the changes of direction, reducing the down times to a minimum. Furthermore, the fact that the connecting passage between both enclosures 2 and 18 is disposed in two vertical portions 32a and 32b allows the longitudinal dimension of the apparatus to be reduced. Also, the economy represented by the presence of a single rotor 52 should be highlighted. | An apparatus for the dry treatment of a fabric having two enclosures for stocks of fabric, and means for the gradual in-feed and drawing out of the fabric from the enclosures. There are pneumatic means blowing air into a passage which comprises a first portion communicating one enclosure with a space and a second portion communicating another enclosure with the same space. A cylindrical drum is located in this space and adapted to rotate alternately in both directions, such that the fabric entering the space through one of the portions leaves it through the other portion, after partially wrapping the drum. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of U.S. application Ser. No. 10/347,384, filed Jan. 21, 2003 (now U.S. Pat. No. 7,722,815). This application relates to and claims priority from Japanese Patent Application No. 2002-055178, filed on Mar. 1, 2002. The entirety of the contents and subject matter of all of the above is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a chemical analysis apparatus, and in particular to a chemical analysis apparatus incorporating an agitating mechanism for mixing a reagent and a sample with each other within a reaction container.
JP-A-8-146007 discloses a method of agitating a sample and a reagent in a noncontact manner by irradiating ultrasonic waves toward an opening of a reaction container containing therein the sample and the reagent, from a position below the container in order to mix the sample and the reagent with each other in a noncontact manner with no use of a spatula or a screw.
Further, JP-A-2000-146986 discloses such a technology that sound waves are irradiated to a reaction container containing therein a substance to be agitated (a sample and a reagent), laterally of the container, in order to agitate the substance in the container, in addition to irradiation of sound waves to the container toward the opening of the container from a position below the container.
Further, JP-A-2001-242177 discloses such a configuration that the means for irradiating sound waves to the container from a position below the container, which is disclosed in the JP-A-2000-146986 is a reflecting plate.
However, in such a case that a substance using a bit of a sample is efficiently agitated in a container so as to carry out an analysis, it has been found that the well-known above-mentioned configurations are insufficient. For example, with a configuration in which sound waves are irradiated from a position below the container toward the opening of the container, or sound wave are irradiated from one side of the container, should strong sound waves be irradiated from a sound wave supply means which is disclosed in the above-mentioned documents and which is located below the container in order to apply a strong agitating power, the liquid surface of the sample would swell upward so as to cause such a risk that a sample solution scatters. On the contrary, should weak sound waves be irradiated, no contribution to sufficient agitation would be obtained.
BRIEF SUMMARY OF THE INVENTION
The present invention is devised in order to solve the above-mentioned problems inherent to prior art, and accordingly, an object of the present invention is to provide a chemical analysis apparatus incorporating a mechanism for efficiently agitating a substance to be agitated.
To the end, according to a general concept of the present invention, there is provided such a mechanism that sound waves are irradiated to a substance to be agitated in a container in several directions in which a wall of the container is laid behind the substance to be agitated.
Specifically, according to a first aspect of the present invention, there is provided a chemical analysis apparatus incorporating a placing portion in which a reaction container containing therein a substance to be analyzed is placed, a sound wave supply portion spaced from the substance to be analyzed, for irradiating sound waves to the substance to be analyzed, and a measuring portion for measuring physical properties of the substance to be analyzed, characterized in that a first sound wave fed from the sound supply portion is irradiated to a position corresponding to a first part of the reaction container, a second sound wave is irradiated to a position corresponding to a second part of the reaction container, and the first and second sound waves are irradiated from a position where a wall of the reaction container is located behind the substance to be analyzed, as viewed in a direction in which the sound waves are propagated.
In a first specific form of the first aspect of the present invention, the chemical analysis apparatus is characterized in that the first part is the one in which an interface of a fluid including the substance to be analyzed, contained in the reaction container, is defined, and the second part is the one which is located, being off from the first part to the bottom side of the reaction container. For example, in the case of liquid, it is not a part where the liquid is made into contact with the container, but a part where the liquid defines a liquid surface.
In a second specific form of the first aspect of the present invention, the second sound wave is the one which is reflected by a reflecting means. This reflecting means is adapted to irradiate a sound wave reflected below the sound waves fed from the sound wave supply portion.
In a third specific form of the first aspect of the present invention, the first sound wave is fed from a first sound wave supply portion, and the second sound wave is fed from a second sound wave supply portion.
In a fourth specific form of the first aspect of the present invention, the reflecting means comprises a reflecting plate having a sound wave reflecting surface which is concave. Alternatively, the reflecting means is adapted to reflect reflected sound waves which are converged toward a zone where the reaction container is placed.
In a fifth specific form of the first aspect of the present invention, the sound wave supply portion is formed of a single piezoelectric vibrator having an outer surface formed thereon with an electrode which is split.
In a sixth specific form of the first aspect of the present invention, there is further incorporated a mechanism for changing the energy of the sound waves irradiated to the substance to be analyzed.
According to a second aspect of the present invention, the first sound wave irradiated to a position at which the reaction container is placed, is fed from a location that is spaced from a location where the second wave irradiated to the position at which the reaction container is placed, is fed, the reaction container intervening between two locations.
According to a third aspect of the present invention, the first sound wave irradiated to a position at which the reaction container is place, is fed from a location that is spaced from a location where the second wave irradiated to the position at which the reaction container is placed, is fed, the reaction container intervening between two locations. Further, the reaction container is placed between the first sound wave supply portion and the second sound wave supply portion.
As mentioned above, in the present invention, there is provided a means for mixing a sample and a reagent in a noncontact manner, in the chemical analysis apparatus incorporating, for example, a reaction container having an opening, sample, reagent and diluent supply means for supplying the sample, the reagent and diluent into the reaction container through the opening thereof so as to obtain a solution to be measured in the reaction container, and a means for measuring physical properties of the solution to be measured during reaction or after completion of the reaction. This mixing means is provided outside of the reaction container, and is provided with a sound wave producing means for irradiating sound waves in parallel with a liquid surface of the solution to be mixed in the reaction container, or obliquely to the liquid surface in a direction from a liquid phase to a gas phase, a means for reflecting sound waves passing through the solution to be measured, so as to introduce the reflected sound wave again into the reaction container, and a mechanism for producing the sound waves while changing their energy. With this arrangement, the mixing of the sample and the reagent can be effective in a non-contact manner.
Other objects, features and advantages of the invention will become apparent from the following description of the embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a perspective view illustrating an entire configuration of a chemical analysis apparatus in an embodiment of the present invention;
FIG. 2 is a vertically sectional view illustrating a part of the embodiment illustrated in FIG. 1 , in detail;
FIGS. 3 a to 3 b are views for explaining a fluidization principle during agitation in the chemical analysis apparatus according to the present invention;
FIGS. 4 a to 4 c are sectional views illustrating various possible configurations of a reflector shown in FIG. 2 ;
FIGS. 5 a to 5 b are views for explaining a sound source in the chemical analysis apparatus according to the present invention;
FIGS. 6 a to 6 d are views for explaining the operation of a drive system for the sound source in the chemical analysis apparatus according to the present invention;
FIG. 7 is a schematic view illustrating another embodiment of the present invention;
FIG. 8 is further another embodiment of the present invention;
FIG. 9 is further another embodiment of the present invention; and
FIG. 10 is further another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Explanation will be hereinbelow made of embodiments of the present invention with reference to the accompanying drawing. It is noted that the present invention should not be limited only to configurations of the embodiments which will be explained, but the present invention can have any other various configurations.
A chemical analysis apparatus in these embodiments may be composed of an automatic sample pipetting mechanism for feeding a sample to be analyzed into a reaction container, an automatic reagent pipetting mechanism for feeding a reagent into the reaction container, an automatic agitating mechanism for agitating the sample and the reagent in the reaction container, a measuring unit for measuring physical properties of the sample during reaction or after completion of the reaction, an automatic washing mechanism for sucking and discharging the sample after the measurement, and for washing the reaction container, and a control mechanism for controlling the operation of the above-mentioned components.
Explanation will be made of a first embodiment of the present invention with reference to FIGS. 1 and 2 . FIG. 1 is a perspective view illustrating a configuration of a chemical analysis apparatus in the first embodiment of the present invention, and FIG. 2 is a vertically sectional view illustrating a configuration of an agitating mechanism of non-intrusion type (non-contact type) incorporated in the chemical analysis apparatus of the first embodiment shown in FIG. 1 , for agitating and mixing a substance to be agitated, in a non-contact manner.
The chemical analysis apparatus in the first embodiment is mainly composed of a reaction disc 101 for accommodating reaction containers 102 , a constant temperature tank 114 for holding a constant temperature condition of the reaction containers accommodated in the reaction disc, a sample turntable 103 for accommodating sample cups 104 , a reagent turntable for accommodating reagent bottles 105 , a sample pipetting mechanism 107 for pipetting a sample into a reaction container, and a reagent pipetting mechanism 108 for pipetting a reagent into the reaction container, an agitating mechanism 109 for agitating the pipetted sample and reagent in the reaction container 102 , an optical measuring mechanism 110 for measuring a light absorbance of the mixed substance in the reaction container during a reaction process or after the reaction process, and a washing mechanism 111 for washing the reaction container after the measurement (of light). The above-mentioned components are operated under control by a program which is automatically prepared by the controller 112 in accordance with data (analysis items, a liquid quantity to be analyzed and the like) which is previously set up on a console 113 before the measurement is initiated.
The above-mentioned agitating mechanism 109 is composed of, as shown in FIG. 2 , a sound wave producing means 201 (which will be referred to simply as “a sound source”) provided, external to and lateral of the reaction container 102 , and a sound wave reflecting means 202 (which will be referred to simply as “reflector”) for reflecting sound waves propagated through the reaction container so as to introduce the sound wave again into the reaction container. The sound source has such a structure that segments 501 , 503 are arranged in an array, as shown in FIGS. 5 a and 5 b so that they can be driven, independent from each other, and accordingly, those of the segments which are appropriate are selected by drivers 504 , 506 through the intermediary of switches or the like in order to irradiate sound waves from an optional position 502 . Further, the driver is composed therein of, as shown in FIG. 6 a which is a block diagram, a wave form producing device 601 for producing an oscillation waveform 602 having a fundamental frequency of sound waves to be irradiated, and an auxiliary waveform producing device 603 for producing an oscillation wave form 604 having a frequency lower than that of the oscillation waveform 602 , a multiplying circuit 605 for creating a multiplied waveform 606 between the both waveforms 602 , 604 , and a power amplifier 607 for power-amplifying the multiplied waveform 606 . The above-mentioned driver is adapted to apply a voltage 608 which has been amplitude-modulated to piezoelectric elements.
Explanation will be hereinbelow made of the operation of the above-mentioned chemical analysis apparatus. A sample is pipetted from a sample cup 104 into a reaction container 102 by means of the sampling mechanism 107 . Next, the turntable accommodated therein with the reaction container 102 is turned so that the reaction container 102 comes to a reagent pipetting position where a reagent is pipetted into the reaction container from a reagent bottle 106 by means of the reagent pipetting mechanism 108 . Further, the turntable is turned so that the reaction container 102 comes to a position where the agitating mechanism 105 is provided, and where the sample and the reagent in the reaction container are agitated. After completion of the agitation, measurements are started, and after completion of the reaction the mixture of the sample and the reagent is sucked up by the washing mechanism 111 for washing the reaction container. The above-mentioned process steps in series are successively carried out for each of a plurality of samples in a batch.
Next, explanation will be made of the operation of the apparatus for agitating a substance to be agitated in the reaction container in a noncontact manner with reference to FIG. 2 which is a vertically sectional view illustrating the agitating device. There is provided a sound wave producing portion (which is a sound wave reflecting means 202 in this embodiment) for irradiating sound waves to the lower part of the reaction container in order to agitate a solution including a sample in the reaction container. Specifically, for example, there may be provided such a configuration that the reaction container 102 is located between the sound wave producing means 201 and the sound wave reflecting means 202 . In this embodiment shown in FIG. 2 , sound waves produced from the sound wave producing means 201 are reflected by the sound wave reflecting means 202 located on the opposite side, and are then fed into the reaction container. Next, explanation will be made of the basic operation thereof. A driver circuit 205 incorporating a driver and switches for the sound source, connected to the main controller 112 for the entire apparatus, receives data 206 relating to a quantity of a solution to be agitated, that is, a quantity of the sample and the reagent which have been pipetted in the reaction container, and a timing for agitating thereof. At first, the driver circuit 205 calculates a height 208 of the liquid surface of a solution to be measured, which is charged in the reaction container, from data relating to the liquid quantity in order to determine an optimum sound wave irradiating zone including the liquid surface, and selects segments 207 in the sound source, corresponding to the irradiating zone in order to drive the sound source. Since the driver circuit causes a piezoelectric element in the sound source to deliver a voltage having a waveform which has been amplitude-modulated, the sound wave to be irradiated are produced in accordance with variations in the amplitude thereof. The irradiated sound waves are propagated to the reaction container through the constant temperature bath 204 , and are introduced into the reaction container. In general, if sound waves which have been propagated through liquid comes to a free liquid surface, a force with which liquid scatters into a gas phase is exerted (which is mainly caused by acoustic radiation pressure) to the liquid. At this stage, in this embodiment, since the voltage having a waveform which has been amplitude-modulated is delivered the sound source from the driver circuit, the sound waves to be irradiated are also dependent upon variation in the amplitude thereof. It is noted that the sound waves which are introduced into the reaction container after reflection, are propagated in a direction toward a position where no liquid surface is present.
Further, the sound reflecting means 202 is provided behind the reaction container in the direction of propagation of the sound waves, with respect to the sound wave producing means 201 , and accordingly, it is possible to restrain the sound waves produced by the sound wave producing means 201 from causing damage to peripheral equipment, or the like.
If an intermittent sound wave 201 is irradiated as shown in FIG. 3 a , the force is exerted to the liquid surface so as to crease a kind of a wave on the liquid surface in the reaction container. Further, the sound wave 301 is irradiated in a beam-like shape having an intensity distribution 303 as shown in the figure, and accordingly, a part thereof is transmitted through the reaction container as indicated by the dotted line. The transmitted sound wave is reflected by the reflector 202 , and is again introduced ( 203 ) into the reaction container. By the way, since a sound flow or an acoustic radiation pressure is produced when sound waves are propagated through liquid, the reintroduction of the transmitted sound wave causes such an effect that the liquid is fluidized in the sound propagating direction. At this time, the direction of the propagation of the sound wave which is reintroduced into the reaction container is set so as to be not directed toward the opening of the container (that is, for example, toward a position where no liquid surface is present), and accordingly, it is possible to restrain the liquid from scattering outside of the reaction container even though the intensity of the sound wave is increased. Due to the fluidization of the liquid accompanied with the wave produced at the liquid surface, and the fluidization caused by the reintroduction of the sound wave through the reflection, the liquid is fluidized as indicated by the arrow 302 . With the repetitions of irradiation of the above-mentioned intermittent sound wave, a swirl flow 305 is produced in the liquid in the reaction container as shown in FIG. 3 b . In the chemical analysis apparatus according to the present invention, there is used a means for mixing a sample and a reagent with the use of the swirl fluidization in a noncontact manner with respect to the liquid.
With the configuration of this embodiment, it is possible to prevent the liquid from scattering in comparison with such a case that sound waves are irradiated from a position external to and below the reaction container toward the opening of the latter. Further, the agitation in this embodiment is effective by applying a suitable sound intensity distribution to the liquid to be measured within the reaction container. Further, in this embodiment with the use of the fluidization whose acoustic radiation pressure is dominant in the vicinity of a liquid interface which is not affected by a friction of the wall surface of the reaction container, the liquid to be measured can be agitated and mixed by sound waves having a smaller intensity in comparison with such a method which utilizes only acoustic fluidization. Further, since sound waves having propagated through the reaction container is again reintroduced into the latter so as to promote the fluidization in the bottom part of the reaction container, the produced sound waves can be effectively used.
Further, since the mixing can be made with a completely noncontact manner with respect to the liquid to be measured contained in the reaction container, agitation with carry-over-less and a bit of liquid can be carried out in a chemical analysis apparatus. Thereby it is possible to materialize a function capable of performing high speed analysis.
Further, it is possible to provide a configuration which is preferable for several inspection items which can accept reagents and samples which have liquid quantities and liquid physical properties in a wide range.
Further, it is possible to carry out the agitation with carry-over-less and a bit of liquid, and to reduce the consumption power.
Further, it is possible to avoid problems including carry-over and contamination caused by sticking inherent to an agitating process with the use of a spatula or a screw, and positioning accuracy caused by miniaturization of the reaction container.
It is specifically noted that since a sample can be agitated effectively, if the present invention is applied in a chemical analysis apparatus capable of performing a high speed process with a high degree of accuracy, in which several samples can be analyzed in a batch with a short time, the time by which a result of an inspection can be obtained after the inspection is completed can be shortened.
Further, even though a sample extracted from a patient or the like is reduced, the sample can be effectively agitated. Thereby it is possible to reduce the quantity of waste liquid to be disposed after the inspection, and further, it is possible to reduce the running costs for the inspection.
It is noted that a sample and a reagent are automatically pipetted into each of reaction containers circumferentially accommodated in the turn table by a pipetter incorporating a robot arm, and a solution to be measured (the sample and the agent which have been pipetted into the reaction container) is mixed by means of the agitating mechanism. Further, a chemical reaction of the solution is measured, and the result of the inspection thereof is outputted. After completion of the measurement, the solution to be measured is sucked, and then, the reaction container is washed. Thus, the inspection of the sample is completed for one of several items thereof. Practically, in general, with the use of a chemical analysis apparatus capable of performing such a process that a plurality of inspections are carried out in sequence under control programmed by the user, of several manipulation steps (pipetting and agitating of the sample and the reagent, and washing of the reaction container), the step of agitating the solution to be measured can be effectively made, that is, it is possible to suppress deficiencies such as that no desired reaction can be fulfilled due to insufficient mixing caused by short-time agitation, and accordingly, precise inspection results cannot be obtained. Further, in the case of using a spatula for agitation, should a bit of a solution which has been used during inspection be carried by the spatula into a reaction container for a next inspection (carry-over), the problem of contamination would be caused. Thus, it is possible to prevent the solution to be measured from being decreased due to sticking to the spatula.
In the configuration disclosed in the above-mentioned JP-A-8-146007, in such a case that sound waves are irradiated to a reaction container from a position external thereto so as to apply a suitable sound intensity distribution in a substance to be agitated in the reaction container in order to induce acoustic fluidization, the smaller the quantity of a solution to be measured, the smaller the reaction container itself, resulting in reduction of the surface area of the reaction container, acoustic energy required for generating the acoustic fluidization can hardly be applied to the substance in the reaction container. Further, in order to create a circulation flow which is effective for the agitation, it is required to create a sharp intensity distribution of the sound field in the reaction container. However, in the case of a small-sized reaction container, relative intensity difference in the sound field is decreased, and accordingly, it is difficult to efficiently agitate the solution to be measured in a short time.
Next, detailed explanation will be made of the distinct features of the sound source and the drive system (around the drive circuit) which are used in this embodiment. Referring to FIG. 5 a which shows the arrayed sound source as mentioned above, this embodiment utilizes such a convenient way that one of electrodes on both sides of a single piezoelectric element is divided into several parts 501 . These divided electrode parts are selectively applied with a voltage 504 , corresponding to a desired irradiating zone as shown in FIG. 5 b , and accordingly, there can be materialized a sound source which is functionally equivalent to sound sources which are arranged in an array. It is noted that a part of the electrode on the side where the electrode is not divided is folded back onto the surface of the piezoelectric element on the side where the electrode is divided, as indicated by 505 , the connection of electric wires from drivers can be concentrated to only one surface thereof. With the use of the single piezoelectric element applied with the electrodes which are fabricated as mentioned above, the costs of the agitating mechanism can be reduced. The configuration of this sound source is advantageous in view of the mass production base thereof, and with the use of an electrode pattern produced by screen printing or the like, the time required for manufacturing the agitating mechanism can be shortened. Further, since the structure thereof is relatively simple, the agitating mechanism is highly reliable. Further, in comparison with a conventional spatula incorporating a robot arm, the size of the agitating mechanism can be greatly reduced, thereby it is possible to contribute to miniaturization of the entire apparatus.
In this embodiment, with the provision of such a feature that pulsation can be applied to a swirl flow in the reaction container by changing, in time, the intensity of ultrasonic waves to be irradiated in the agitating mechanism, the mixing can be enhanced thereby so as to shorten the time required for the agitation, and to save consumption power.
As to a wave form which is used as a subwaveform for amplitude modulation, there may be used a rectangular waveform which repeats turn-on and -off as shown in FIG. 6 d , in addition to a waveform as shown in FIG. 6 c , in which it sinusoidally varies between its minimum value and its maximum value. In this case, a relatively simplified waveform creating mechanism can be used, thereby it is possible to reduce the costs of the driver. Further, the above-mentioned turn-on and -off operation can be made only by turning on and off the driver which produces only a fundamental frequency of sound waves, thereby it is possible to further reduce the costs of the driver.
Further, as to another measures for saving consumption power, there may be used such a method that the reflecting surface of the reflector 202 is fabricated. FIGS. 4 b and 4 c are sectional views along line A-B shown in FIG. 4 a , illustrating the reaction container 102 and the reflector 202 which have been explained hereinabove. Specifically, FIG. 4 b shows a pattern of sound rays in which sound waves 401 irradiated from the left side of the figure is propagated through the reaction container, and is reflected by the reflector so as to be again introduced into the reaction container. As shown in Figure, since the reflecting surface is fabricated in a spherical shape, reflected sound waves can be converged to one single point due to an effect similar to that of a parabola antenna. Since the intensity of the sound waves is increased, correspondingly, at a position where the sound waves are converged, if the converged point is set to a suitable position (for example, the center of the reaction container), the fluidization with a high degree of efficiency can be obtained. FIG. 4 c shows an example in which the sound waves 403 propagated outside of the reaction container are reflected toward the reaction container. In this case, the surface at which the propagated waves are reflected, is set to be perpendicular to the propagated waves, and a surface at which the sound waves 403 propagated outside of the reaction container is reflected is fanned so as to direct the reflected waves toward reaction container. In either of the cases, the sound waves 403 propagated outside of the reaction container can be effectively used, and can be also converged together with the sound waves propagated through the reaction container, thereby it is possible to enhance the intensity of the sound waves to be reintroduced into the reaction container.
In the case of using a piezoelectric element in a sound source, there may be used a thickness resonance of the piezoelectric element. In the case of manufacturing such a sound source on a mass production base, unevenness among piezoelectric elements would be possibly serious due to trade-off between manufacturing costs and machining accuracy. Referring to FIG. 6 b which schematically shows frequency response characteristics of three piezoelectric elements (they are fabricated with their uneven thicknesses) around their thickness resonances, it will be found that uneven thicknesses of piezoelectric elements cause uneven resonant frequencies with which the piezoelectric elements produce output powers with maximum intensity. Accordingly, such a problem that unevenness among piezoelectric elements would be serious can be solved by frequency modulation to the frequency of sound waves around their resonant frequencies. In the above-mentioned embodiment, although the waveform producing device 601 for producing the oscillation frequency wave 602 having a single frequency has been explained, with the provision of a function capable of frequency-modulation around a resonant frequency with a suitable frequency width in this waveform producing device 601 , individual differences among piezoelectric elements can be absorbed.
The essential feature of the present invention is the provision of such a configuration that in order to mix a sample and a reagent with each other, first, sound waves are irradiated in a direction toward the liquid surface of a solution so as to create a wave at the liquid surface, and second, sound waves are irradiated to the solution in another direction in order to enhance the efficiency of the fluidization of the solution, that is, to efficiently mix the sample and the reagent. In the above-mentioned embodiment, a part of the sound waves irradiated toward the liquid surface of the solution and propagated through the reaction container is reintroduced into the reaction container with the use of the reflector, and accordingly, two way irradiation can be materialized with the use of a single sound source.
Next, explanation will be hereinbelow made of another embodiment in which the irradiation is made in two ways.
Referring to FIG. 7 which shows a second embodiment of the present invention, this second embodiment has a configuration similar to the first embodiment, comprising a single sound source and a reflector, except that it has a different transmission path 704 through which sound waves are irradiated to the lower part 706 of the inside of the reaction container. The embodiment shown in FIG. 7 is the same as that of the embodiment shown in FIG. 2 in which the sound waves 701 are irradiated toward the liquid surface. However, sound waves 702 irradiated for fluidizing the solution in the bottom part of the reaction container are propagated outside of the reaction container, as indicated by the arrow 704 , by means of the reflector 703 , and is then introduced into the reaction container so as to create fluidization 705 of the solution in the bottom part of the reaction container. In this embodiment, as a result, although two kind of waves are produced from the sound source, with the use of the array-like sound source shown in FIG. 5 , the above-mentioned production of the sound waves can be simply made. As stated above, even with the configuration shown in FIG. 7 , a high degree of efficiency of mixing similar to that of the embodiment shown in FIG. 2 can be obtained.
Further, in another embodiment shown in FIG. 8 , which can materialize both configurations shown in FIGS. 2 and 7 . That is, it is composed of a reflector 803 which reflects sound waves 801 irradiated toward the liquid surface of a solution in a reaction container so as to reintroduce the sound waves into the bottom part of the reaction container, similar to the embodiments shown in FIGS. 2 and 7 , and a reflector 804 which propagates sound wave outside of the reaction container and then introduces sound waves in the bottom part of the reaction container, similar to the embodiment shown in FIG. 7 . With this configuration, it is possible to aim at synergistically fluidizing the solution in the bottom part of the reaction container.
Although the present invention has been explained in the form of the preferred embodiments as mentioned above, in which a single sound source and a reflector are used, as shown in FIGS. 5 a and 5 b , so as to irradiate sound waves in two directions toward the liquid surface of a solution in the reaction container and the bottom part of the reaction container, respectively, the same technical effects and advantages can be attained by such a configuration that two sound sources are arranged, independent from each other so as to sound waves are irradiated toward the liquid surface of the solution in the reaction container and the bottom of the reaction container, respectively. FIG. 9 shows an embodiment having this configuration. In this embodiment shown in FIG. 9 , sound waves 901 irradiated toward the liquid surface of a solution in the reaction container are similar to that explained in the aforementioned embodiments, but another sound source 902 is provided, instead of the reflector which is used in the aforementioned embodiments, so as to irradiate sound waves 903 toward the bottom part of the reaction container.
It is noted that the reflector is an important component, in addition to the sound source, in any of the embodiments shown in FIGS. 2 , 7 , 8 and 10 . In general, the greater the difference in acoustic impedance (which is the product of a density of a medium and a sound velocity) between two media at the interface therebetween, the higher the reflectivity. Thus, in the embodiments of the present invention, the reflectors for reflecting sound waves propagated through the water 204 (in the constant temperature bath 204 ) are made of SUS. However, it may be made of any of materials which satisfy the above-mentioned condition, that is, a great difference in the acoustic impedance between water and the material, instead of SUS.
In the embodiments stated hereinabove, the sound source composed of a piezoelectric element with divided electrode pieces arranged in an array is used, as shown in FIGS. 5 a and 5 b , in order to control the sound wave irradiating position which depends upon a liquid quantity, that is, a liquid surface height which is different among inspection items. However, it goes without saying that a sound source incorporating a shift mechanism, as shown in FIG. 10 , may be used, instead of the above-mentioned sound source. In the embodiment shown in FIG. 10 , the vertical shift 102 and the fanning 103 thereof can be controlled, and accordingly, the direction of sound waves to be irradiated toward the liquid surface of a solution in the reaction container can be optionally adjusted. Since the direction of the sound waves irradiated toward the liquid surface can be adjusted, thereby it is possible to optimally control the waveform created at the liquid surface.
Further, in the embodiments which have been hereinabove explained, the sound waves are irradiated in two or three directions. It may be irradiated in much more directions.
Although there have been explained in the above-mentioned embodiments the configuration of the agitation for mixing a sample and a reagent in a noncontact manner, this configuration may also be effective for fluidization of washing liquid in a reaction container which is washed by the washing mechanism 111 shown in FIG. 1 .
The present invention can be materialized as an analysis device such as a biochemical analysis apparatus, an immune analysis apparatus, a DNA analysis apparatus or the like, a medicine preparing apparatus or an agitating apparatus.
According to the present invention, it is possible to provide a chemical analysis apparatus which can be efficiently agitate a substance to be agitated.
It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims. | A chemical analysis apparatus comprising reaction containers containing therein a substance to be analyzed; an agitating mechanism spaced from the substance to be analyzed and agitating said substance to be analyzed with a liquid in said reaction container; and, a measuring portion for measuring physical properties of the substance to be analyzed, said agitating mechanism having a sound supply portion supplying sound waves to the substance to be analyzed, wherein said sound supply portion comprises a mechanism changing, in time, intensity of ultrasonic waves to be irradiated so as to apply pulsation to a swirl flow in the reaction container. | 8 |
TECHNICAL FIELD
The present invention relates to a curable composition.
BACKGROUND ART
As has been well known, ultraviolet rays in the sunlight degrades polymers by breaking the chemical bonds in the polymers. In order to prevent such degradation, light stabilizers, ultraviolet absorbers, or the like are added to polymer products such as plastics, fibers, and paints. In particular, a hindered amine light stabilizer (hereinafter referred to as HALS) is said to have a function of preventing a polymer material from being degraded because the HALS hardly absorb the ultraviolet ray while efficiently scavenging harmful free radicals generated by ultraviolet rays.
A typical HALS, however, is not chemically bonded to a polymer material. Thus, the HALS may bleed out from the polymer material if exposed outdoors for a long time. Therefore, it has been pointed out that such bleeding out of the HALS may lead to the loss of the original functions of the HALS. For suppressing the bleeding out of the HALS from the polymer material, a high molecular weight HALS prepared from methacrylic acid piperidyl ester has been studied (see, Patent Documents 1 to 3).
CITATION LIST
Patent Literature
Patent Document 1: JP-A-10-176016
Patent Document 2: JP-A-2008-56906
Patent Document 3: JP-T-2000-509082
SUMMARY OF INVENTION
Technical Problem
However, when the compounds disclosed in Patent Documents 1 to 3 are applied to active energy ray-curable resins, phase separation may be caused depending on the amounts of the compounds added as well as the types of the resins. In addition, when such compounds are applied to active energy ray-curable resins, such compounds may not effectively provide the effects as the HALS in the presence of acids.
Hence, the present invention intends to provide a curable composition capable of producing a polymer having a HALS skeleton with excellent weather resistance and outer appearance.
Solutions to Problem
The following aspects of the invention [1] to [8] are solutions to the above problem.
[1] A curable composition that contains a monomer component containing: a monomer (A) represented by formula (1) below; and a monomer (B) polymerizable with the monomer (A), in which
the content of the monomer (A) is 0.01 to 35 mol % in the monomer component, and
the content of the monomer (B) is 65 to 99.99 mol % in the monomer component.
In the formula (1), R 1 represents a hydrogen atom or a methyl group; X represents an oxygen atom, an imino group, a compound represented by formula (2) below or a compound represented by formula (3) below; and R 2 , R 3 and R 4 each represent a hydrogen atom, a linear alkyl group having 1 to 8 carbon atoms, a branched linear alkyl group having 1 to 8 carbon atoms, a substituted or unsubstituted cycloalkyl group having 6 to 8 carbon atoms, or a substituted or unsubstituted aryl group having 6 to 12 carbon atoms, where R 2 , R 3 and R 4 may be the same or different from one another, a combination of R 2 and R 3 , R 2 and R 4 , R 3 and R 4 , or R 2 , R 3 and R 4 may form a ring structure and the ring structure may have a substituted group.
In the formula (2), n representing an integer of 1 to 10; R 5 and R 6 each represents a hydrogen atom or a methyl group; and at least one of R 5 and R 6 represents a hydrogen atom.
In the formula (3), n represents an integer of 1 to 10.
[2] The curable composition according to the above [1], further including a polymer containing a monomer (C) polymerizable with the monomer (A).
[3] The curable composition according to the above [1] or [2], in which the monomer (B) contains methyl methacrylate at the content of 50 mol % or more.
[4] A method of manufacturing a polymer, including: polymerizing the curable composition according to any one of the above [1] to [3] with irradiation of active energy ray.
[5] A resin sheet produced by polymerizing the curable composition according to any one of the above [1] to [3].
[6] The resin sheet according to the above [5], in which the total light transmittance is 85 to 100%, and haze value is less than 5%.
[7] A cured coating film produced by applying the curable composition according to any one of the above [1] to [3] to a substrate and subsequently polymerizing the curable composition.
[8] The cured coating film according to the above [7], in which the total light transmittance is 85 to 100%, and haze value is less than 5%.
Effects of Invention
Using the curable composition according to any aspect of the invention, a polymer with excellent weather resistance and outer appearance can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating an exemplary apparatus for producing a resin sheet.
DESCRIPTION OF EMBODIMENTS
The curable composition according to the invention includes at least a monomer component that includes: a polymerizable monomer (A) having a HALS skeleton serving as a light stabilizer; and a monomer (B) polymerizable with the monomer (A). The curable composition may further contain a radical polymerization initiator (C). The polymerization of the curable composition may be initiated by active energy rays.
Since the polymer obtained from the curable composition according to the invention includes the polymerizable monomer unit having the HALS skeleton, the polymer can be prevented from bleeding out even after experiencing a weather resistant test for a long time. In addition, since the monomer (A) is favorably compatible with the monomer (B) added to the composition, the obtained polymer can be highly transparent and excellent in outer appearance.
In the description made below, the invention will be described in detail.
<Monomer (A)>
The polymerizable monomer (A) having the HALS skeleton (hereinafter abbreviated as monomer (A)) is represented by the following formula (1).
In the formula (1), R 1 represents a hydrogen atom or a methyl group. X represents an oxygen atom, an imino group, a compound represented by formula (2) below or a compound represented by formula (3) below. R 2 , R 3 and R 4 each represent a hydrogen atom, a linear alkyl group having 1 to 8 carbon atoms, a branched linear alkyl group having 1 to 8 carbon atoms, a substituted or unsubstituted cycloalkyl group having 6 to 8 carbon atoms, or a substituted or unsubstituted aryl group having 6 to 12 carbon atoms. R 2 , R 3 and R 4 may be the same or different from one another. Further, a combination of R 2 and R 3 , R 2 and R 4 , R 3 and R 4 , or R 2 , R 3 and R 4 may form a ring structure. Such ring structure may have a saturated group.
In the formula (2), n represents an integer of 1 to 10. R 5 and R 6 each represent a hydrogen atom or a methyl group. At least one of R 5 and R 6 represents a hydrogen atom.
In the formula (3), n represents an integer of 1 to 10.
In the formula (1), X preferably represents an oxygen atom. With such configuration, the synthesis of the monomer (A) is facilitated. Further, in the formula (2), R 5 and R 6 both preferably represent hydrogen atoms respectively because of ease of synthesis of the monomer (A).
In the formula (1), X is represented such that an oxygen atom at the right end of the compound represented by any of the formulae (2) and (3) is bonded to the carbon atom of the piperidine ring in the formula (1).
In the above formula (1), it is preferred that (i) R 2 to R 4 all represent hydrogen atoms, and alternatively (ii) any two of R 2 to R 4 preferably represent hydrogen atoms while one of the remainder represents a linear alkyl group having 1 to 8 carbon atoms or a branched linear alkyl group having 1 to 8 carbon atoms. With this configuration, the coloring at the time of the polymerization or the molding is reduced, and the obtained products have favorable weather resistance.
When the monomer (B) contains methyl methacrylate at the content of 50 mol % or more and the polymer (C) contains methyl methacrylate unit at the content of 50 mass % or more, the number of the carbon atoms contained in the linear or branched linear alkyl group is preferably 1 to 6 and more preferably 1 to 4. With this configuration, favorable compatibility is obtained.
Examples of the substitute are a linear or branched linear alkyl group having 1 to 4, a hydroxyl group, a phosphate ester group or a halogen atom.
Examples of the monomer (A) are 1-octyloxy-2,2,6,6-tetramethyl-4-(meth) acryloyloxy piperidine, 1-octyloxy-2,2,6,6-tetramethyl-4-(meth)acrylamide piperidine, 1-propyloxy-2,2,6,6-tetramethyl-4-(meth)acryloyloxy piperidine, 1-propyloxy-2,2,6,6-tetramethyl-4-(meth)acrylamide piperidine, 1-cyclohexyloxy-2,2,6,6-tetramethyl-4-(meth)acryloyloxy piperidine, 1-cyclohexyloxy-2,2,6,6-tetramethyl-4-(meth)acrylamide piperidine, 1-methyloxy-2,2,6,6-tetramethyl-4-(meth)acryloyloxy piperidine, 1-methyloxy-2,2,6,6-tetramethyl-4-(meth)acrylamide piperidine, 1-octyloxy-2,2,6,6-tetramethyl-4-(2-(2-(meth)acryloyloxy)ethoxy)ethoxy piperidine, and 1-octyloxy-2,2,6,6-tetramethyl-4-(4-(2-(meth)acryloyloxy)ethoxy-1,4-dioxo) butoxy piperidine.
Among the above compounds, the preferable compounds are 1-methyloxy-2,2,6,6-tetramethyl-4-(meth)acryloyloxy piperidine, 1-propyloxy-2,2,6,6-tetramethyl-4-methacryloyloxy piperidine, 1-octyloxy-2,2,6,6-tetramethyl-4-(2-(2-methacryloyloxy)ethoxy)ethoxy piperidine, 1-octyloxy-2,2,6,6-tetramethyl-4-(4-(2-methacryloyloxy)ethoxy-1,4-dioxo) butoxy piperidine, and 1-octyloxy-2,2,6,6-tetramethyl-4-(meth)acryloyloxy piperidine. Thus, the obtained products can have favorable weather resistance.
The monomer (A) may be a single compound or a combination of two or more compounds.
In this description, (meth)acryl means acryl or methacryl. In addition, (meth)acryloyl means acryloyl or methacryloyl.
The monomer (A) can be synthesized by a known method.
For instance, 1-octyloxy-2,2,6,6-tetramethyl-4-methacryloyloxy piperidine (hereinafter referred to as “monomer unit (A-1)”) is synthesized in the following manner. Specifically, in the presence of sodium tungstate, 4-hydroxy-2,2,6,6-tetramethyl piperidine is oxidized using hydrogen peroxide solution of 30% concentration. Then, the hydroxyl group contained in the obtained 4-hydroxy-2,2,6,6-tetramethyl piperidine-N-oxide is protectively acetylated with acetic acid anhydride. By using octane as the solvent and the reactant, the 4-hydroxy-2,2,6,6-tetramethyl piperidine-N-oxide is reacted with t-butyl hydroperoxide, so that the acetyl protection is deprotected. Subsequently, the 4-hydroxy-2,2,6,6-tetramethyl piperidine-N-oxide is reacted with methacryloyl chloride, and the monomer (A-1) is synthesized.
Further, the synthesis of the monomer (A-1) can be conducted by a method disclosed in JP-T-2008-519003.
Specifically, in the presence of sodium tungstate dehydrate, triacetonamine is oxidized using hydrogen peroxide solution of 30% concentration, and converted into triacetoneamine-N-oxide. Then, the triacetoneamine-N-oxide is reacted with 1-octane and t-butyl hydroperoxide, and reduced by Ru-supported charcoal and hydrogen. The thus-obtained mixture of 4-hydroxy-1-(1-octyloxy)-2,2,6,6-tetramethyl piperidine and 4-hydroxy-1-(3-octyloxy)-2,2,6,6-tetramethyl piperidine is reacted with methacryloyl chloride, and the monomer (A-1) is synthesized.
In addition, 1-propyloxy-2,2,6,6-tetramethyl-4-methacryloyloxy piperidine (hereinafter referred to as “monomer (A-2)”) can be synthesized according to the method disclosed in JP-T-2008-519003, using propylene in place of 1-octane.
Further, 1-octyloxy-2,2,6,6-tetramethyl-4-(2-(2-methacryloyloxy)ethoxy) ethoxy piperidine (hereinafter referred to as “monomer (A-3)”) is synthesized in the following manner. Specifically, the hydroxyl group contained in 2,2,6,6-tetramethyl-4-(2-(2-hydroxy ethoxy)ethoxy piperidine-N-oxide is protectively acetylated using acetic acid anhydride. By using octane as the solvent and the reactant, the 2,2,6,6-tetramethyl-4-(2-(2-hydroxy ethoxy)ethoxy piperidine-N-oxide is reacted with t-butyl hydroperoxide, so that the acetyl protection is deprotected. Subsequently, the 2,2,6,6-tetramethyl-4-(2-(2-hydroxy ethoxy)ethoxy piperidine-N-oxide is reacted with methacryloyl chloride, and the monomer (A-3) is synthesized.
Further, 1-octyloxy-2,2,6,6-tetramethyl-4-(4-(2-methacryloyloxy)ethoxy-1,4-dioxy) butoxy piperidine (hereinafter referred to as “monomer (A-4)”) is synthesized in the following manner. Specifically, in the presence of sodium tungstate, 4-hydroxy-2,2,6,6-tetramethyl piperidine is oxidized using hydrogen peroxide solution of 30% concentration. Then, the hydroxyl group in the obtained 4-hydroxy-2,2,6,6-tetramethyl piperidine-N-oxide is protectively acetylated using acetic acid anhydride. By using octane as the solvent and the reactant, the 4-hydroxy-2,2,6,6-tetramethyl piperidine-N-oxide is reacted with t-butyl hydroperoxide, so that the acetyl protection is deprotected. Subsequently, succinic anhydride is added. By subjecting the obtained carboxylic acid and 2-hydroxyethyl methacrylate to dehydration condensation, the monomer (A-4) is synthesized.
In addition, 1-methyloxy-2,2,6,6-tetramethyl-4-methacryloyloxy piperidine (hereinafter referred to as “monomer unit (A-5)”) is synthesized in the following manner. Specifically, according to the method disclosed in JP-T-2009-541428, 1-methyloxy-2,2,6,6-tetramethyl-4-hydroxy piperidine is synthesized. Then, the obtained 1-methyloxy-2,2,6,6-tetramethyl-4-hydroxy piperidine is reacted with methacryloyl chloride, and the monomer (A-5) is synthesized.
More specifically, in the presence of copper chloride (I), 2,2,6,6-tetramethyl-4-hydroxy piperidine-N-oxide is reacted with acetone and hydrogen peroxide solution of 30% concentration. Then, the obtained 1-methyloxy-2,2,6,6-tetramethyl-4-hydroxy piperidine is reacted with methacryloyl chloride, and the monomer (A-5) is synthesized.
The content of the monomer (A) in the monomer component is 0.01 to 35 mol %, preferably 0.05 to 20 mol %, and more preferably 0.05 to 5 mol %. When the content of the monomer (A) is 0.01 mol % or more, the cured coating film has sufficient weather resistance. As the result, the degradation of the cured coating film is effectively prevented. When the content of the monomer (A) is 35 mol % or less, the insufficient curing of the coating is effectively prevented. As the result, the toughness, heat resistance and wear resistance of the cured coating film are further enhanced.
<Monomer (B)>
The monomer (B) is a polymerizable monomer other than the monomer (A). The monomer (B) is not limited to a specific one as long as it is polymerizable with the monomer (A). Examples of the monomer (B) are monofunctional (meth)acrylate or polyfunctional (meth)acrylate. The monomer (B) may be suitably selected according to the required specifications of the coating. Other examples of the polymerizable monomer usable as the monomer (B) are urethane (meth)acrylate, epoxy (meth)acrylate, polyester (meth)acrylate, or a monomer having a polymerizable unsaturated bond such as organic-inorganic hybrid (meth)acrylate obtained by condensing colloidal silica and (meth)acryloyloxy alkoxysilane.
Examples of monofunctional (meth)acrylate applicable as the monomer (B) are mono(meth)acrylate such as methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, propyl (meth)acrylate, n-butyl (meth)acrylate, i-butyl (meth)acrylate, t-butyl (meth)acrylate, hexyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, lauryl (meth)acrylate, stearyl (meth)acrylate, morpholyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, glycidyl (meth)acrylate, dimethylaminoethyl (meth)acrylate, diethylaminoethyl (meth)acrylate, tricyclodecane (meth)acrylate, polyethyleneglycol mono (meth)acrylate, cyclohexyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, dicyclopentanyl (meth)acrylate, dicyclopentenyl (meth)acrylate, isobornyl (meth)acrylate, allyl (meth)acrylate, 2-ethoxyethyl (meth)acrylate, benzyl (meth)acrylate, phenoxyethyl (meth)acrylate or phenyl (meth)acrylate, or mono(meth)acrylate compound such as an adduct of acid phthalic anhydride and 2-hydroxyethyl (meth)acrylate.
Examples of polyfunctional (meth)acrylate applicable as the monomer (B) are neopentyl glycol di(meth)acrylate, ethylene glycol di(meth)acrylate, polyethylene glycol (repeating unit number (hereinafter referred to as “n”) is 2 to 15) di(meth)acrylate, polypropylene glycol (n=2 to 15) di(meth)acrylate, polybutylene glycol (n=2 to 15) di(meth)acrylate, 2,2-bis(4-(meth)acryloxyethoxy phenyl) propane, 2,2-bis(4-(meth)acryloxydiethoxy phenyl) propane, trimethylolpropane diacrylate, bis(2-(meth)acryloxyethyl) hydroxyethyl isocyanurate, trimethylolpropane tri(meth)acrylate, tris(2-(meth)acryloxyethyl) isocyanurate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, epoxy poly(meth)acrylate such as epoxy di(meth)acrylate formed by reacting bisphenol A diepoxy with (meth)acrylic acid, urethane poly(meth)acrylate such as urethane tri(meth)acrylate formed by reacting trimer of 1,6-hexamethylene diisocyanate with 2-hydroxy ethyl (meth)acrylate, urethane di(meth)acrylate formed by reacting isophorone diisocyanate with 2-hydroxy propyl (meth)arylate, urethane hexa(meth)acrylate formed by reacting isophorone diisocyanate with pentaerythritol tri(meth)acrylate, urethane di(meth)acrylate formed by reacting dicyclo methane diisocyanate with 2-hydroxy ethyl (meth)acrylate, or urethane di(meth)acrylate formed by reacting 2-hydroxy ethyl (meth)acrylate with an urethane reactant of dicyclo methane diisocyanate and poly(n=6 to 15) tetramethylene glycol, polyester (meth)acrylate formed by reacting trimethylolethane with succinic acid and (meth)acrylic acid, or polyester poly(meth)acrylate such as polyester (meth)acrylate formed by reacting trimethylol propane with succinic acid, ethylene glycol and (meth)acrylic acid.
Organic-inorganic hybrid (meth)acrylate obtained by condensing colloidal silica with, for instance, (meth)acryloyloxy alkoxysilane is also used for raising, for example, the hardness of the coating. Examples therefor are an organic-inorganic hybrid vinyl compound or an organic-inorganic hybrid (meth)acrylate compound containing a combination of, for instance, colloidal silica with any one selected from: vinyltrimethoxysilane, vinyltriethoxysilane, p-styryltrimethoxysilane, 3-(meth)acryloxy propyl methyldimethoxysilane, 3-(meth)acryloxy propyl trimethoxysilane, 2-(meth)acryloxy ethyl trimethoxysilane, 2-(meth)acryloxy ethyl triethoxysilane, 3-(meth)acryloxy propylmethyl diethoxysilane and 3-(meth)acryloxy propyl triethoxysilane.
Among the above compounds, in view of dynamics characteristics of the cured product after the curing with active energy or the like, the preferable compositions are monofunctional (meth)acrylate or polyfunctional (meth)acrylate having polymerizable unsaturated bond. Monofunctional (meth)acrylate is more preferable. Further, in view of the transparency of the obtained polymer, methyl methacrylate is particularly preferable.
The content of the monomer (B) in the monomer component is 65 to 99.99 mol %, more preferably 80 to 99.9 mol %. When the content of the monomer (B) is 65 mol % or more, the cured coating film has sufficient weather resistance and transparency. When the content of the monomer (B) is 99.99 mol % or less, the insufficient curing of the coating is suppressed. As the result, the toughness, heat resistance and wear resistance of the cured coating film are enhanced.
The monomer for the monomer (B) may be made of a single one of the above materials or a combination of two or more of the above materials.
Further, in view of the dynamics characteristics, transparency and weather resistance of the cured product after the curing, the monomer (B) preferably contains methyl methacrylate at the content of 50 mol % or more of the entire monomer (B), and the content is more preferably 60 to 100 mol %. When the content of methyl methacrylate is 60 mol % or more, the cured coating film has more sufficient weather resistance and transparency. When the content of methyl methacrylate is 99.9 mol % or less, the insufficient curing of the coating is further suppressed. As the result, the toughness, heat resistance and wear resistance of the cured coating film are further enhanced.
<Monomer (C)>
The curable composition according to the invention may further contain, in addition to the monomer (A) and the monomer (B), a polymer (C) containing a monomer (C) polymerizable with the monomer (A). The monomer (C) is a polymerizable monomer other than the monomer (A). The monomer (C) is not limited to a specific one as long as it is polymerizable with the monomer (A). The monomer (C) is preferably soluble in a mixture of the monomers (A) and (B). Examples of the monomer (C) are those materials enumerated in the description of the monomer (B). Among such materials, the monomer (C) preferably contains the methyl methacrylate units at the content of 50 mass % or more of the monomer (C).
The content of the polymer (C) is preferably 10 to 100 parts by mass when the monomer component is 100 parts by mass, more preferably 10 to 80 parts by mass.
The molecular weight of the polymer (C) is, but not limited thereto, preferably in the range of 10,000 to 1,000,000, more preferably 20,000 to 300,000 in terms of weight-average molecular weight (Mw) because the polymer (C) can be easily mixed and dissolved with the monomer.
The manufacturing method of the polymer (C) is not subject to any limitation. The polymer (C) is preferably manufactured by radical polymerization of the monomers. The monomers may be polymerized in the presence of solvent, or the monomers alone may be polymerized by mass polymerization.
When the polymer (C) is obtained by radical polymerization of the monomers containing at least the monomer (A), the polymerization temperature of the radical polymerization is preferably 210° C. or less. When the temperature is 210° C. or less, the HALS skeleton is stably incorporated into the cured product, and a transparent cured product is obtained.
<Radical Polymerization Initiator (D)>
The curable composition according to the invention may contain the radical polymerization initiator (D) as described above. The radical polymerization initiator (D), which may be suitably selected in view of the solubility of the initiator in the curable composition, is not subject to any limitation.
Concrete examples of the radical polymerization initiator (D) are preferably polymerization initiators activated by irradiation of active energy rays, and among them photo polymerization initiators are preferable. Examples of such radical polymerization initiator (D) are carbonyl compounds such as benzoin, benzoin monomethyl ether, benzoin isopropyl ether, acetoin, benzyl, benzophenone, p-methoxybenzophenone, diethoxyacetophenone, benzyl dimethyl ketal, 2,2-diethoxyacetophenone, 1-hydroxycyclohexyl phenyl ketone, methyl phenyl glyoxylate, and 2-hydroxy-2-methyl-1-phenylpropane-1-on; sulfur compounds such as tetramethyl thiuram monosulphide and tetramethyl thiuram disulphide; phosphorus compounds such as 2,4,6-trimethylbenzoil diphenylphosphine oxide, 2,4,6-trimethylbenzoil phenylethoxy phosphine oxide, bis(2,4,6-trimethyl benzoil)-phenyl phosphine oxide and bis(2,6-dimethoxy benzoil)-2,4,4-trimethyl-pentylphosphine oxide; 2-benzyl-2-dimethylamino-1-(4-morpholino phenyl) butanone-1; or camphorquinone. These inhibitors may be used alone or in combination of two or more of them. These photo polymerization initiators may be optionally combined according to the required film performance.
The content of the radical polymerization initiator (D) is preferably in the range of 0.1 to 10 parts by mass when the summed amount of the monomer (A) and the monomer (B) is 100 parts by mass, more preferably in the range of 0.2 to 6 parts by mass. When the content of the radical polymerization initiator (D) is 0.1 parts by mass or more, the curing speed of the coated cured product tends to be sufficiently increased. As the result, the obtained cured coating film tends to have excellent hardness (wear resistance) and weather resistance, and tends to be closely attached to the substrate. When the content of the radical polymerization initiator (D) is 10 parts by mass or less, the coloring of the cured coating film and the reduction in the weather resistance thereof are prevented.
<Ultraviolet Absorber (E)>
The curable composition according to the invention may contain an ultraviolet absorber (E). The ultraviolet absorber (E) is, but not limited thereto. The ultraviolet absorber (E) is preferably selected in the light of its uniform solubility ability of facilitating curing by active energy rays, and ability of providing the obtained cured product with the desired weather resistance. Ultraviolet absorbers particularly preferable for the ultraviolet absorber (E) are compounds: that are derived from materials based on benzophenone, benzotriazole, phenyl salicylate, phenyl benzoate or hydroxyphenyl triazine; and whose wavelength of maximum absorption is in the range of 240 to 380 nm. In particular, benzophenone-based ultraviolet absorbers, benzotriazole-based ultraviolet absorbers and hydroxyphenyl triazine-based ultraviolet absorbers are preferable for the ultraviolet absorber (E). Further, a combination of two or more of the above compounds in use is the most preferable.
Among the above compounds, preferably, concrete examples of the ultraviolet absorber (E) are 2-hydroxy-4-octoxybenzophenone and 2,4-dihydroxy benzophenone (i.e., benzophenone-based materials), 2-(2-hydroxy-tert-butylphenyl)benzotriazole (i.e., benzotriazole-based material), and 2-[4-(octyl-2-methylethanoate)oxy-2-hydroxyphenyl]-4,6-[bis(2,4-dimethylphenyl)]-1,3,5-triazine (i.e., hydroxyphenyl triazine-based material). A combination of two or more of the above in use is more preferable. The content of the ultraviolet absorber (E) is preferably 0.01 to 10 parts by mass when the summed amount of the monomer (A) and the monomer (B) is 100 parts by mass, more preferably 0.05 to 1 parts by mass. When the content of the ultraviolet absorber (E) is 2 parts by mass or more, the cured coating film has sufficient weather resistance. When the content of the ultraviolet absorber (E) is 30 parts by mass or less, the insufficient curing of the coating is further suppressed. Further, the hardness, heat resistance and wear resistance of the cured coating film are not reduced.
The curable composition preferably contains the above components (A), (B) and (D) as the primary components, and may further preferably contain the component (E).
If required, the curable composition may further contain a variety of additives such as organic solvent, antioxidant, yellow turning inhibitor, bluing agent, colorant, leveling agent, antifoaming agent, thickener, antisettling agent, antistatic agent, and surfactant. The antioxidant may be a phenol-based antioxidant such as IRGANOX 1010, IRGANOX 1076 or IRGANOX 1035 (each manufactured by BASF Ltd. (previously known as CIBA Limited)), sulfur-based antioxidant such as SUMILIZER TP-D (manufactured by Sumitomo Chemical Company, Limited) or Adekastab AO series (manufactured by ADEKA Corporation) or phosphorus-based antioxidant. The organic solvent is suitably selected according to the coating method. Specifically, when the curable composition is applied to spray coating, the organic solvent is preferably a suitable combination of alcohol-based solvent such as isobutanol, ester-based solvent such as n-butyl acetate, ketone-based solvent such as methyl isobutyl ketone and aromatic-based solvent such as toluene. Further, the active energy ray-curable composition (hereinafter also referred to as a coating material) preferably has a viscosity of 20 mPa·s or less. When the curable composition is used in coating such as shower flow coating or dip coating, the viscosity of the coating material is preferably set at 100 mPa·s or less. On the other hand, when the curable composition is used in a high-solid coating material having a solid content of more than 80 mass %, it is desired that the solvent for the curable composition be suitably selected in the view of the solubility of the additives such as ultraviolet absorbers.
<Polymerization>
Polymerization of the curable composition is not subject to any limitation. In polymerizing the curable composition, active energy ray is usable. Examples of the active energy ray are X-ray, ultraviolet and electron ray. The active energy ray is preferably ultraviolet.
Ultraviolet is irradiated by a variety of ultraviolet irradiators. Examples of the irradiating source are high-pressure mercury lamps, low-pressure mercury lamps, metal-halide lamps, Xenon lamps, chemical lamps, bacterical lamps, black lighting devices and ultraviolet LEDs.
The irradiation intensity of the active energy ray is suitably determined based on the relationship between the concentration of the polymerization initiator contained in the curable composition and dissolvable by active energy rays and the irradiation time. Further, in the above polymerizable liquid polymerizable with the active energy ray, the irradiation intensity is preferably in the range of 1 mW/cm 2 to 30 mw/cm 2 , in view of the monomer growth speed. Too low irradiation intensity is not preferable. Specifically, when the irradiation intensity is too low, the polymerization initiator may not sufficiently dissolve, and the polymerization speed may be decreased. On the other hand, too high irradiation intensity is not preferable. Specifically, when the irradiation intensity is too high, no matter how much the initiator is increased, the monomer growth speed is not sufficiently increased in the polymerizable liquid polymerizable with active energy rays according to this method. Thus, much of the initiator is consumed in the termination reaction. When the irradiation intensity is too high, the reduction in the molecular amount of the product sheet and the excessive irradiation of active energy rays may cause the product to turn yellow.
The curable composition is polymerized into a cured coating film by irradiation with active energy rays after being applied to a substrate, a plastic product. Examples of the plastic are preferably a variety of thermoplastic resins and heat curing resins. These resins have been thus far demanded to, for instance, improve their weather resistance. Examples of the thermoplastic resins and heat curing resins are polymethyl methacryl resins, polycarbonate resins, polyester resins, poly(polyester) carbonate resins, polystylene resins, ABS resins, AS resins, polyamide resins, polyarylate resins, polymethacrylimide resins, polyallyl diglycol carbonate resins, polyolefin resins and amorphous polyolefin resins. In particular, polymethyl methacryl resins, polycarbonate resins, polystylene resins, polymethacrylimide resins and amorphous polyolefin resins are excellent in transparency, and improvement of the wear resistance in these resins has been strongly demanded. Accordingly, the coating composition according to the invention is effectively applicable to these resins in particular. When the coating material is cured with the irradiation of the active energy ray, the coating composition is applied to the substrate to have a predetermined thickness, and the solvent is thereafter volatilized. Then, using, for instance, a high pressure mercury lamp or metal-halide lamp, ultraviolet or electron ray is irradiated. The atmosphere under which the irradiation is conducted may be air atmosphere or may be atmosphere of inert gas such as nitrogen or argon.
The polymer obtained by polymerizing the curable compositions according to the invention may be added as a light stabilizer to a polymerizable composition intended to be used outdoor in particular. Such a polymerizable composition is mainly applicable to the exterior of automobile headlamp lenses and vehicle sensors. The exterior substrate of the headlamp lenses or the vehicle sensors are made of polycarbonate. Polycarbonate has high impact resistance, heat resistance, transparency and lightness. Therefore, polycarbonate is used as the material for headlamp lenses or vehicle sensors. However, polycarbonate may not have characteristics such as chemical resistance, weather resistance and excoriation resistance. Thus, polycarbonate is preferably applied with a coating material containing the polymer obtained by polymerizing the curable composition according to the invention. In other words, the polymerizable composition contains at least the polymer obtained by polymerizing the curable composition according to the invention and the polymerizable monomers.
The curable composition according to the invention is applicable as a coating material. Polycarbonate whose surface is applied with the coating material formed of the polymer obtained from the curable composition according to the invention has the characteristics comparative to glass, and is light in weight and easy to mold. Therefore, the polycarbonate whose surface is applied with the coating material is favorably applicable not only to automobile headlamp lenses and vehicle sensors but also in other fields. The polycarbonate whose surface is applied with the coating material is widely applicable to, for instance, outdoor signs, greenhouses, window glasses of outdoor buildings, roofs and balconies of terraces and garage and gauge covers.
Besides the above usage, the curable composition may be applied to a variety of resin sheets or resin films to have a predetermined thickness. After being applied thereto, the solvent is volatilized, and then irradiated by, for example, ultraviolet or electron rays using a high pressure mercury lamp or metal-halide lamp. The atmosphere under which the irradiation is conducted may be air atmosphere or may be atmosphere of inert gas such as nitrogen or argon.
The polymer obtained from the curable composition according to the invention is also applicable as resin sheets.
When the resin sheets are manufactured from the curable composition according to the invention, the content of the methyl methacrylate unit in the obtained polymer is preferably 50 mol % or more. In the above, the curable composition preferably uses polymethyl methacrylate as the polymer (C) described above, in view of the optical characteristics.
The polymer used according to the invention preferably has a weight-average molecular weight Mw of 30,000 to 500,000. When the polymer has the weight-average molecular weight of 30,000 or more, the heat resistance of the manufactured products is further enhanced. On the other hand, when the polymer has the weight-average molecular weight of 500,000 or less, the time for dissolving various components into the polymer during the preparation of the curable composition is shortened.
The curable composition preferably has a viscosity of 5000 mPa·s or more, more preferably 10000 mPa·s or more at 20° C. With this configuration, when the curable composition is fed to an endless belt, the curable composition is formed into products having a predetermined thickness. Alternatively, by covering either surface of the composition with a material having low rigidity (e.g., film), the surface of the composition has favorable outer appearance.
The method of feeding the curable composition to the endless belt is not subject to any limitation. Examples of the methods are a method to feed the composition through a typical piping or hose, and a variety of coating methods. The curable composition is fed to the endless belt and formed into continuous sheet. Accordingly, the curable composition is preferably fed by a feeding die to form a sheet shape. Examples of the method to form the curable composition into sheet shape are a method of feeding the curable composition via the feeding die as described above, and a method of spreading the curable composition fed to the endless belt using a roll and a roll mediated by the endless belt. In addition, the above methods may be combined to form the curable compositions into sheet shape.
The material of the belt in use is not limited to a specific one. The material may be freely selected (e.g., a metal or a resin), as long as the belt holds the curable composition. In order to manufacture the resin sheet in a continuous form, the belt is preferably an endless belt. Since the polymerization and curing of the composition involves polymerization shrinkage, the endless belt is more preferably a metal endless belt having high rigidity. In view of corrosion of the monomers, the endless belt is further preferably a stainless endless belt. The surface of the resin sheet transcribes the surface of the endless belt. Therefore, the endless belt is the most preferably a stainless endless belt whose surface is processed with mirror finishing.
The curable composition fed to the belt is covered with active energy ray-transmissive film.
The active energy ray-transmissive film in use is made of a transparent flexible synthetic resin film. The active energy ray-transmissive film is preferably made of film deformed at 100° C. or more to prevent the film from being deformed by heat during the polymerization. Examples of the film are film of synthetic resin such as polyethylene telephthalate, polyethylene naphthalate or polycarbonate. Among the above materials, polyethylene telephthalate film is preferably usable, in view of its high permeability of the active energy ray and its high surface texture. In view of the rigidity, the thickness of the film is preferably 10 μm or more, more preferably 50 μm or more. In view of the cost, the thickness is preferably 300 μm or less, more preferably 200 μm or less.
The surface of the active energy ray-transmissive film in contact with the active energy ray-curable composition is transcribed in the surface of the resin sheet obtained as the product. Therefore, the surface roughness (Ra) provided in JIS B0601 is preferably 100 nm or less, more preferably 10 nm or less.
The width of the active energy ray-transmissive film is set to be equal to or more than the width of the active energy ray-curable composition spread on the belt. The “width” herein means the length extending in the direction perpendicular to the direction in which the belt is transported.
The widthwise ends of the active energy ray-transmissive film are preferably both attached to the belt by adhesive tapes. With this configuration, the active energy ray-transmissive film serves similarly to a gasket. In other words, by closing the both ends of the active energy ray-transmissive film, the active energy ray-curable composition is prevented from leaking through the ends.
The adhesive tapes to be used are not subject to any limitations, as long as the adhesive tapes close the ends. The width of the adhesive tapes may be suitably determined. Examples of the material for the adhesive tapes are polyester-based resin such as PET, polyolefin-based resin such as polypropylene, polyimide-based resin, fluorine-based resin such as PTFE, cloth such as cotton cloth, staple fiber and non-woven textile fabrics, and aluminum foil. Examples of the adhesive for use in the adhesive tapes are acryl-based adhesive, silicone-based adhesive or rubber-based adhesive. The adhesive tapes may be one-sided adhesive tapes or double-sided adhesive tapes. When the ends are closed using one-sided adhesive tapes, such one-sided adhesive tapes are exemplarily attached as illustrated in FIG. 1 . When the ends are closed using double-sided adhesive tapes, such double-sided adhesive tapes are exemplarily attached as illustrated in FIG. 2 .
When one-sided adhesive tapes are utilized, the widthwise ends of the active energy ray-transmissive film each are preferably located at positions interior with respect to the widthwise ends of the belt, spaced apart respectively from the widthwise ends of the belt by 5 mm or more. With this configuration, the tapes are easily attached.
When the adhesive tapes are removed from the belt, the belt is preferably free from adhesive of the adhesive tapes. More preferably, the adhesive of the adhesive tapes does not remain on the belt when the adhesive tapes are removed from the belt after the adhesive tapes are heat-treated under the condition 1 described below. Further preferably, the adhesive of the adhesive tapes does not remain on the belt when the adhesive tapes are removed from the belt after the adhesive tapes are heat-treated under the condition 2 described below. With this configuration, contamination during the manufacturing process is prevented. Alternatively, the belt is prevented from having adhesive residual spots formed by repeatedly attaching the tapes to the belt.
Condition 1: heat treatment under the atmosphere of 100° C. for 20 minutes
Condition 2: heat treatment under the atmosphere of 150° C. for 10 minutes
Examples of the adhesive tapes that do not leave their adhesive on the belt after being heat-treated under the above condition 1 are No. 31B manufactured by Nitto Denko Corporation, No. 644 manufactured by Teraoka Seisakusho Co., Ltd., and No. 754 and No. 4734 manufactured by Sumitomo 3M Limited. Further, examples of the adhesive tapes that do not leave their adhesive on the belt after being heat-treated under the above condition 2 are No. 609 manufactured by Teraoka Seisakusho Co., Ltd., No. 923UL manufactured by Nitto Denko Corporation, and No. 5434 manufactured by Sumitomo 3M Limited.
The transportation speed of the belt is preferably 0.5 to 15 m/min, more preferably 1 to 10 m/min. Too low speed is not preferable. Specifically, when the speed is too low, the production amount of the resin sheet obtained as the products may be reduced. Too high speed is not preferable. Specifically, when the speed is too high, the section irradiated with the active energy ray for obtaining the time for polymerization may be increased.
The temperature condition during the curing may be suitably determined based on, for instance, the polymerization speed or the viscosity condition. However, the temperature when the active energy ray is irradiated is preferably the boiling point of the polymerizable monomer or less. For instance, when methyl methacrylate is used, the temperature is preferably 100° C. or less. In addition, it is known that when methyl methacrylate is contained, the lower the temperature during the polymerization is, the more the syndiotactic component is increased by the location of the bonds between the polymerizable monomer units in the polymer. The more the syndiotactic component is, the higher the glass transition temperature Tg of the polymer tends to be, which leads to higher heat resistance. Accordingly, the polymerization temperature when the active energy ray is irradiated is more preferably 50° C. or less. With this configuration, the heat resistance is enhanced.
The resin cured with the irradiation of the active energy ray may be further suitably subjected to a heat treatment at a temperature equal to or more than the glass transition temperature Tg obtained by the combination of the polymerizable monomer in use and the obtained polymer. With this configuration, the amount of the residue polymerizable monomers is reducible. When methyl methacrylate is used, the heat treatment is preferably conducted at 100° C. or more.
The thickness of the resin sheet is not specifically limited, but it is preferably 0.01 mm or more and 5 mm or less, more preferably 0.1 mm or more and 5 mm or less. When the thickness of the resin sheet is 5 mm or less, polymerization heat is easily eliminated. With this configuration, boiling of the non-polymerized monomers and the foaming within the resin sheets caused by such boiling are prevented. When the thickness of the resin sheet is 0.01 mm or more, the sheet is easily handled, and the advantageous effects of the invention are easily obtained.
The cured coating film or the resin sheet obtained from the curable composition according to the invention is excellent in transparency. The total light transmittance of the cured coating film or the resin sheet obtained by curing the curable composition is preferably 85 to 100%, more preferably 90 to 100%. The haze value thereof is preferably 5% or less, more preferably less than 5%. The cured coating film obtained from the curable composition according to the invention has reduced yellowness. The yellowness of the cured coating film is preferably 10 or less, more preferably 5 or less.
EXAMPLES
In the following description, the invention will be described further in details, by describing synthesis examples, examples and Comparative Examples. The invention is not specifically limited to such synthesis examples or examples.
In the following description, the formulation and number average molecular weight of the polymers synthesized in the synthesis examples, examples, and comparative examples were evaluated by the following method.
In the description of the examples, the “parts” and “%” respectively mean “parts by mass” and “mass %.”
(1) Identification of Monomer (A)
Identification of the monomer (A) structure was conducted using 1H-NMR JNM-EX270 (a product name, manufactured by JEOL Ltd.).
The monomer (A) was dissolved in deuterated chloroform. The compound was identified based on the peak integrated intensity and the peak position. The measurement temperature was 25° C., and the cumulative number was 16.
(2) Polymerization Conversion
The polymerization conversion of the monomer component was identified using 1H-NMR JNM-EX270 (a product name, manufactured by JEOL Ltd.).
In the copolymerization of the monomer (A) and methyl methacrylate, the polymerization conversion was calculated based on the integral ratio between: the peak attributed to the hydrogen in the alkoxyl group originating from the monomer and the polymer; and the peak attributed to the hydrogen in the C—C double bonds originating from the monomer.
(3) Outer Appearance (Coloring)
By visually observing the product, whether or not the product was colored was determined.
(4) Weather Resistance Test
The product was cut into a size of 40 mm×40 mm. After the surface of the product was cleaned with neutral detergent, a weather resistance test was conducted using a Metal Weather KU-R5N-A (manufactured by Daipla Wintes Co., Ltd.) with an irradiation intensity of 80 mW/cm 2 at a temperature of 63° C. for 344 hours.
The total light transmittance and haze value of the product were measured using a Haze Meter HM-65 W Type (manufactured by Murakami Color Research Laboratory Co., Ltd.) according to the method described in JIS-K7105.
Yellowness was measured by measuring the transmission spectrums before and after the weather resistance test using a spectrophotometer MCPD-3000 (manufactured by Otsuka Electronics Co., Ltd.). The measured values were corrected according to the following formula, based on the thickness of the sample.
Yellowness(corrected value)=Yellowness(measured value)/Plate Thickness (mm)
In addition, a difference between the yellowness (corrected value) before the weather resistance test and the yellowness (corrected value) after the weather resistance test was obtained, and the difference was then used as the displacement of the yellowness.
Synthesis Example 1
Synthesis of 1-octyloxy-2,2,6,6-tetramethyl-4-methacryloyloxy piperidine (monomer (A-1))
A solution prepared by dissolving 30.3 g (330 mmol) of triethylamine and 34.4 g (200 mmol) of 4-hydroxy-2,2,6,6-tetramethyl piperidine-N-oxide (TEMPOL) in 200 ml of tetrahydrofuran (THF) was added with 25.5 g (250 mmol) of acetic anhydride at 0° C.
The solution was warmed up to 25° C. and left for reaction for 12 hours, and concentrated using a rotary evaporator. The residue was put into 1 litter of iced water. By filtering the precipitated orange solid, 33.8 g of 4-acetyloxy-2,2,6,6-tetramethyl piperidine-N-oxide was obtained.
In 200 ml of octane, 21.4 g (100 mmol) of 4-acetyloxy-2,2,6,6-tetramethyl piperidine-N-oxide was dissolved. Subsequently, 0.9 g (6 mmol) of molybdenum oxide (VI) was added to the resulting solution, and the solution was then dehydrated by heating under reflux. While the solution was being dehydrated by azeotropy, 19.2 g (150 mmol) of the 70% t-butyl hydroperoxide aqueous solution was dropped therein for 9 hours, and left so that reactions took place. Then, the solution was cooled to room temperature. Subsequently, by gradually adding 30 ml of saturated aqueous solution of sodium bisulphites thereto, non-reacted peroxides were deactivated. The organic layers were concentrated using a rotary evaporator. Then, the residue was dissolved in 100 ml of ethanol, added with 6.7 g (150 mmol) of potassium hydroxide, and left for reaction at 25° C. for 2 hours.
The mixture was concentrated using a rotary evaporator. Then, 200 ml of water was added to the residue, and extraction was conducted using 200 ml of dichloromethane in total. After the organic layers were concentrated using a rotary evaporator, the organic layers were dissolved in 20 ml of dichloromethane and 10 ml of triethylamine. The solution was added with 10.5 g (100 mmol) of methacryloyl chloride at 0° C., and left for reaction for 1 hour. The mixture was concentrated using a rotary evaporator. Then, 200 ml of water was added to the residue, and extraction was conducted using 200 ml of acetic ether in total. The organic layers were concentrated using a rotary evaporator. The residue was refined by column chromatography (silica gel, hexane/acetic ether=20/1 in volume ratio). With this operation, 26.3 g of colorless liquid was obtained (the yield was 74.4%).
By 1H-NMR measurement, the obtained product was identified as the monomer (A-1) represented by the formula (101) as follows.
1H-NMR (CDCl 3 ): δ (ppm): 0.89 (m, 6H), 1.17 (m, 10H), 1.18 (s, 6H), 1.21 (s, 6H), 1.61 (m, 2H), 1.85 (m, 2H), 1.92 (s, 3H), 3.60-3.93 (m, 1H), 5.07 (m, 1H), 5.53 (s, 1H), 6.03 (s, 1H)
In the formula, Oc represents any one of the structures represented by the following formulae (I) to (III). In the following description, the structures represented by the following formulae (I) to (III) will be referred to as “Oc.”
Synthesis Example 2
Synthesis of 1-propyloxy-2,2,6,6-tetramethyl-4-methacryloyloxy piperidine (monomer (A-2))
A solution prepared by dissolving 48.6 g (480 mmol) of triethylamine and 68.9 g (400 mmol) of 4-hydroxy-2,2,6,6-tetramethyl piperidine-N-oxide (TEMPOL) in 100 ml of dichloromethane was added with 47.8 g (440 mmol) of trimethylsilyl chloride at 0° C.
The solution was warmed up to 25° C. and left for reaction for 2 hours. Then, the solution was concentrated using a rotary evaporator. 500 ml of water was added to the residue, and extraction was conducted using 500 ml of acetic ether in total. The organic layers were concentrated using a rotary evaporator, and the residue was dissolved in hexane. By recrystallization, 96.2 g of 4-trimethylsilyloxy-2,2,6,6-tetramethyl piperidine-N-oxide was obtained.
4.6 g (190 mmol) of chipped magnesium, 100 ml of dehydrated THF and 10 mg of iodine were put into the reaction container. The atmosphere in the container was replaced with argon. Subsequently, 23.4 g (190 mmol) of 1-bromopropane was dropped into the container while the temperature within the container was kept at 55° C. to 65° C., and Grignard reactant was prepared.
In another reaction container, 96.2 g (394 mmol) of 4-trimethylsilyloxy-2,2,2,6-tetramethyl piperidine-N-oxide was dissolved in 100 ml of dehydrated THF. The prepared Grignard reactant was dropped thereinto at 0° C. After being left for reaction for 3 hours, the solution was concentrated using a rotary evaporator. 500 ml of water was added to the residue, and extraction was conducted using 500 ml of acetic ether in total. The organic layers were concentrated using a rotary evaporator. The residue was refined by column chromatography (silica gel, hexane/acetic ether=20/1 in volume ratio), and 38.5 g of 1-(1-propyl)oxy-2,2,6,6-tetramethyl-4-trimethylsilyloxy piperidine was obtained.
38.5 g of 1-(1-propyl)oxy-2,2,6,6-tetramethyl-4-trimethylsilyloxy piperidine was dissolved in 300 ml of methanol. The solution was added with 0.14 g (0.1 mmol) of potassium carbonate and left for reaction for 3 hours. Then, the solution was concentrated using a rotary evaporator. 300 ml of water was added to the residue, and extraction was conducted using 300 ml of acetic ether in total. The organic layers were concentrated using a rotary evaporator. The residue was dissolved in 20 ml of dichloromethane and 20 ml of triethylamine. The solution was added with 14.1 g (135 mmol) of methacryloyl chloride at 0° C. After the solution was left for reaction for 1 hour, the precipitated triethylamine hydrochloride was filtered. The solution was concentrated using a rotary evaporator. The residue was refined by column chromatography (silica gel, hexane/acetic ether=20/1 in volume ratio), and 29.7 g of colorless liquid was obtained (the yield was 26.2%).
By 1H-NMR measurement, the obtained product was identified as the monomer (A-2) represented by the formula (102) as follows.
1H-NMR (CDCl 3 ): δ (ppm): 0.94 (t, 3H), 1.21 (s, 12H), 1.53 (m, 2H), 1.61 (m, 2H), 1.86 (m, 2H), 1.92 (s, 3H), 3.70 (t, 2H), 5.07 (m, 1H), 5.53 (s, 1H), 6.06 (s, 1H)
Synthesis Example 3
Synthesis of 1-octyloxy-2,2,6,6-tetramethyl-4-(2-(2-methacryloyloxy) ethoxy) ethoxy piperidine (monomer (A-3))
17.8 g (100 mmol) of 2,2,6,6-tetramethyl-4-hydroxy piperidine-N-oxide was dissolved in 100 ml of acetone. 34 g (300 mmol) of 30% hydrogen peroxide aqueous solution was slowly added thereto for 10 minutes or more. While the solution was cooled to 5° C., 0.49 g (5.0 mol %) of copper chloride (I) was added thereto. The temperature of the reaction mixture was kept at 5° C. to 55° C. In 15 minutes later, 0.5 g of 35% acidum hydrochloricum was added thereto, and the reaction mixture was stirred for 2 hours at the room temperature. In 2 hours later, the reaction mixture was added with 50 ml of sodium bisulfite aqueous solution (4 mol/L) and 100 ml of saturated aqueous solution of potassium bicarbonate, and extraction was conducted using 300 ml of acetic ether. By concentrating the organic layers using a rotary evaporator, 1-methyloxy-2,2,6,6-tetramethyl-4-hydroxy piperidine was obtained.
The obtained 1-methyloxy-2,2,6,6-tetramethyl-4-hydroxy piperidine was dissolved in 50 ml of dichloromethane and 50 ml of triethylamine. The solution was slowly added with 10.4 g (100 mmol) of methacryloyl chloride at 0° C. The solution was gradually warmed up to the room temperature and left for reaction for 1 hour. In 1 hour later, the reaction mixture was concentrated using a rotary evaporator. 300 ml of water was added to the residue, and extraction was conducted using 300 ml of acetic ether. The organic layers were concentrated using a rotary evaporator. The residue was refined by column chromatography (silica gel, hexane/acetic ether=10/1 in volume ratio), and 19.0 g of colorless liquid was obtained (the yield was 74.3%).
By 1H-NMR measurement, the obtained product was identified as the monomer (A-3) represented by the formula (103) as follows.
1H-NMR(CDCl 3 ): δ (ppm): 0.89 (m, 6H), 1.15 (s, 6H), 1.18 (s, 6H), 1.29 (m, 10H), 1.30-1.41 (m, 2H), 1.59-1.82 (m, 2H), 1.95 (s, 3H), 2.62 (m, 4H), 3.73 (m, 1H), 4.35 (s, 4H), 5.02 (m, 1H), 5.60 (s, 1H), 6.13 (s, 1H)
Synthesis Example 4
Synthesis of 1-octyloxy-2,2,6,6-tetramethyl-4-(4-(2-methacryloyloxy) ethoxy-1,4-dioxo) butoxy piperidine (monomer (A-4))
A solution prepared by dissolving 20.2 g (200 mmol) of triethylamine and 26.0 g (100 mmol) of 2,2,6,6-tetramethyl-4-(2-(2-hydroxy) ethoxy) ethoxy piperidine in 100 ml of THF was added with 12.3 g (120 mmol) of acetic anhydride at 0° C.
The solution was warmed up to 25° C. and left for reaction for 12 hours. Then, the solution was concentrated using a rotary evaporator. 500 ml of water was added to the residue, and extraction was conducted using 500 ml of acetic ether in total. The organic layers were concentrated using a rotary evaporator. The residue was refined by column chromatography (silica gel, hexane/acetic ether=1/1 in volume ratio), and 5.6 g (22 mmol) of 2,2,6,6-tetramethyl-4-(2-(2-acetyloxy) ethoxy) ethoxy piperidine was obtained.
In 100 ml of octane, 3.0 g (10 mmol) of 2,2,6,6-tetramethyl-4-(2-(2-acetyloxy) ethoxy) ethoxy piperidine was dissolved. After being added with 0.07 g (0.5 mmol) of molybdenum oxide (VI), the solution was dehydrated by heating under reflux. While the solution was being dehydrated by azeotropy, 12.8 g (100 mmol) of the 70% t-butyl hydroperoxide aqueous solution was dropped therein for 6 hours, left so that reactions took place. Then, the solution was cooled to the room temperature. Subsequently, by gradually adding 20 ml of saturated aqueous solution of sodium bisulphites thereto, non-reacted peroxides were deactivated. The organic layers were concentrated using a rotary evaporator. Then, the residue was dissolved in 15 ml of ethanol. The solution was added with 0.6 g (15 mmol) of sodium hydroxide, and left for reaction for 2 hours at 25° C.
The mixture was concentrated using a rotary evaporator. 100 ml of water was added to the residue, and extraction was conducted using 100 ml of dichloromethane in total. The organic layers were concentrated using a rotary evaporator. Then, the organic layers were dissolved in 10 ml of triethylamine, and the solution was added with 1.1 g (10 mmol) of methacryloyl chloride at 0° C., and left for reaction for 1 hour. The mixture was concentrated using a rotary evaporator. 50 ml of water was added to the residue, and extraction was conducted using 50 ml of acetic ether in total. The organic layers were concentrated using a rotary evaporator. The residue was refined by column chromatography (silica gel, hexane/acetic ether=3/1 in volume ratio), and 1.9 g (3.1 mmol) of colorless liquid was obtained (the yield was 3.1%).
By 1H-NMR measurement, the obtained product was identified as the vinyl monomer (A-4) represented by the formula (104) as follows.
1H-NMR(CDCl 3 ): δ (ppm): 0.89 (m, 6H), 1.14 (s, 12H), 1.28 (m, 10H), 1.35-1.47 (m, 2H), 1.63-1.84 (m, 2H), 1.95 (s, 3H), 3.54-3.87 (m, 2H), 3.61 (m, 4H), 3.75 (t, 2H), 4.30 (t, 2H), 5.57 (s, 1H), 6.14 (s, 1H)
Synthesis Example 5
Synthesis of 1-methyloxy-2,2,6,6-tetramethyl-4-methacryloyloxy piperidine (monomer (A-5))
In 100 ml of octane, 6.4 g (30 mmol) of 4-acetyloxy-2,2,6,6-tetramethyl piperidine-N-oxide, which was synthesized according to the method described in Synthesis Example 1 above, was dissolved. After being added with 0.1 g (0.7 mmol) of molybdenum oxide (VI), the solution was dehydrated by heating under reflux. While the solution was being dehydrated by azeotropy, 12.8 g (100 mmol) of the 70% t-butyl hydroperoxide aqueous solution was dropped therein for 6 hours, left so that reactions took place. Then, the solution was cooled to the room temperature. Subsequently, by gradually adding 50 ml of saturated aqueous solution of sodium bisulphites thereto, non-reacted peroxides were deactivated. The organic layers were concentrated using a rotary evaporator. Then, the residue was dissolved in 50 ml of ethanol. The solution was added with 2.8 g (50 mmol) of sodium hydroxide, and left for reaction for 4 hours at 25° C.
The mixture was concentrated using a rotary evaporator. 100 ml of water was added to the residue, and extraction was conducted using 100 ml of dichloromethane in total. The organic layers were concentrated using a rotary evaporator. The residue was added with 20 ml of tetrahydrofuran, 4.0 g (40 mmol) of triethylamine and 3.0 g (30 mmol) of succinic anhydride. The solution was stirred continuously for 4 hours at 70° C. In 4 hours later, the solution was concentrated using a rotary evaporator. 100 ml of saturated aqueous solution of ammonium chloride was added to the residue, and extraction was conducted using 100 ml of acetic ether in total.
The organic layers were concentrated using a rotary evaporator. The residue was added with 3.9 g (30 mmol) of 2-hydroxyethyl methacrylate, 0.24 g (2 mmol) of N,N′-dimethyl-4-aminopyridine and 5 ml of dichloromethane. A solution prepared by dissolving 6.2 g (30 mmol) of N, N′-dicyclohexylcarbodiimide in 20 ml of dichloromethane was dropped thereinto at 0° C., and left for reaction for 4 hours. In 4 hours later, the precipitated solid was filtered. The filtrate was concentrated using a rotary evaporator. The residue was refined by column chromatography (silica gel, hexane/acetic ether=5/1 in volume ratio), and 5.58 g of colorless liquid was obtained (the yield was 56.1%).
By 1H-NMR measurement, the obtained product was identified as the vinyl monomer (A-5) represented by the formula (105) as follows.
1H-NMR (CDCl 3 ): δ (ppm): 1.19 (s, 6H), 1.23 (s, 6H), 1.60 (m, 2H), 1.87 (m, 2H), 1.92 (s, 3H), 3.62 (s, 3H), 5.07 (m, 1H), 5.53 (s, 1H), 6.06 (s, 1H)
Example 1
A monomer component was prepared by mixing 60 parts of methyl methacrylate (MMA) with 0.35 parts of the monomer (A-1). The resulting monomer component (100 mol %) contained 0.10 mol % of the monomer (A-1).
To the monomer component, 0.30 parts of 1-hydroxycyclohexyl-phenyl ketone (IRGACURE 184 manufactured by Ciba Specialty Chemicals Inc.) as a polymerization initiator and 0.05 parts of di(2-ethylhexyl) sodium sulfosuccinate (AEROSOL OT-100 manufactured by Mitsui Cyanamid Ltd.) as a release agent were added. The resulting mixture was then dissolved at normal temperature. Subsequently, 40 parts of polymethylmethacrylate (BR-83 manufactured by Mitsubishi Rayon Co., Ltd., 40,000 in weight-average molecular weight) was heat-melted at 80° C. for 30 minutes to give the active energy ray-curable composition (1). Subsequently, the resulting composition (1) was left at 50° C. for 2 hours, and naturally cooled to normal temperature.
Using apparatus similar to that the apparatus illustrated in FIG. 1 , resin sheets were manufactured. A stainless endless belt having a width of 500 mm was used as an endless belt 3. A ultraviolet transmissive film 5 was a polyethylene terephthalate film of 450 mm in width and 188 μm in thickness (COSMOSHINE A4100 manufactured by Toyobo Co., Ltd.). A ultraviolet irradiator 4 was an FL30S-BL Lamp (product name) manufactured by Toshiba Corporation. A pre-heating mechanism 9 and a post-heating mechanism 10 were hot-air heaters, respectively.
The transportation speed of the endless belt 3 was set at 1.5 m/min. The active energy ray-curable composition (1) was fed from a feeding die 1 so that the composition (1) formed a sheet of 400 mm in width and 1 mm in thickness. The ultraviolet transmissive film 5 was covered thereon. Then, with the pre-heating mechanism, the composition was controlled to be 60° C. before being irradiated with the ultraviolet. Using the ultraviolet irradiator 4, ultraviolet was irradiated thereto for 10 minutes at an irradiation intensity of 5 mW/cm 2 . The composition was then heat treated by the post-heating mechanism 10 for 5 minutes at 130° C. Thereafter, the composition was air-cooled to 90° C., and the resin sheet was removed from the ultraviolet transmissive film 5 and the endless belt 3.
The upper and lower surfaces of the obtained transparent resin sheet (product (1)) were flat and smooth, and the product had good outer appearance. The obtained transparent resin sheet had a slightly reduced thickness at its edges, due to flux before the irradiation of ultraviolet or the like.
The polymer conversion, outer appearance and yellowness (due to the weather resistance test) of the product (1) are shown in Table 1.
Examples 2 to 5
Products (2) to (5) were obtained through the same operations as in Example 1 except that the types and amounts of the monomer (A) were changed to those shown in Table 1. The polymer conversion, outer appearance and yellowness (due to the weather resistance test) of the products (2) to (5) are shown in Table 1.
Comparative Examples 1 to 4
Products (6) to (9) were obtained through the same operations as in Example 1 except that: the monomer (A-1) was not used. The HALS shown in Table 2 was used in the amount as shown in Table 2). The polymer conversion, outer appearance and yellowness (due to the weather resistance test) of the products (6) to (9) are shown in Table 2.
Comparative Example 5
A product (10) was obtained through the same operations as in Example 1 (except that the monomer (A-1) was not used). The polymer conversion, outer appearance and yellowness (due to the weather resistance test) of the product (10) are shown in Table 2.
TABLE 1
Total Light
Transmittance
Yellowness (corrected)
Monomer
Outer
[%]
Haze (%)
Weather Resistance Test
MMA
(A)
Conversion
Appearance
before
after
before
after
before
after
Product
[parts]
[parts]
[mol %]
[%]
[color]
test
test
test
test
test
test
displacement
Example 1
1
60
A-1
0.35
0.10
99.3
colorless
92.2
91.8
0.35
0.39
0.22
1.02
0.80
Example 2
2
60
A-2
0.28
0.10
99.2
colorless
92.1
91.2
0.26
0.41
0.22
1.15
0.93
Example 3
3
60
A-3
0.21
0.10
99.4
colorless
92.2
91.8
0.59
0.65
0.20
1.19
0.99
Example 4
4
60
A-4
0.46
0.10
99.1
colorless
91.8
91.9
0.29
0.42
0.21
1.18
0.97
Example 5
5
60
A-5
0.49
0.10
99.2
colorless
91.8
—
0.48
—
0.24
—
—
TABLE 2
Total Light
Transmittance
Yellowness (corrected)
Outer
[%]
Haze (%)
Weather Resistance Test
MMA
HALS
Conversion
Appearance
before
after
before
after
before
after
dis-
Product
[parts]
[parts]
[mol %]
[%]
[color]
test
test
test
test
test
test
placement
Comparative
6
60
LA-87
0.23
0.10
99.3
colorless
91.9
90.2
0.52
0.96
0.23
1.43
1.20
Example 1
Comparative
7
60
LA-82
0.24
0.10
99.3
colorless
92.1
91.6
0.48
1.01
0.23
1.36
1.13
Example 2
Comparative
8
60
LS770
0.24
0.05*
99.3
colorless
92.3
91.2
0.48
1.03
0.21
1.47
1.26
Example 3
Comparative
9
60
TV-292
0.25
0.05*
99.3
colorless
92.0
91.8
0.65
1.02
0.23
1.33
1.10
Example 4
Comparative
10
60
—
—
—
99.3
colorless
92.4
91.6
0.32
0.89
0.23
1.58
1.35
Example 5
ABBREVIATION IN TABLES
LA-87: 2,2,6,6-tetramethyl-4-methacryloyloxy piperidine (LA-87 manufactured by ADEKA Corporation)
LA-82: 1,2,2,6-pentamethyl-4-methacryloyloxy piperidine (LA-82 manufactured by ADEKA Corporation)
LS770: bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate (manufactured by ADEKA Corporation)
TV-292: bis(1,2,2,6,6-pentamethyl-4-piperidyl) sebacate (TV-292 manufactured by Ciba Japan K.K.)
LS 770 and TV-292 have hindered amine structures with piperidine skeletons in their molecules (hereinafter referred to as “HALS portions”). Thus, they were added as HALS portions in amount of 0.10 mol %.
As is clear from Table 1, the product (Examples 1 to 5) obtained from the manufacturing method according to the invention had small yellowness displacement and favorable weather resistance. Comparative Examples 1 to 5, which contained no monomer (A), had great yellowness displacement and inferior weather resistance.
Next, cured coating films obtained from the manufacturing method according to the invention will be described with reference to examples and Comparative Examples, through which the invention will be described in further detail. The invention is not limited by such synthesis examples and examples.
Examples 6 to 15, Comparative Examples 6 to 10
Method of Forming Cured Coating Film Test Piece
Polycarbonate resin plates of 3 mm in thickness (product name “Lexan LS-2” manufactured by General Electric Company) were coated with the curable compositions composed as in Tables 3 and 4 by bar coating to give a cured coating film of 8 μm in thickness. The coated plates were heated in a heating furnace of 60° C. for 90 seconds, and the organic solvents were volatilized. Then, using a high-pressure mercury lamp in the air, energy having a wavelength of 340 to 380 nm and a light integral of 3000 mJ/cm 2 was irradiated to cure the curable compositions. In this manner, products 11 to 25 in the form of the cured coating film were obtained.
<Weather Resistance Test of Cured Coating Film>
The method of the weather resistance test of the cured coating film was as described below. Using a Sunshine Carbon Weather Meter (WEL-SUN-HC-B type weather resistance tester manufactured by Suga Test Instruments Co., Ltd.), the cured coating film on the test pieces was tested. The black panel temperature of the weather resistance tester is 63±3° C. Changes of the cured coating film after exposed to cycles of rainfall of 12 minutes and irradiation of 48 minutes for 3500 hours were observed in the following manner.
<Evaluation Method of Samples Before and After Weather Resistance Test>
(1) Outer Appearance
The outer appearance of the test pieces after the weather test was visually evaluated. The test samples whose surfaces were free from cracks and natural separation were rated as “G.” The test samples whose surfaces had cracks or natural separation were rated as “NG.”
(2) Measurement of Transparency of Test Sample
The total light transmittance and haze value of the test pieces were measured using a Haze Meter HM-65 W Type (manufactured by Murakami Color Research Laboratory Co., Ltd.) according to the method described in JIS-K7105. When the measured haze value after the weather resistance test was 0% or more and less than 5%, such test pieces were rated as good (1). When the haze value was 5% or more and less than 10%, such test pieces were rated as medium (2). When the haze value was 10% or more, such test pieces were rated as bad (3).
(3) Measurement of Yellowness (Yellow Index) of Test Sample
Yellowness (yellow index) of the test pieces were measured using a Multi Channel Photo Detector MCPD-3000 (manufactured by Otsuka Electronics Co., Ltd.) according to the method described in JIS-K7105. When the measured yellow index value after the weather resistance test was 0 or more and less than 5, such test pieces were rated as good (1). When the yellow index value was 5 or more and less than 10, such test pieces were rated as medium (2). When the yellow index was 10 or more, such test pieces were rated as bad (3).
Table 3 shows the compositions of the active energy ray-curable compositions according to Examples 6 to 15. Table 4 shows the compositions of the active energy ray-curable compositions according to Comparative Examples 6 to 10. The results of the weather resistance test conducted on the prepared compositions are also shown. The numeric values in Tables 3 and 4 are represented in parts by mass.
TABLE 3
Monomer
DPHA
TAIC
UA1
BNP
MPG
MAPO
HBPB
Product
(A)
[parts]
[parts]
[parts]
[parts]
[parts]
[parts]
[parts]
[parts]
Example 6
11
A-1
1
33
40
27
1
1
1
10
Example 7
12
A-2
1
33
40
27
1
1
1
10
Example 8
13
A-3
1
33
40
27
1
1
1
10
Example 9
14
A-4
1
33
40
27
1
1
1
10
Example 10
15
A-5
1
33
40
27
1
1
1
10
Example 11
16
A-1
2
33
40
27
1
1
1
10
Example 12
17
A-2
2
33
40
27
1
1
1
10
Example 13
18
A-3
2
33
40
27
1
1
1
10
Example 14
19
A-4
2
33
40
27
1
1
1
10
Example 15
20
A-5
2
33
40
27
1
1
1
10
Results of Weather Resistance Test
Total Light
Solvent
Transmittance
n-butyl
Outer
(%)
Haze (%)
Yellowness
acetate
ECA
Appear-
before
after
before
after
before
after
[parts]
[parts]
ance
test
test
test
test
Rating
test
test
Rating
Example 6
15
13
G
89.1
87.2
1.3
1.4
1
1.2
1.5
1
Example 7
15
13
G
88.9
86.9
1.1
1.5
1
1.2
1.8
1
Example 8
15
13
G
89.6
87.9
0.9
1.3
1
1.1
1.3
1
Example 9
15
13
G
88.9
87.1
1.1
1.3
1
1.2
1.3
1
Example 10
15
13
G
90.0
86.9
1.0
1.2
1
1.3
1.6
1
Example 11
15
13
G
89.2
88.3
1.0
1.3
1
1.4
1.8
1
Example 12
15
13
G
90.1
88.6
0.9
1.6
1
1.3
1.4
1
Example 13
15
13
G
88.9
88.1
0.8
1.9
1
1.5
1.8
1
Example 14
15
13
G
89.8
88.8
0.8
1.8
1
1.8
2.0
1
Example 15
15
13
G
90.2
87.9
1.3
2.0
1
1.7
2.1
1
TABLE 4
Monomer
DPHA
TAIC
UA1
BNP
MPG
MAPO
HBPB
Product
(A)
[parts]
[parts]
[parts]
[parts]
[parts]
[parts]
[parts]
[parts]
Comparative
21
LS-
1
33
40
27
1
1
1
10
Example 6
292
Comparative
22
T-152
1
33
40
27
1
1
1
10
Example 7
Comparative
23
LS-
1
33
40
27
1
1
1
10
Example 8
3410
Comparative
24
PR-31
1
33
40
27
1
1
1
10
Example 9
Comparative
25
—
—
33
40
27
1
1
1
10
Example 10
Results of Weather Resistance Test
Total Light
Solvent
Transmittance
n-butyl
Outer
(%)
Haze (%)
Yellowness
acetate
ECA
Appear-
before
after
before
after
before
after
[parts]
[parts]
ance
test
test
test
test
Rating
test
test
Rating
Comparative
15
13
G
89.2
87.2
3.2
12.3
3
1.8
6.9
2
Example 6
Comparative
15
13
G
90.2
86.9
1.0
8.6
2
1.5
3.5
1
Example 7
Comparative
15
13
G
88.6
86.5
1.9
12.1
3
1.6
3.8
1
Example 8
Comparative
15
13
G
89.5
85.9
2.1
6.9
2
1.6
2.9
1
Example 9
Comparative
15
13
G
88.9
86.9
2.3
10.8
3
1.8
2.8
1
Example 10
In Tables 3 and 4, the following signs represent the following compounds.
DPHA: di-pentaerythritol hexaacrylate
UA1: urethane acrylate having a molecular weight of 2500 and synthesized from 2 mol of dicyclohexyl methanediol, 1 mol of nonabutylene glycol and 2 mol of 2-hydroxyethyl acrylate
TAIC: tris(2-acryloyloxyethyl)isocyanurate
HBPB: 2-(2-hydroxy-5-tert-butylphenyl)benzotriazole
BNP: benzophenone
MPG: methyl phenylglyoxylate
MAPO: 2,4,6-trimethylbenzoyl diphenyl phosphine oxide
ECA: ethyl diglycol acetate
LS-292: Product name “Sanol LS-292” manufactured by Sankyo Kasei Co., Ltd. (a mixture of his (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate and methyl (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate)
T-152: Product name “TINUVIN 152” manufactured by Ciba Specialty Chemicals Inc. (2,4-bis [N-butyl-N-(1-cyclohexyloxy-2,2,6,6-tetramethyl piperidine-4-yl)amino]-6-(2-hydroxyethylamine)-1,3,5-triazin)
LS-3410: Product name “Sanol LS-3410” manufactured by Sankyo Kasei Co., Ltd. (N-methyl-2,2,6,6-tetramethyl piperidyl methacrylate) PR-31: Product name “SANDUVOR PR-31” manufactured by Clariant (Japan) K.K. (propanedioic acid [{4-methoxyphenyl}methylene]-bis(1,2,2,6,6-pentamethyl-4-piperidyl) ester)
In the cured coating film according to Examples 6 to 15, the monomer (A) was used. Accordingly, the cured coating film according to Examples 6 to 15 had good outer experience, good transparency, and yellowness after the weather resistance test.
In the cured coating film according to Comparative Examples 6 to 10, only a known light stabilizer (i.e., other than the monomer (A)) was used, or no HALS portion was included. Therefore, in the cured coating film according to Comparative Examples 6 to 10, either haze value after the weather resistance test after the weather resistance test or the yellowness was not good.
REFERENCE SIGNS LIST
1 Feeding die
2 Curable composition
2 ′ Transparent resin sheet
3 Endless belt
4 Active energy ray irradiator
5 Active energy ray-transmissive film
6 Active energy ray-transmissive film feeding device
7 Active energy ray-transmissive film winding device
8 Upper-side pressing roll
8 ′ Lower-side pressing roll
9 Pre-heating mechanism
10 Post-heating mechanism
11 Main pulley
12 Main pulley | An object of the invention is to provide a curable composition having a HALS skeleton and capable of producing polymers having excellent weather resistance and outer appearance. The present invention provides a curable composition including at least a monomer component that contains a monomer (A) represented by a certain formula and a monomer (B) polymerizable with the monomer (A). In the curable composition, the content of the monomer (A) is 0.01 to 35 mol % in the monomer component, and the content of the monomer (B) is 65 to 99.99 mol % in the monomer component. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional application Ser. No. 60/591,694, entitled “SURGICAL INSTRUMENT INCORPORATING AN ELECTRICALLY ACTUATED ARTICULATION MECHANISM” to Shelton IV, filed 28 Jul. 2004.
FIELD OF THE INVENTION
The present invention relates in general to surgical stapler instruments that are capable of applying lines of staples to tissue while cutting the tissue between those staple lines and, more particularly, to improvements relating to stapler instruments and improvements in processes for forming various components of such stapler instruments including adding bolstering material to the severed and stapled tissue.
BACKGROUND OF THE INVENTION
Endoscopic and laparoscopic surgical instruments are often preferred over traditional open surgical devices since a smaller incision tends to reduce the post-operative recovery time and complications. The use of laparoscopic and endoscopic surgical procedures has been relatively popular and has provided additional incentive to develop the procedures further. In laparoscopic procedures, surgery is performed in the interior of the abdomen through a small incision. Similarly, in endoscopic procedures, surgery is performed in any hollow viscus of the body through narrow endoscopic tubes inserted through small entrance wounds in the skin.
Laparoscopic and endoscopic procedures generally require that the surgical region be insufflated. Accordingly, any instrumentation inserted into the body must be sealed to ensure that gases do not enter or exit the body through the incision. Moreover, laparoscopic and endoscopic procedures often require the surgeon to act on organs, tissues and/or vessels far removed from the incision. Thus, instruments used in such procedures are typically long and narrow while being functionally controllable from the proximal end of the instrument.
Significant development has gone into a range of endoscopic surgical instruments that are suitable for precise placement of a distal end effector at a desired surgical site through a cannula of a trocar. These distal end effectors engage the tissue in a number of ways to achieve a diagnostic or therapeutic effect (e.g., endocutter, grasper, cutter, staplers, clip applier, access device, drug/gene therapy delivery device, and energy device using ultrasound, RF, laser, etc.).
Known surgical staplers include an end effector that simultaneously makes a longitudinal incision in tissue and applies lines of staples on opposing sides of the incision. The end effector includes a pair of cooperating jaw members that, if the instrument is intended for endoscopic or laparoscopic applications, are capable of passing through a cannula passageway. One of the jaw members receives a staple cartridge having at least two laterally spaced rows of staples. The other jaw member defines an anvil having staple-forming pockets aligned with the rows of staples in the cartridge. The instrument includes a plurality of reciprocating wedges which, when driven distally, pass through openings in the staple cartridge and engage drivers supporting the staples to effect the firing of the staples toward the anvil.
One known problem with using surgical staplers in this fashion has been the formation of air leaks in stapled lung tissue. The leaks can occur in the cut line, and/or in the staple holes themselves. Frequently, the diseased lung tissue is thin and friable and can tear at the staples as the lungs re-inflate. These air leaks can be persistent and can extend the hospital stay for a patient by weeks. To alleviate these leakage problems, surgeons reinforce the staple line by applying a buttress or pledget material to the desired stapling site and stapling through the buttress material. The buttress material provides reinforcement to the friable tissue. The tissue is compressed against the staple holes resulting in increased pneumostasis. This reduces the chances of tissue tearing at the staple line, and reduces staple pullout in friable tissue.
These reinforcement materials are typically releasably mounted onto the jaw members of a surgical stapling device such that upon firing, the reinforcement material is stapled to the lung tissue. Optimally the lung tissue is “sandwiched” between two layers of this reinforcement material. Alternately, buttress materials can be used in a number of other surgical procedures such as but not limited to: an ovarian hysterectomy, a gastric bypass, an anastomosis of intestinal tissue, or any other procedure that requires reinforcement of a staple line or increased hemostasis in tissue.
Releasably attaching the buttress material to the jaw members of the surgical stapling device presents a special challenge. The buttress material must be fastened securely to the jaws of the surgical stapling device so that it will not fall off during normal operation, yet the material must be easily released from the surgical stapling device after the staples are fired. A variety of adhesive and mechanical attachment means are known. Both adhesive and mechanical attachment means are discussed below, and both have their deficiencies.
One example of a device which attaches a buttress material to a linear cutter with an adhesive is described in U.S. Pat. No. 5,441,193 by Gravener et al. This device attaches buttress materials to a surgical instrument with a biocompatible cyanoacrylate adhesive. The adhesive bonding is applied along the edge portions of the buttress material and dashed lines of perforations are placed within the buttress material (adjacent to the glue line) so that the unglued central portion of the buttress material can be torn from the glued edge portions. However, the portions of the buttress material having the adhesive applied thereto are not releasable from the device. As a consequence, removing the buttress from the instrument (after firing) can be especially difficult, as all of the material between the perforations must be torn simultaneously to release the surgical stapling device from tissue. An improved approach to adhesively engaged buttress material was subsequently disclosed in U.S. Pat. No. 6,656,193 to Grant that included both mechanical alignment features in combination with a reliable adhesive with beneficial characteristics for attachment and detachment.
It is also known to employ various mechanical attachments of the buttress material to the surgical stapling and severing instrument. Many methods of mechanical attachment exist, and a common one is the placement of a sleeve over the clamping members of the surgical stapling device. The sleeves can be formed from flexible fabric such as buttress material, or can contain a releasable strip of buttress material attached to a different fabric. Many of these sleeves are described in U.S. Pat. Nos. 5,503,638 and 5,549,628 by Cooper et al, in U.S. Pat. No. 5,702,409 by Rayburn et al., in U.S. Pat. No. 5,810,855 by Rayburn et al., and in U.S. Pat. No. 5,964,774 by McKean et al.
While sleeves can effectively be used to attach the buttress material to the end effector of the surgical stapling device, sleeves can cause other complications during surgery. For example, if the sleeve is formed from a solid sleeve of buttress material, such as in U.S. Pat. Nos. 5,902,312 and 5,769,892, firing the surgical stapling device staples the buttress and tissue and severs the buttress sleeve and tissue between the staple lines. This action leaves the portions of tissue (on either side of the cut line) attached together by a sheet of buttress material. This requires the surgeon to go in and sever the cut sleeve of the buttress to separate the severed tissue, and remove any unwanted portion of the buttress material.
It is also known to incorporate frangible features that are a compromise between a strong hold to prevent inadvertent detachment and unduly high force to detach after stapling. For instance, in U.S. Pat. Nos. 5,542,594, 5,908,427, and 5,964,774 to McKean et al., buttress material is pinned onto end effector surfaces. In U.S. Pat. Nos. 5,702,409 and 5,810,855 to Rayburn et al., porous polytetrafluoroethylene (PTFE) tubes fit over each jaw with each having a tear away flat face. As a compromise, it would be desirable that retention force be higher prior to stapling and reduced after stapling.
Consequently, a significant need exists for an improved surgical stapling and severing instrument that may reliability position buttress material on each side of tissue that is to be stapled and severed with the buttress material thereafter easily deployed from the instrument.
BRIEF SUMMARY OF THE INVENTION
The invention overcomes the above-noted and other deficiencies of the prior art by providing a surgical instrument that reliably engages buttress material to a tissue compression surface of a fastener applying assembly by use of an electrically actuated retention member. Thereby, a strong engagement avoids inadvertent deployment yet the electrically actuated retention member may be switched to a disengaged state to effect deployment of the buttress material after fastening to tissue without need for subsequent surgical procedures.
In one aspect of the invention, a surgical instrument for fastening buttress material to tissue has a staple applying assembly distally attached to an elongate shaft that responds to distal motion of a firing member to form staples between opposing tissue compression surfaces through first and second buttress pads and interposed compressed tissue. Electrically actuated retention members selectively positioned between an engaged position holding a selected buttress pad to a selected tissue compression surface are controlled by circuitry to effect a selected one of retaining and deploying the buttress pad. Thereby, reliance of a static amount of retention force is replaced by a selectable amount of force.
In another aspect of the invention, a surgical instrument for fastening buttress material to tissue incorporates the advantages of electroactive polymers to serve as a means for engaging a buttress pad to each of a pair of tissue compression surfaces and to remotely electrically control deployment of the buttress pads after their stapling to interposed tissue. Thereby, an implement portion of such a surgical instrument may be desirably small in transverse cross section for insertion through a cannula of a trocar for endoscopic or laparoscopic procedures.
These and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and the description thereof.
BRIEF DESCRIPTION OF THE FIGURES
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and, together with the general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the principles of the present invention.
FIG. 1 depicts a partially cutaway side elevation view of a surgical stapling and severing instrument in an open position with an electrically actuated buttress deployment mechanism with a lower buttress pad exploded off a lower jaw and an elongate shaft partially cut away.
FIG. 2 depicts a left side view in elevation of a staple applying assembly of the surgical stapling and severing instrument of FIG. 1 .
FIG. 3 depicts a left front perspective view of a replaceable staple cartridge removed from the lower jaw of the staple applying assembly of FIG. 2 .
FIG. 4 is a left front perspective disassembled view of the replaceable staple cartridge of FIG. 3 .
FIG. 5 is a front view of a right side of the lower jaw taken in cross section along lines 5 — 5 of FIG. 2 with a lower, lateral electroactive polymer (EAP) buttress latch in a locked state.
FIG. 6 is a front view of the right side of the lower jaw taken in cross section along lines 5 — 5 of FIG. 2 with the lower, lateral EAP buttress latch in an unlocked state.
FIG. 7 is a left side detail view of an aft EAP buttress latch in an unlocked state.
FIG. 8 is a left perspective view of an upper jaw (anvil) of the staple applying assembly of FIG. 2 .
FIG. 9 is a left perspective, disassembled view of the upper jaw (anvil) of the staple applying assembly of FIG. 2 .
FIG. 10 is a front view of the upper jaw (anvil) of the staple applying assembly of FIG. 2 taken in cross section through lines 10 — 10 with an upper, lateral EAP latch engaged to a buttress pad.
FIG. 11 is a front view of the upper jaw (anvil) of the staple applying assembly of FIG. 2 taken in cross section through lines 10 — 10 with the upper lateral EAP latch actuated and the deployed buttress pad omitted.
FIG. 12 is a left side view in elevation of an alternative staple applying assembly for the surgical stapling and severing instrument of FIG. 1 with a lower, front EAP latch engaged to a lower buttress pad.
FIG. 13 is a front left perspective view of a replaceable staple cartridge removed from the lower jaw of the alternative staple applying assembly of FIG. 12 .
FIG. 14 is a left side detail view of the lower jaw of FIG. 12 with the lower, front EAP latch activated to disengage from an omitted deployed buttress pad.
FIG. 15 is a left perspective disassembled view of the lower jaw of FIG. 12 with a slotted buttress pad.
FIG. 16 is a front perspective view of an alternative replaceable staple cartridge with EAP latching channels for the lower jaw for the staple applying assembly of FIG. 2 .
FIG. 17 is a front perspective view of the alternative replaceable staple cartridge of FIG. 16 taken in cross section through lines 17 — 17 through the deactivated (contracted) EAP latching channel engaged to a buttress pad.
FIG. 18 is a front perspective view of the alternative replaceable staple cartridge of FIG. 16 taken in cross section through lines 17 — 17 through an activated (expanded) EAP latching channel disengaged from an omitted deployed buttress pad.
FIG. 19 is a front perspective of a right side of an additional alternative lower jaw for the staple applying assembly of FIG. 2 taken in transverse cross section through a rigid buttress channel with an EAP pinching lock depicted in a deactived, expanded position locking a buttress pad.
FIG. 20 is a front perspective of the right side of the additional alternative lower jaw of FIG. 19 for the staple applying assembly of FIG. 2 taken in transverse cross section through the rigid buttress channel with the EAP pinching lock depicted in an activated, contracted position unlocked from an omitted deployed buttress pad.
FIG. 21 is a perspective view of a circular surgical stapler with an EAP buttress latching mechanism.
DETAILED DESCRIPTION OF THE INVENTION
Turning to the Drawings, wherein like numerals denote like components throughout the several views, in FIGS. 1–2 , a surgical stapling and severing instrument 10 includes a handle portion 12 that manipulates to position an implement portion 14 formed from a fastening end effector, specifically a staple applying assembly 16 , distally attached to an elongate shaft 18 . The implement portion 14 is sized for insertion through a cannula of a trocar (not shown) for an endoscopic or laparoscopic surgical procedure. Advantageously, an electrically actuated buttress deployment mechanism 20 reliability retains upper and lower buttress pads 22 , 24 respectively on an upper jaw (anvil) 26 and a lower jaw 28 until tissue clamped within the staple applying assembly 16 is stapled and severed. Thereafter, the electrically actuated buttress deployment mechanism 20 deploys the buttress pads 22 , 24 without undue force or ancillary surgical procedures (e.g., use of a grasper).
The surgical stapling and severing instrument 10 is in an initial state as depicted in FIG. 1 , with a closure trigger 30 and a more distal firing trigger 32 both released from a pistol grip 34 . Release of the closure trigger 30 proximally draws a closure sleeve 36 , which is an outer portion of the elongate shaft 18 that pivots the anvil 26 . The lower jaw 28 is supported by a frame ground 38 that is encompassed by the closure sleeve 36 and is rotatably engaged to the handle portion 12 . A rotation knob 40 allows reciprocating longitudinal motion of the closure sleeve 36 while engaging the closure sleeve 36 and frame ground 38 for rotation about a longitudinal axis of the elongate shaft 18 . The firing trigger 32 is either directly or intermittently coupled to a firing member, specifically a firing rod 42 , guided by the frame ground 38 that transfers a firing motion to the staple applying assembly 16 to effect stapling and severing.
A power button 44 may be depressed by the user to activate a control module 46 of the electrically actuated buttress deployment mechanism 20 , powered by a battery 48 . A visual confirmation on the handle portion 12 may be given to the user as to the state of the electrically actuated buttress deployment mechanism 20 (e.g., color/flash illumination of the power button 44 ). For instance, the power button 44 and/or other user interfaces (not shown) may advantageously be depressed a number of times to toggle through several available operational states of the electrically actuated buttress deployment mechanism 20 , such as “POWER ON”, “BUILT-IN TEST PASSED”, INSERT BUTTRESS PADS, “SYSTEM LOADED/AWAITING FIRING”, “FAULT DETECTED”, and “BUTTRESS OVERRIDE/FIRING WITHOUT INSTALLED BUTTRESS PADS”. Additional programming flexibility may be achieved by incorporating a wired or wireless (e.g., BLUETOOTH) protocol to interface the control module 46 to an external graphical user interface (e.g., personal computer). In the initial state, the control module 46 electrically actuated buttress retention elements, in the version depicted, comprise upper and lower latch arms 50 , 52 that are electrically urged outwardly so that the upper buttress pad 22 may be inserted against an inner surface of the anvil 26 as depicted and a lower buttress pad 24 may be placed upon and latched to an inner surface of the lower jaw 28 , in particular, upon a replaceable staple cartridge 54 that is engaged in an elongate staple channel 56 of the lower jaw 28 .
With the buttress pads 22 , 24 inserted and the power button 44 depressed again to latch, the implement portion 14 may be inserted endoscopically or laparoscopically to a surgical site. The closure trigger 30 is depressed and released as necessary until an amount of tissue is gripped in the staple applying assembly 16 . Drawing the closure trigger 30 fully to the pistol grip 34 causes the closure trigger 30 , and thus the anvil 26 , to clamp in a closed position. Then, the firing trigger 32 is depressed, either in a single stroke or in a series of strokes depending upon the configuration of the handle portion 12 causing full firing travel of the firing rod 42 . For multiple firing strokes, a firing indicator wheel 58 on the handle portion 12 gives a visual indication as to the amount of firing that has occurred. It should be appreciated that a distal end of the firing rod 42 includes or is coupled to a knife that traverses a vertical slot in the staple cartridge 54 to sever clamped tissue and the buttress pads 22 , 24 . The firing rod is also coupled to a wedge assembly that cams staples upwardly out of the staple cartridge 54 through the clamped tissue and buttress pads 22 , 24 to close and form against the anvil 26 . Thereafter, the firing rod 42 is withdrawn by an end-of-firing travel release mechanism and a retraction bias in the handle portion 12 . For manually releasing and/or manually retracting the firing rod 42 , a manual retraction lever 60 may be rotated upwardly on the handle portion 12 . The control module 46 of the electrically actuated buttress deployment mechanism 20 advantageously senses that firing has been accomplished, such as by being responsive to a firing position sensor 62 in the handle portion 12 . With the unclamping of the closure trigger 30 by depressing a closure release button 64 , the severed ends of buttressed, stapled tissue (not shown) is released from the staple applying assembly 16 .
An illustrative version of the handle portion 12 without an electrically actuated buttress deployment mechanism 20 is described in U.S. patent application Ser. No. 11/052,387 entitled “SURGICAL STAPLING INSTRUMENT INCORPORATING A MULTI-STROKE FIRING MECHANISM WITH RETURN SPRING ROTARY MANUAL RETRACTION SYSTEM” to Shelton et al., the disclosure of which is hereby incorporated by reference in its entirety.
ELECTROACTIVE POLYMERS
While a number of electrical actuators (e.g., solenoids) may be integrated into the staple applying assembly 16 , illustrative versions described herein advantageously employ electroactive polymers (EAP), which are conductive doped polymers that change shape when electrical voltage is applied. In essence, the conductive polymer is paired to some form of ionic fluid or gel and electrodes. Flow of the ions from the fluid/gel into or out of the conductive polymer is induced by the voltage potential applied and this flow induces the shape change of the polymer. The voltage potential ranges from 1V to 4 kV, depending on the polymer and ionic fluid used. Some of the EAPs contract when voltage is applied and some expand. The EAPs may be paired to mechanical means such as springs or flexible plates to change the effect that is caused when the voltage is applied.
There are two basic types of EAPs and multiple configurations of each type. The two basic types are a fiber bundle and a laminate version. The fiber bundle consists of fibers around 30–50 microns. These fibers may be woven into a bundle much like textiles and are often called EAP yarn because of this. This type of EAP contracts when voltage is applied. The electrodes are usually made up of a central wire core and a conductive outer sheath that also serves to contain the ionic fluid that surrounds the fiber bundles. An example of a commercially available fiber EAP material, manufactured by Santa Fe Science and Technology and sold as PANION™ fiber, is described in U.S. Pat. No. 6,667,825, which is hereby incorporated by reference in its entirety.
The other type is a laminate structure, which consists of a layer of EAP polymer, a layer of ionic gel and two flexible plates that are attached to either side of the laminate. When a voltage is applied, the square laminate plate expands in one direction and contracts in the perpendicular direction. An example of a commercially available laminate (plate) EAP material is from Artificial Muscle Inc, a division of SRI Laboratories. Plate EAP material is also available from EAMEX of Japan and is referred to as thin film EAP.
It should be noted that EAPs do not change volume when energized; they merely expand or contract in one direction while doing the opposite in the transverse direction. The laminate version may be used in its basic form by containing one side against a rigid structure and using the other much like a piston. The laminate version may also be adhered to either side of a flexible plate. When one side of the flexible plate EAP is energized, it expands flexing the plate in the opposite direction. This allows the plate to be flexed in either direction, depending on which side is energized.
An EAP actuator usually consists of numerous layers or fibers bundled together to work in cooperation. The mechanical configuration of the EAP determines the EAP actuator and its capabilities for motion. The EAP may be formed into long stands and wrapped around a single central electrode. A flexible exterior outer sleeve will form the other electrode for the actuator as well as contain the ionic fluid necessary for the function of the device. In this configuration when the electrical field is applied to the electrodes, the strands of EAP shorten. This configuration of EAP actuator is called a fiber EAP actuator. Likewise, the laminate configuration may be placed in numerous layers on either side of a flexible plate or merely in layers on itself to increase its capabilities. Typical fiber structures have an effective strain of 2–4% where the typical laminate version achieves 20–30%, utilizing much higher voltages.
For instance, a laminate EAP composite may be formed from a positive plate electrode layer attached to an EAP layer, which in turn is attached to an ionic cell layer, which in turn is attached to a negative plate electrode layer. A plurality of laminate EAP composites may be affixed in a stack by adhesive layers therebetween to form an EAP plate actuator. It should be appreciated that opposing EAP actuators may be formed that can selectively bend in either direction.
A contracting EAP fiber actuator may include a longitudinal platinum cathode wire that passes through an insulative polymer proximal end cap through an elongate cylindrical cavity formed within a plastic cylinder wall that is conductively doped to serve as a positive anode. A distal end of the platinum cathode wire is embedded into an insulative polymer distal end cap. A plurality of contracting polymer fibers are arranged parallel with and surrounding the cathode wire and have their ends embedded into respective end caps. The plastic cylinder wall is peripherally attached around respective end caps to enclose the cylindrical cavity to seal in ionic fluid or gel that fills the space between contracting polymer fibers and cathode wire. When a voltage is applied across the plastic cylinder wall (anode) and cathode wire, ionic fluid enters the contracting polymer fibers, causing their outer diameter to swell with a corresponding contraction in length, thereby drawing the end caps toward one another.
In FIGS. 3–7 , the lower latch arms 52 of the electrically actuated buttress deployment mechanism 20 selectively hold the lower buttress pad 24 by electrically actuating cylindrical EAP actuators 74 positioned in holes 76 formed in left and right lateral lips 78 , 79 of a staple cartridge body 80 of the replaceable staple cartridge 54 . With particular reference to FIG. 4 , the polymeric staple body 80 has an aft vertical slot 82 that receives a knife of a firing bar (not shown). A plurality of vertical staple apertures 84 are formed in the polymeric staple body 80 with each containing a staple supported by staple drivers (not shown). A staple cartridge tray 85 underlies and laterally encompasses the polymeric staple body 80 to retain these components. Left and right aft rectangular EAP actuators 86 , 88 extend out of left and right aft rectangular apertures 90 , 92 formed in the staple cartridge body 80 on each side of the aft vertical slot 82 . Left and right aft latch arms 94 , 96 are formed into the staple cartridge tray 85 attached at their aft portion and horizontally extending distally to bend front upwardly as the respective aft rectangular EAP actuators 86 , 88 expand ( FIG. 7 ). Separate left and right side brackets 98 , 100 each include a plurality of opposing and inwardly bent top and bottom flanges 102 , 104 that grip respective left and right lateral lips 78 , 79 . The lower latch arms 52 are formed from the left and right side brackets 98 , 100 as L-shaped flanges that overlie and are spaced away from the respective left and right lateral lips 78 , 79 . Each side latch arm 52 and aft latch arm 94 , 96 has a down turned inward edge 106 that assists in gripping the lower buttress pad 24 ( FIGS. 3 , 5 ). In FIG. 6 , electrical activation of cylindrical EAP actuators 74 rotates the lower latch arms 52 upwardly and laterally allowing the lower buttress pad 24 to deploy away from a top compression surface 108 of the replaceable staple cartridge 54 .
In FIGS. 8–11 , the upper latch arms 50 of the electrically actuated buttress deployment mechanism 20 are curved to closely overlay the anvil 26 with inwardly curved left and right tips 120 , 122 that parallel a respective outer edge of the anvil 26 . Each upper latch arm 50 is electrically actuated by a pair of cylindrical EAP actuators 124 that extend out of a respective left and right holes 126 , 128 formed into arm recess 130 that is formed laterally across a top surface 132 of the anvil 26 . At a longitudinal apex of the anvil 26 , each upper latch arm 50 is fastened to the anvil 26 by a fastener 134 . Thus expansion of the pair of cylindrical EAP actuators 124 on each side of the respective fastener 134 causes the left and right tips 120 , 122 of each upper latch arm 50 to raise and rotate away from the retained upper buttress pad 22 allowing deployment from a staple forming inner compression surface 136 of the anvil 26 ( FIG. 11 ).
In FIGS. 12–15 , a version of a replaceable staple cartridge 54 ′ of a lower jaw 28 ′ of a staple applying assembly 16 ′ as otherwise described in FIGS. 3–6 further includes a lower distal latch 140 that is a plate bent into an obtuse angle corresponding to a beveled lead edge 142 and the top compression surface 108 of a staple cartridge body 80 ′. A lower distal EAP actuator 144 extends out of a distal EAP recess 146 , adhered to both the staple cartridge body 80 ′ and the lower distal latch 140 for pulling a hooked proximal end 148 of the lower distal latch 140 down into engagement with a distal side of a lower buttress pad 24 ′ or for pushing the hooked proximal end 148 up and out of engagement. A distal longitudinal slot 150 in the lower buttress pad 24 ′ corresponds to a proximal longitudinal slot 152 formed in the lower distal latch 140 to assist in achieving engagement without contact with the knife or for incomplete severing of the lower buttress pad 24 ′.
In FIGS. 16–18 , alternative left and right EAP buttress latches 200 , 202 for an electrically actuated buttress deployment mechanism 20 ′ are formed as inwardly open C-channels of EAP material embedded into left and right lateral lips 78 ′, 79 ′ of a staple cartridge body 80 ″ and are configured to vertically contract when deactivated ( FIG. 17 ) to grip a lower buttress pad 24 and to expand when actuated to deploy ( FIG. 18 ).
In FIGS. 19–20 , an alternative EAP locking actuator 74 ′ is used in the replaceable staple cartridge 54 along with alternative left and right side brackets 100 ′ (the latter depicted) with increased vertical spacing from the top compression surface 108 of the staple cartridge body 80 to loosely hold the lower buttress pad 24 . The EAP locking actuator 74 ′ has a vertically expanded locking state ( FIG. 19 ) that pushes the lower buttress pad 24 upwardly into tight engagement in an upper flange 240 of the respective side bracket 100 ′. The EAP locking actuator 74 ′ has a retracted unlocking state ( FIG. 20 ) that allows deployment. It should be appreciated that recessing the EAP locking actuator 74 ′ into the staple cartridge body 80 provides for a desired amount of extension to deform the buttress pad 24 . Alternatively or in addition, an EAP actuator may be placed in an opposing position under the upper flange 240 .
In FIG. 21 , a circular stapler instrument 310 has distal and proximal buttress rings 312 , 314 depicted as exploded away from distal and proximal circular compression surfaces 316 , 318 . EAP latches 320 extending inwardly from the compression surfaces 316 , 318 and controlled from a handle 322 selectively engage and deploy the buttress rings 312 , 314 .
While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications may readily appear to those skilled in the art.
For example, while a staple applying assembly 16 is depicted in the illustrative version, it should be appreciated that electrically actuated buttress deployment may be advantageously used in fastener instruments that utilize clips, anchors, sutures, etc.
For another example, while a manually operated surgical stapling and severing instrument 10 is depicted for clarity, it should be appreciated that a robotically manipulated and/or controlled fastening device may incorporate electrically actuated buttress retention members consistent with aspects of the invention.
For yet another example, sensing of tissue thickness and/or presence of buttress material may advantageously enable or disable firing to avoid inadvertent firing when buttress material is warranted but not installed or buttress material is installed but not warranted.
For yet a further example, an electrically actuated buttress retention element may comprise a combination of a passive resilient member (e.g., compression spring) that provides a power off retention bias within a buttress gripping channel with an active electrical component. For instance, an EAP fiber actuator passing through the compression spring to a cap may be activated to contract, compressing the compression spring for deployment of a buttress pad.
As yet another example, a staple cartridge may be manufactured with a buttress pad attached to a compression surface by pins, crimped-on clamps, etc., or may be forcibly deployed by an underlying EAP actuator that deforms the buttress pad and/or the attachment to effect separation.
As yet a further example, applications consistent with the present invention may incorporate electrically actuated retention members that are activated to perform engagement to the buttress pad and/or activated to disengage for deployment of the buttress pad. For instance, a retention member may have a loose frictional engagement without power that allows insertion of buttress pads prior to use. Powered activation of a locking EAP actuator thereafter may effectively lock the buttress pad prior to use. Alternatively or in addition to such a locking EAP actuator, activation after stapling of a deployment EAP actuator may effectively reduce engagement or frictional engagement of the buttress pad facilitating deployment.
As yet another additional example, while endosocopic and laparoscopic applications benefit from aspects of the present invention, it should be appreciated that open surgical procedures may also benefit. | A surgical instrument for being endoscopically or laparoscopically inserted to a surgical site for simultaneous stapling and severing of tissue includes electrically actuated deployment of buttress pads held on inner surfaces of upper and lower jaws of a staple applying assembly. Thereby, thick or thin layers may be stapled and severed without improper staple formation nor with nonoptimal deployment of the buttress pads. Electroactive polymer (EAP) actuated latches, an EAP channel, or a rigid channel with an EAP pinch lock reliably hold the buttress pad until deployment is desired with a low force to separate the stapled and severed buttress pad/tissue combination with the respective EAP mechanism activated for deployment. | 0 |
BACKGROUND OF THE INVENTION
Ground fault circuit interruption (GFCI) devices have been sanctioned by the National Electric Code for use in residential circuits to protect against the hazards of electrical shock. Such GFCI devices, as presently commercially available, utilize a differential current transformer to sense a current imbalance in the line and neutral conductors occasioned by ground leakage current from the line conductor returning to the source through an unintended ground circuit path other than the neutral conductor. To prevent injurious electrical shock, the differential current transformer must develop a signal voltage of sufficient magnitude to enable a signal processor to initiate circuit interruption in the event of a current differential in the line and neutral conductors as low as 5 milliamps. For ease of manufacture and to provide a compact design, the line and neutral conductors, which constitute the primary windings of the differential current transformer, typically each make a single pass through the aperture of the toroidal transformer core. Thus to satisfy a 5 milliamp trip level, the signal processor must respond to a transformer primary excitation of less than 0.005 ampere-turns. To ease design constraints on the signal processor, the differential transformer should have a high permeability core and a secondary winding of many turns -- typically in excess of a thousand turns of very fine wire -- in order to develop signal voltages of manageable amplitudes. Signal levels are, nevertheless, quite low, 1 to 10 millivolts, requiring high amplification. With such high amplification, the processor design must insure amplifier stability and adequate noise immunity to prevent nuisance tripping.
An additional requirement of GFCI devices of this type necessary for Underwriters Laboratories listing is the capability of detecting a low impedance ground fault on the neutral conductor adjacent the load. Since the neutral conductor is also grounded at the source, such double grounding of the neutral conductor could create a situation where a portion of the ground fault current from the line conductor returns to the source through the neutral conductor. As a consequence, the current differential showing up in the differential transformer would not be truly indicative of the magnitude of the ground leakage current. It is thus seen that a low impedance neutral to ground fault has the potential of desensitizing the differential current sensor such that the GFCI would trip only in response to considerably higher ground leakage current levels. Under these circumstances, the GFCI device cannot afford protection to the degree intended.
Applicant's co-pending application, Ser. No. 571,930, filed Apr. 28, 1975, which is a continuation-in-part of application Ser. No. 509,462, filed Sept. 26, 1974, discloses an approach to GFCI sensor design which dramatically increases the fault signal amplitude while permitting utilization of a differential current transformer of less expensive construction. The disclosure of this co-pending application is specifically incorporated herein by reference. Pursuant to the approach disclosed therein, the differential transformer secondary is normally operated in a short circuited mode through an electronic switch. Current developed in the secondary winding in response to a current differential in the line and neutral conductors flows through the switch in shunt with a relatively high burden resistance. Periodically, the switch is momentarily opened to divert this secondary current through the burden resistance, developing thereacross a signal voltage of higher magnitude than can otherwise be achieved. A working embodiment of the invention disclosed in this co-pending application was found capable of developing signal voltage spikes of 200 millivolts peak amplitude in response to a 0.005 ampere differential in one-turn primary windings. With the prior art approach of continuously flowing secondary current through a burden resistor, signal voltages of 1 to 10 millivolts are typical. The differential current transformer embodied a ferrite core with a 125-turn secondary winding, as contrasted to an expensive, high permeability, nickel-iron core with on the order of 1500 secondary turns.
It is accordingly an object of the present invention to provide an improved ground fault circuit interrupting device of the type disclosed in the above-noted co-pending application having the capability of detecting desensitizing ground faults on the neutral conductor.
A further object is to provide a ground fault circuit interrupting device of the above character which is simple in design and inexpensive to manufacture.
Other objects of the invention will in part be obvious and in part appear hereinafter.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided an improved ground fault circuit interrupting device having the capability of detecting ground faults on the line and neutral conductors of a power distribution circuit and for interrupting the circuit should these ground faults be of a hazardous character. More specifically, the present invention utilizes a differential current sensor of the type disclosed and claimed in my above-noted co-pending application. This current sensor is in the form of a differential current transformer comprising a toroidal core having a pair of preferably single-turn primary windings which are respectively connected in the line and neutral sides of the distribution circuit for which ground fault protection is sought. The transformer can and preferably does utilize an inexpensive, low permeability ferrite core, rather than an expensive, high permeability nickel-iron core as currently employed in GFCI differential current transformers. The secondary of the current sensor is a multi-turn secondary winding, however, the number of turns can be and preferably is considerably fewer -- as much as an order of magnitude fewer turns -- than existing GFCI differential current transformers.
The secondary winding is periodically, preferably at the zero crossing of line voltage, shorted on itself through an electronic switch connected in parallel with a relatively high resistance burden resistor. Any secondary current flow occasioned by the existence of a current differential in the primary windings normally flows through the electronic switch, rather than always through a burden resistor, as is the conventional practice. Periodically, preferably approximate the peak of each alternate half cycle of the line voltage, the electronic switch is opened to divert the secondary current through the burden resistor, thereby developing, by virtue of the higher burden resistance, a momentary, relatively large signal voltage thereacross for application to signal processing circuitry pursuant to initiating a trip function. To control the switch operation in accordance with the present invention, a relaxation oscillator synchronized to the line frequency momentarily opens the electronic switch. The oscillator includes a timing capacitor which charges up to a predetermined threshold voltage and then discharges to open the electronic switch. In accordance with a specific feature of the invention, the timing capacitor discharge current is directed through a primary winding of a second transformer having at least one secondary winding connected in series with the neutral side of the distribution circuit. If the neutral conductor, in addition to being grounded at the source, is also connected to ground through a ground fault adjacent the load, it is seen that the secondary of this second or neutral transformer becomes a closed loop. Thus, excitation of its primary winding by the timing capacitor produces a current flow in the neutral conductor, and, if the fault impedance is sufficiently low, this secondary current will create a sufficient current differential in the line and neutral conductors to precipitate circuit interruption.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified in the construction hereinafter set forth and the scope of the invention will be indicated in the claims. For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a ground fault circuit interruption (GFCI) device embodying the present invention; and
FIGS. 2 and 3 are a series of voltage waveforms useful in understanding the operation of the GFCI device of FIG. 1.
DETAILED DESCRIPTION
Referring now to the drawing, the ground fault circuit interrupting (GFCI) device of FIG. 1 is shown implemented to interrupt a power distribution circuit consisting of a line conductor L and a neutral conductor N in the event of a high impedance ground fault, indicated at 12, on the line conductor or a low impedance ground fault, indicated at 14, on the neutral conductor. The neutral conductor is illustrated as being grounded at the source, as is conventional practice in residential circuits. The GFCI device may include overload and short circuit trip initiating elements, indicated diagrammatically at 16, as is also conventional. To detect the line and neutral ground faults 12 and 14, the GFCI device includes a module, generally indicated at 18, for sensing a current imbalance in the line and neutral conductors occasioned by either one of these ground faults. When this current imbalance reaches a predetermined threshold level, the module 18 functions to enable energization of a trip coil TC connected to the line conductor and consequent opening of the line conductor by contacts 20.
Module 18 includes a differential current transformer DX and a neutral transformer NX having toroidal cores 22 and 24, respectively. The line and neutral sides of the distribution circuit pass through the apertures in these toroidal cores to serve as respective one-turn transformer windings. Differential current transformer DX is equipped with a multi-turn secondary winding 26, while neutral transformer 24 is equipped with a multi-turn primary winding 28. The differential current transformer functions as a sensor by developing in its secondary circuit a current proportional to the differential in the currents flowing in the line and neutral conductors. As will be described in greater detail, this secondary current develops a fault signal voltage across a burden resistor Rb which is applied to a threshold detection network, generally indicated at 30. The threshold detection network controls a clamp and driver network, generally indicated at 32, connected to the gate of a thyristor SCR included in series with trip coil TC across the line and neutral conductors. The primary winding 28 of neutral transformer NX is driven by a relaxation oscillator, generally indicated at 34, which also functions to control the condition of an electronic switch, in the form of a dual collector transistor Q3 operating to normally shunt differential transformer secondary current around burden resistor Rb.
Turning to a detailed description of the schematic diagram of FIG. 1, the lower terminal of trip coil TC is connected to a positive voltage bus 36 through resistor R10 and to the anode of thyristor SCR through a resistor R11. The cathode of thyristor SCR is connected to a bus 38, which is referenced to ground by virtue of its connection via lead 39 to neutral conductor N. A filtering capacitor C3 is connected from junction of resistors R10 and R11 to bus 38. Power supply current and voltage are derived from the line conductor through the trip coil and resistor R10 to bus 36. This supply current powering the active portion of the module 18 is of a level well below the actuation level of the trip coil and thus the contacts 20 remain closed. As will be seen, actuation of the trip coil is achieved when thyristor SCR is triggered to its conductive state by the clamp and driver circuit 32 to thus complete a low impedance energizing circuit drawing sufficient current through the trip solenoid to achieve its actuation and consequent opening of contacts 20.
As the line voltage, illustrated by waveform 40 of FIG. 2, starts into each positive half cycle, supply current flows through resistors R10 and R8 to provide base drive for transistor Q8. This transistor becomes conductive, connecting the anode of zener diode D1 to bus 38 and also shorting the gate and cathode of thyristor SCR together. This insures that thyristor SCR is maintained in its non-conductive condition during the initial portion of each positive half cycle of the module supply voltage. Zener diode D1, with its cathode connected to bus 36, serves as a shunt voltage regulator, clamping the voltage on bus 36 to a positive voltage level, for example 10 volts. The regulated voltage on bus 36 is illustrated by waveform 42 in FIG. 2. The current conducted by zener diode D1 while clamping bus 36 normally flows through the collector-emitter circuit of transistor Q8. However, when transistor Q8 is rendered non-conductive, this current provides gate drive for triggering the thyristor SCR into conduction to precipitate a trip function. During negative half cycles of the line voltage, current flows through resistor R10 and diodes D1 and D2 in their forward directions.
Under normal conditions, the voltage established at the emitter of transistor Q4, in conjunction with appropriate selection of the resistors R7, R8 and R9 and transistors Q4, Q5 and Q6, dictates that transistor Q5 is in a low conductance state and transistor Q6 in a high conductance state. As a consequence, there is sufficient voltage at the collector of transistor Q5 to provide base drive current for sustaining the conductance of transistor Q8, while the voltage at the collector of transistor Q6 is too low to drive transistor Q7 into conduction. To achieve this, the current density in transistor Q6 is limited to a value less than that of transistor Q4, and the current density in transistor Q5 is designed for a value higher than that of transistor Q4. For example, to establish a tripping response threshold to a positive or negative charge of 30 millivolts in the voltage at the emitter of transistor Q4, with transistors Q4, Q5 and Q6 having equal emitter areas, resistor R8 should be approximately one-third and resistor R9 approximately three times the resistance value of resistor R7. While transistor Q6 is conducting, transistor Q7 is cut off. To turn transistor Q8 off and thus enable triggering of rectifier SCR, it is seen that either transistor Q5 or transistor Q7 must be driven into saturation to divert base current from transistor Q8.
Transistor Q3, constituting the electronic switch shorting secondary winding 26 of differential transformer DX, is illustrated as being a dual collector transistor switch which advantageously exhibits a low impedance and a low offset voltage between the two collectors during its ON condition. However, since the voltage between its emitter and collectors is not zero, the differential transformer winding 26 must be returned to ground through a resistor R6 having a resistance in the order of 100 ohms. Burden resistor RB may be on the order of 1,000 ohms for a differential current transformer having a turns-ratio of 1 to 125. Capacitor C2, connected between one side of secondary winding 26 and bus 38, filters out high frequency noise appearing in the differential transformer secondary circuit. It will be appreciated that the transistor switch Q3 may take other forms, such as two carefully matched transistors connected in parallel.
Normally, the base drive current is drawn from bus 36 through resistor R5 to turn transistor Q3 on, rendering the impedance between its two collectors essentially zero. As a consequence, the two sides of the differential transformer secondary winding 26 are shorted together through the two collectors of transistor Q3, shunting out burden resistor Rb. Control of the condition of electronic switch Q3 is performed by oscillator 34 having, as its active element, a programmable unijunction transistor Q1. The anode of this transistor is connected to one side of the neutral transformer secondary winding 28 and its cathode is connected to the bus 38 through a resistor R4. The other side of winding 28 is connected to the junction between a resistor R1 and a timing capacitor C1. The upper terminal of resistor R1 is connected to bus 36, while the lower terminal of capacitor C1 is connected to bus 38. Gate voltage for transistor Q1 is derived from a voltage divider consisting of resistors R2 and R3 connected across buses 36 and 38. The cathode of transistor Q1 is connected directly to the base of a transistor Q2.
As the voltage on bus 36 begins rising toward its regulated level during each positive half cycle of the line voltage, unijunction transistor Q1 is non-conductive. Base drive current through resistor R5 is thus available to turn transistor switch Q3 on, short circuiting the differential transformer secondary winding 26. Meanwhile, timing capacitor C1 is being charged through resistor R1 toward the regulated voltage to which bus 36 is clamped by zener diode D1 (waveform 44, FIG. 2). When the voltage at the junction of capacitor C1 and resistor R1, as applied through neutral transformer primary winding 28 to the anode of unijunction transistor Q1, rises to a level exceeding the gate voltage, the unijunction transistor fires (time t1 in FIG. 2). Capacitor C1 thus abruptly discharges through primary winding 28 and the unijunction transistor, driving transistor Q2 into conduction. Base drive current is shunted from transistor Q3, causing this transistor to cut off and remove the short across the secondary winding 26. The voltage at the base of transistor Q3 is illustrated by waveform 46 of FIG. 2.
As was fully disclosed in the above-noted co-pending application, the abrupt removal of the shunt across the burden resistor Rb diverts any secondary current through burden resistor Rb to develop a signal voltage of significantly greater amplitude than is otherwise obtainable. This signal voltage, applied to the base of transistor Q4, may be either of a positive or negative polarity, as illustrated in waveforms 48, 48a of FIG. 3, depending upon whether the ground fault current is in phase or out of phase with the line voltage. Transistor Q4 functions essentially as an emitter-follower, and thus this signal voltage, depending on its polarity, either increases or depresses the normal voltage at the emitter thereof. If the signal voltage increases the emitter voltage of transistor Q4 above a positive threshold level (indicated at 49a in FIG. 3), transistor Q5 is driven into saturation, depriving base drive current for transistor Q8. This latter transistor goes into cutoff, unclamping the gate of thyristor SCR. The current flowing through zener diode D1 is thus diverted to the gate of thyristor SCR, triggering it into conduction and opening of contacts 20 ensues. If the signal voltage at the base of transistor Q4 depresses its emitter voltage below threshold level 49b in FIG. 3, transistor Q6 is turned off, causing transistor Q7 to turn on and likewise divert base drive current from transistor Q8. Transistor Q8 is thus cut off and zener current is diverted to trigger thyristor SCR, initiating a trip function.
After timing capacitor C1 is discharged, unijunction transistor Q1 returns to its non-conductive state, and transistor Q2 turns off. Transistor switch Q3 thus turns on at time t2 in FIG. 2 to reimpose the short across the secondary winding 26. By way of example, unijunction transistor Q1 may be programmed to maintain transistor switch Q3 closed for the first 3.2 milliseconds of each positive half cycle of the line voltage. At time t1, indicated in FIG. 2, the voltage on capacitor C1 has reached the level where transistor Q1 fires and transistor switch Q3 is opened for a very short interval t1 to t2 of, for example, 60 microseconds.
As previously noted, timing capacitor C1 discharges through primary winding 28 of neutral transformer NX. Because of the inductance of neutral transformer primary winding 28, the discharge current of capacitor C1 is one-half cycle of a sine wave of a frequency determined by its capacitance and the inductance of the neutral transformer. This frequency may be on the order of 10 kiloHertz. The voltage appearing across the primary winding of the neutral transformer therefore has a cosine waveform of one-half cycle and this same voltage waveform is induced on the neutral conductor N. If the neutral conductor, while grounded at the source end, is also connected to ground through a ground fault 14 of sufficiently low resistance, for example 6 ohms or less, the resulting current flow produced in the neutral conductor will unbalance the differential current transformer DX. The resulting signal voltage developed across burden resistor Rn while transistor switch Q3 is open is illustrated by waveform 60 in FIG. 3 as having positive and negative-going spikes. In the absence of line-to-ground fault current, either polarity of this neutral fault signal voltage is of sufficient amplitude to render transistor Q8 non-conductive, with consequent triggering of thyristor SCR. If, at the same time, the line conductor L is also experiencing a ground fault, the current imbalance occasioned thereby will produce a signal voltage at the base of transistor Q4 effective to add to the neutral fault signal voltage in either the positive or negative direction. Thus, in the presence of ground faults on both line and neutral conductors, it is seen that interruption will be achieved at lower values of ground leakage current and higher values of neutral ground fault resistance.
It will thus be seen that the objects set forth above, among those made apparent in the preceding description, are efficiently attained and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | The secondary winding of the differential current transformer in a ground fault circuit interrupter is normally short circuited through an electronic switch. A relaxation oscillator, including a timing capacitor, acts to periodically open the switch and divert any secondary current through a burden resistor, developing thereacross a relatively high amplitude fault signal voltage indicative of a liine ground fault. The timing capacitor discharges through the primary winding of a second transformer coupled with the neutral conductor to develop, in the event of a desensitizing neutral ground fault, a fault signal voltage across the burden resistor. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method and apparatus for facilitating the completion of a business transaction between one or more first company potential business partners and one or more second company potential business partners. More specifically, the invention relates to a multiple computer-based and internet-based data processing system adapted for allowing a third company to function as a facilitator for facilitating the completion of a business transaction between one or more first company potential business partners and one or more second company potential business partners. The third company stores a plurality of data, including but not limited to customer data, which is accessible via the internet by the first company potential business partners and the second company potential business partners. This allows the third company to function as a facilitator for the purpose of facilitating the culmination or completion of a business transaction pertaining to the plurality of data, between a first company potential business partner and a second company potential business partner.
[0002] Before the deregulation of the electric and gas utility industries, these utilities provided energy services to a wide range of customer-types. These customer-types included industrial customers (such as manufacturing plants and large business buildings), commercial customers (such as supermarkets and retail centers), and residential customers (such as residential homes). However, since the deregulation of the electric and gas utility industries, energy service providers (those entities responsible for supplying energy to the end-use customers), in an effort to compete against other energy service providers, are establishing niche markets. For example, as a result of deregulation, energy service provider A may decide to supply energy only to high-end residential customers, energy service provider B may decide to supply energy only to industrial customers, energy service provider C may decide to supply energy only to small commercial customers and low-end residential customers, and energy service provider D may decide to supply energy only to electricity customers (as opposed to both electricity and gas customers).
[0003] Energy service providers may decide to service a particular niche market for a number of reasons. The following two reasons are illustrative only and are not an exhaustive list of the many reasons an energy service provider may decide to do so. First, by servicing only one type of customer, the energy service provider can implement marketing and promotional campaigns customized for that particular customer-type. For example, energy service provider A may market or promote its services to its niche market—the high end residential market—by tying its programs to other incentive programs—such as frequent flier mileage programs, auto-rental programs, and home-security programs. Similarly, as an incentive for using its services, energy service provider B may offer its industrial customers special hardware or software tools that will assist its customers in managing or controlling their loads.
[0004] Second, an energy service provider may need to service a particular niche market because it is only able to supply energy to certain customer-types with specific load requirements. For example, energy service provider A may only be able to service residential-type loads and may be unable to provide energy to the more complex load requirements of an industrial or commercial-type customer. Similarly, energy service provider D may decide it only wants to remain in the electricity industry and therefore decide to sell off its gas business.
[0005] Once an energy service provider decides to provide energy only to a niche market, it will want to (or may need to) transfer certain specific assets that are as a result no longer needed. A transfer may include a sale of existing assets or a trade of existing assets for the assets, goods, or services of another energy service provider. Assets that may be transferred may include, but are not limited to, a utility's customer base or a specified portion of a utility's customer base. In one embodiment, an energy service provider may want to “sell” or “trade” an existing customer base that it no longer plans to service. For example, once energy service provider A decides to service only high-end residential customers, it will want to transfer (i.e., “sell” or “trade”) its existing industrial, commercial, and small-residential type customer base. Similarly, once energy service provider B decides to service only industrial-type customers, it will want to transfer (i.e., “sell” or “trade”) its existing commercial and residential-type customer base. Energy service provider C will want to transfer (i.e., “sell” or “trade”) its industrial, large commercial and large residential customers, so that it will only supply service to small commercial and low-end residential customers. Energy service provider D will want to transfer (i.e., “sell” or “trade”) its gas customers, so that it will only supply service to its electricity customers. Thus, the customer base that an energy service provider no longer plans to service is a potential revenue-generating asset of the energy service provider for which there is a market in the deregulated utility environment.
[0006] In the before-mentioned example, energy service provider A may be interested in buying energy service provider B's or C's high-end residential customers; energy service provider B may be interested in buying energy service provider A's or C's industrial customers; energy service provider C may be interested in buying energy service provider A's or B's commercial and low-end residential customers; and energy service provider D may be interested in buying any of energy service provider A's, B's, or C's electricity customers. Additionally, the before-mentioned energy service providers may opt to trade one customer-type for another customer-type with another energy service provider. For example, energy service provider A may be interested in trading a certain number of its industrial customers for a certain number of energy service provider B's high-end residential customers.
[0007] Currently, when energy service providers have an interest in transferring their assets (including parts of its customer base), they must contact via telephone other energy service providers to inquire whether they have similar assets available for sale or trade, or whether they would be interested in acquiring certain assets. This proves to be a tedious, inefficient, and time-consuming process as the electric and gas utility industries (as well as other industries) continue to deregulate and change across the nation.
[0008] Now that Electronic Commerce (E-commerce) technologies (involving the internet) are maturing, an opportunity now exists to improve the efficiency of the process typically practiced when the need arises to transfer, sell, trade, or otherwise dispose of existing utility assets (such as an existing customer base that the utility no longer wishes to service), by using a set of processes and associated apparatus that are typically used by the e-commerce technologies during and in combination with the processes and associated apparatus that are used during the transfer of utility assets.
[0009] The use of such e-commerce technologies has been disclosed in the prior art. For example, in U.S. Pat. No. 5,897,620 to Walker et al., a method and apparatus is disclosed for the sale of airline-specified flight tickets. However, the use of e-commerce technologies and processes for use in combination with the transfer of assets belonging to a utility-based commodity (such as a water, gas, or electric utility), particularly in regard to the sale or trade of an existing customer base, has not been disclosed, taught, or suggested in the prior art.
SUMMARY OF THE INVENTION
[0010] Therefore, a need has arisen for a method and system for efficiently facilitating the transfer of a utility-based commodity's assets. More specifically, a need has arisen for a method and system for efficiently facilitating the transfer of a utility-based commodity's customer base or a portion of its customer base. Accordingly, it is an object of the present invention to disclose a method and associated apparatus for the transfer of utility assets, including but not limited to the transfer of a utility's customer base or portion of its customer base, using electronic commerce (e-commerce) technologies and processes, thereby improving the efficiency and ease by which the utility performs the transfer. More specifically, it is an object of the present invention to disclose a method and associated apparatus for the efficient transfer of utility assets, where one or more than one first company potential business partners can post via the internet the assets that they are making available for transfer to the website of a third company facilitator, and where one or more than one second company potential business partners can view the assets that are available for transfer via the internet on the third company facilitator's website, and when any second company potential business partner indicates via the internet an intention to acquire the assets of any of the first company potential business partners, the third company facilitator facilitates the completion of the business transaction.
[0011] As a result of the above object of the present invention, the invention concerns a method using electronic commerce for performing a transfer of a utility's customer base. The method involves the use of a computer that is adapted to access the internet for performing the transfer of assets. Using a computer, a potential seller accesses via the internet a website belonging to a third company facilitator and posts information about one or more utility customers it wishes to make available for transfer. Using a computer, a potential buyer accesses via the internet a website belonging to the third company facilitator and views the information posted by the potential seller concerning the one or more utility customers the seller has made available for transfer. The potential buyer can view detailed information about each customer or a group of customers, such as an energy customer-type per customer or group of customers, a load customer-type per customer or group of customers, a load characteristic of the group of customers, a load characteristic of each individual customer, and the location of each customer or group of customers. The buyer can also search through the information by sorting the customers available for transfer by energy customer-type (such as water, gas, or electric-type customers), by load customer-type (such as industrial, commercial, or residential customer-type or by actual load data), and by geographic location (such as by country, state or province, city, county, or other geographic region). The third company facilitator acquires information about the buyer's viewing habits while the buyer is accessing the information on the third company facilitator's website. If the buyer is interested in acquiring the seller's one or more utility customers that are posted to the third company facilitator's website by the seller, the buyer indicates an intention via the third company facilitator's website and indicates which utility customer or group of utility customers of the seller the buyer wishes to acquire.
[0012] The invention also concerns a method for performing a transfer of the assets of a utility-based commodity by using electronic commerce (e-commerce) technologies and processes thereby improving the efficiency of the performance of the transfer of utility assets.
[0013] The invention also concerns an e-commerce based data processing system that consists of a first server, a second server, and a third server and at least one personal computer/workstation connected to the third server that is adapted for use by a third “facilitator” company. The third server is accessible via the internet to the first server, which is adapted for use by a first company potential business partner. The third server is also accessible via the internet to the second server, which is adapted for use by a second company potential business partner. The third company functions as a facilitator for facilitating a culmination or a completion of a business transaction between the first company and the second company.
[0014] The invention concerns the above referenced e-commerce based data processing system, wherein the business transaction may include the transfer of utility assets.
[0015] The invention concerns the above referenced e-commerce based data processing system, wherein the utility assets include the transfer of a utility's customer base.
[0016] The invention concerns the above referenced e-commerce based data processing system, wherein, when the second company accesses the internet and logs onto the third server of the third company, the second company's username and password is validated, the second company's clearance level is validated, and the second company's credit history is validated, whereupon: (1) the second company then views on its workstation display screen a display that has a plurality of options including the ability to use one or more selected software applications that reside on the third company's third server, (2) the second company selects one or more of these software applications, a set of data (and in particular a set of utility asset data), and a set of parameters relevant to the use of that set of data, (3) the third server of the third company unlocks the selected software application and the data and executes the selected software application using the selected data and the selected parameters, and (4) a set of results are displayed remotely at the second company's workstation or personal computer.
[0017] The invention concerns the above referenced e-commerce based data processing system, wherein at the end of the session being executed on the third company's server, the third company's third server calculates the value of the applications and data that have been used, and an amount is charged against an account that has been established with the second company.
[0018] The invention concerns the above referenced e-commerce based data processing system, wherein when the second company logs off, the second company's selected parameters are saved both on the third company's third server and on the second company's computer for future use as a history file.
[0019] The invention concerns the above referenced e-commerce based data processing system, wherein, when the second company logs into the third server of the third company, a set of security levels of the user are checked and validated.
[0020] The invention concerns the above referenced e-commerce based data processing system, wherein a “granularity” of the security levels transcends from a high level to a lower level, as follows: (1) access to the third company's website or portal is controlled, (2) access to specific services offered within that website is controlled, (3) access to certain data, information types is controlled, (4) access to different resolutions of the data is controlled, and (5) each data element of the property owner's data is tagged with its own security level, the tag being further controlled by the owner of the data.
[0021] The invention concerns a method for storing and viewing data at successively higher user selectable levels of resolution, which includes utilizing a graphical model, viewing a customer demographic available for transfer as a layer of information, and further viewing data linked to that customer demographic including the number of customers available for transfer, the load characteristics for that customer demographic, and the load characteristics for each customer within the customer demographic.
[0022] The invention concerns a method using electronic commerce for facilitating a transfer of utility information, where a potential buyer accesses a third company facilitator's website to view information posted by one or more potential sellers, and the third company facilitator acquires information concerning the buyer's usage and viewing habits while the buyer is accessing the information posted by one or more potential sellers on the third company facilitator's website.
[0023] The invention concerns a method using electronic commerce for performing a transfer of utility assets, the method involving the use of a computer, the computer adapted to access an internet for performing the transfer of assets. The method includes the use of a computer by a second company to access the internet for obtaining and viewing a web page belonging to a third company facilitator, such web page containing information belonging to a first company which relates to the transfer of utility assets; and (b) if such second company is interested in such information being displayed on the third company's web page and which belongs to the first company, the use of the third company web page by the second company to complete a business transaction with the first company.
[0024] The invention concerns the above-referenced method using electronic commerce for performing a transfer of utility assets, wherein the information being displayed on the third company's web page, being accessed by the second company, and belonging to the first company relates to a customer base of the first company offered for transfer, the first company selling or trading the customer base, and the second company accessing the third company's web page when the second company is interested in acquiring the customer base available from the first company.
[0025] The invention concerns a method for performing and practicing the transfer of utility assets comprising the steps of: (1) using a computer, accessing, by a second company, an internet, (2) when the internet is accessed, accessing, by the second company, a third company server, (3) when the third company server is accessed, further accessing a website of the third company, (4) when the third company website is accessed, accessing, by the second company, a list of information in the third company website for the purpose of performing a business transaction with a first company, (5) during the step of accessing the list of information in the third company website, indicating an intention, by the second company, to complete the business transaction with the first company, and (6) when the step of indicating the intention is implemented, completing by the second company said business transaction with the first company.
[0026] The invention concerns the above-referenced method for performing and practicing the transfer of utility assets, wherein the list of information in the third company website comprises a list of a plurality of customers available for transfer by the first company.
[0027] The invention concerns a method for performing and practicing the transfer of utility assets, wherein the indicating step for indicating the intention by the second company to complete the business transaction with the first company comprises the step of indicating an intention to purchase one or more of the customers from the first company.
[0028] The invention concerns a method for performing and practicing the transfer of utility assets, wherein the step of accessing a website of the third company includes the further steps of accessing a public area for viewing an asset list, accessing a registered user's area for viewing an asset summary and for executing a confidentiality agreement, and accessing a confidential area after the confidentiality agreement is executed for viewing details of the customers listed on the customer list and described in the customer summary.
[0029] By way of example only (which example is not intended to limit the present invention), one such sub-web page, which is stored in the third server of the third company facilitator, stores data and other information relating to one or more assets which is/are available for transfer by the first company potential business partners. The first company potential business partners posted via the internet their assets, which are available for transfer, on the third company's third server in order to enable the third company to function as a facilitator for facilitating the transfer of the utility assets to one or more than one second company potential business partners. In operation, when a second company potential business partner is interested in purchasing or trading (or otherwise acquiring) utility assets, the second company uses a computer to access, via the internet, the main web page of a third company facilitator. When the main web page is accessed, the second company uses its computer to access (also via the internet and via the main web page of the third company) a sub-web page of the third company, which contains the specific information regarding utility assets that are available for transfer by one or more than one first company potential business partner. That asset information belongs to the first company potential business partner that posted its information to the third company server. Using that sub-web page of the third company, the second company examines the asset information regarding the assets belonging to each first company potential business partner that are available for transfer. If the second company is interested in purchasing, trading, or otherwise acquiring the assets belonging to any of the first company potential business partners, the second company, while still using a computer to access the third company facilitator's third server and other sub-web pages of the third company, agrees to purchase and/or trade the utility assets. The second company will then view, via the computer while accessing the third company's third server, a purchase and sale agreement, a trade agreement, or other transfer of assets agreement, whereby the second company agrees to buy and/or trade a particular first company's assets. A “closing” will take place at another physical location.
[0030] Further scope of the applicability of the present invention will become apparent from the detailed description presented hereinafter. It should be understood, however, that the detailed description and the specific examples, while representing an embodiment of the present invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become obvious to one skilled in the art from a reading of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] A full understanding of the present invention will be obtained from the detailed description of the embodiment presented herein below, and the accompanying drawings, which are given by way of illustration only and are not intended to limit the present invention, and wherein:
[0032] [0032]FIG. 1 is a basic diagram depicting a method, in accordance with the present invention, which is practiced by an infinite number of first company potential business partners and an infinite number of second company potential business partners for performing a transfer of utility assets, including the step of using a computer to access the internet for the purpose of completing a business transaction between any of the first companies and any of the second companies.
[0033] [0033]FIG. 2 is a basic block diagram depicting a method, in accordance with the present invention, which is practiced by a particular first company potential business partner and a particular second company potential business partner for performing a transfer of utility assets, including the step of using a computer to access the internet for the purpose of completing a business transaction between the first company and the second company;
[0034] [0034]FIG. 3 is a schematic of the first company potential business partner, the second company potential business partner, and the third company facilitator using the method of FIG. 2;
[0035] [0035]FIG. 4 illustrates a data processing system including a second server of a second company potential business partner, and a first server of a first company potential business partner, accessing the third server of a third company facilitator via the internet;
[0036] [0036]FIG. 5 illustrates a log in screen where a first company or a second company logs in to post or view assets available for transfer;
[0037] [0037]FIG. 6 illustrates the options available to a second company wishing to acquire assets via a third company facilitator's webpage where a first company posts utility assets for transfer and where the second company can evaluate those assets to determine if the second company will acquire certain assets;
[0038] [0038]FIGS. 7 through 10 illustrate sub-web pages of the third company facilitator wherein the first company can post information about assets available for transfer and the second company can evaluate that information to determine if the second company will acquire that asset;
[0039] [0039]FIG. 11 illustrates how the second company can indicate its intention to acquire a specific asset from the first company and how a “closing” will take place where the transfer of such specific utility assets from the first company to the second company will take place.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] Referring to FIG. 1, a method, in accordance with the present invention, is illustrated which makes maximum use of Electronic Commerce “E-commerce” technologies (i.e., using a computer to access the internet) during the performance of an online transfer of the assets of a utility-based commodity. In FIG. 1, an infinite number of first companies 100 and an infinite number of second companies 200 wish to perform a business transaction. Specifically, the first companies wish to transfer (i.e., sell or trade) utility assets, such as a utility's customer base or a portion of its customer base. In other words, any first company is a potential “seller” of its utility customer base or a portion of its customer base. In contrast, the second companies wish to acquire utility assets, such as utility customers. In other words, any second company is a potential “buyer” of any of the assets made available by the first company sellers. Though any second company buyer can perform a business transaction with any first company seller, for explanatory purposes only, a single transaction will be described between first company seller 10 and second company buyer 20 . Additionally, though the third company facilitator could also be a first company seller 10 or a second company buyer 20 in any given transaction or potential transaction, for the purposes of explanation only, the third company facilitator will be described as performing only its third company facilitating role.
[0041] In FIG. 1, a first company 10 wishes to transfer its customer base or a portion thereof. It logs into the third company facilitator's system via the internet to post information regarding the assets it wishes to transfer. A second company 20 wishes to acquire a customer or a group of customers. The second company 20 logs into the third company facilitator's system to view which assets are available for transfer. Upon reviewing the assets available, the second company 20 may decide that it wishes to perform the business transaction with the first company 10 . A third company 30 performs the function of a “facilitator” for facilitating the completion of the business transaction between the first company 10 and the second company 20 over the Internet 50 .
[0042] Referring to FIG. 2, a block diagram illustrating a business transaction being performed between a first company 10 and a second company 20 . The first company has decided it wishes to transfer (i.e., sell or trade) a utility asset, such as a customer base or a portion of its customer base. The second company 20 has decided it wishes to acquire (i.e., buy or trade) the specific asset of the first company 10 . The third company 30 facilitates the business transaction between the first company 10 and the second company 20 over the Internet 50 .
[0043] Referring to FIG. 3, a schematic drawing of the interaction between the first 10 , second 20 , and third companies 30 of FIG. 1 is illustrated. In FIG. 2, the third company 30 is the “facilitator.” That is, the third company 30 stores detailed information regarding the business transaction that has been posted to its system by the first company 10 via the internet. If the business transaction involves the transfer of utility assets (for example, a portion of a utility's customer base), the third company 30 stores detailed information regarding that available asset for transfer, such as the energy customer-type 200 (such as water, gas, electric), the load customer-type 210 (such as industrial, commercial, residential), the number of customers available, the load characteristics of the group of customers 220 , the load characteristics of each individual customer 230 , and the location of the customer 240 . Additionally, the third company facilitator 30 monitors and stores detailed information about the usage and viewing activity of the second company 20 as the second company 20 uses the third company facilitator's system. The second company 20 can access the information belonging to the third company 30 by using a computer 40 to access the internet 50 .
[0044] Referring to FIG. 4, a system block diagram illustrates the first company 10 wishing to perform a business transaction with a second company 20 , the second company 20 wishing to perform the business transaction with the first company 10 , and the third company 30 performing the function of a “facilitator” for facilitating the completion of the business transaction between the first company 10 and the second company 20 over the internet 50 . Of course, any first company of an infinite number of first companies 100 and any second company of an infinite number of second companies 200 can perform a business transaction for the transfer of a first company's assets over the internet 50 . However, for explanatory purposes, only one business transaction will be described between a first company 10 and a second company 20 performed over the internet 50 . In the system block diagram of FIG. 4, the first company 10 has a server 310 and a first workstation or PC 312 is connected to the server 310 and any number of additional workstations or PCs 314 are connected to the server 310 . The second company 20 has a server 320 , and a first workstation or PC 322 is connected to the server 320 and any number of additional workstations or PCs 324 are connected to the server 320 . The first company server 310 and the second company server 320 are operatively connected to a server 330 of a third company 30 via the Internet 50 . The third company server 330 has a first workstation or PC 332 connected thereto and any number of additional workstations or PCs 334 connected thereto. The functional operation of the system block diagram of FIG. 4 will become apparent from a reading of the paragraphs set forth below with reference to FIG. 5, and with further reference to FIGS. 6 through 11.
[0045] Referring to FIGS. 4, 5, and 6 recall from FIG. 4 that the second company 20 (wishing to perform a business transaction with the first company 10 ) accesses the third company server 330 via the internet 50 , since the third company 30 performs the function of a facilitator for facilitating the completion of the business transaction between the first company 10 and the second company 20 . In FIG. 6, the first company 10 and the second company 20 each have access, via the internet 50 , to the third company's main “home page” 530 . However, before accessing the homepage, the first company 10 and the second company 20 must first log in to the third company's server 330 through a log in screen 400 . After logging in to the server 330 , the first company 10 or the second company 20 will now view several web pages on its computer, and those web pages are discussed below with reference to FIGS. 6 through 11 of the drawings.
[0046] In FIG. 6, the first company 10 and the second company 20 each have access, via the internet 50 , to the third company's main “home page” 530 . Because the first company 10 is interested in making its assets available for transfer to any second company, it will access the third company's server 330 and main home page 530 via the Internet 50 to post information about the assets it wishes to make available. Similarly, since the second company 20 is interested in performing a business transaction with any first company by accessing the third company facilitator's server 330 , the second company 20 will access the main “home page” 530 of the third company's server 330 for the purpose of evaluating the assets available for transfer, including the assets posted as available for transfer by the first company 10 . The second company 20 may at any time access that home page 530 of the third company 30 to complete a business transaction between it and any first company.
[0047] In FIG. 6, therefore, the second company 20 accesses, via the internet, the third company's main “home page” 530 of the third company's server 330 . When the second company 20 has accessed the main “home page” 530 of the third company 30 , the second company 20 must then decide which “business transaction” it will attempt to complete with another first company. In FIG. 6, assume that the third company's 30 server 330 stores four different sub-web pages in association with its main “home page” 530 , the four different sub-web pages of FIG. 6 involving four different means of searching for assets available for transfer: (1) Search Assets by Location sub-web page 532 , (2) Search by Asset Type sub-web page 534 , (3) Search by Load Characteristic sub-web page 536 , and (4) Search by Utility Type sub-web page 538 . In FIG. 6, assume further that the second company 20 decides to access the Search by Load Characteristic sub-web page 536 after having accessed the third company's main “home page” 530 that is stored in the third company's server 330 .
[0048] Referring to FIGS. 7 through 10, and referring initially to FIG. 6, recalling that the second company 20 has accessed the “Search by Load Characteristic” sub-web page (hereinafter called the “Load Characteristic web page”) 536 , which was accessed from the third company's main “home page” 530 , and which is stored in the third company server 330 , the second company 20 will specify what load characteristics the assets it wishes to acquire should have by navigating through additional sub-web pages 546 and by entering additional information. The second company will then click the “search” button. This will allow the second company to view assets available for transfer that match the specified load criteria, including the assets available for transfer by the first company 10 that match the specified load criteria.
[0049] After the search is performed and the results are displayed in FIG. 6, the second company 20 may wish to view certain weekly load characteristics for a group of customers. FIG. 7 illustrates the graphical results 600 obtained upon performing a load characteristic search on a group of customers available for transfer.
[0050] Additionally, after the search is performed and the results are displayed in FIG. 6, the second company 20 may wish to view certain load characteristics per end customer. FIG. 8 illustrates the graphical results 700 of a daily load characteristic for a particular customer available for transfer.
[0051] Similarly, after the search is performed and the results are displayed in FIG. 6, the second company 20 may wish to view certain load characteristic information per end customer or per group of customers. FIG. 9 illustrates the tabular results 800 obtained upon performing a load characteristic search on a particular customer available for transfer.
[0052] In addition to the search performed and the results displayed in FIGS. 6 - 9 , the second company 20 may wish to view the load characteristics of a specified group of customers available for transfer by the first company 10 . FIG. 10 illustrates the tabular results 900 obtained upon performing a load characteristic search on a group of customers available for transfer.
[0053] Referring to FIG. 11, when the second company 20 decides to purchase the asset from the first company 10 , the second company 20 will view, via its computer 40 , another web page 1030 which is stored in the third company server 330 , that other web page 1030 allowing the second company 20 to indicate, by clicking in the appropriate place, its intention 1030 to acquire the utility asset. In FIG. 11, after clicking in the appropriate place on that other web page 1030 indicating its intention to acquire the asset of FIG. 11, the second company 20 will be notified where and when a “closing” will take place 1040 , wherein during the “closing,” the first company 10 and the second company 20 will meet to close on the transfer of the asset from the first company 10 to the second company 20 .
[0054] A functional description of the operation of the present invention will be set forth in the following paragraphs with reference to FIGS. 1 through 11 of the drawings.
[0055] A first company seller 10 has a plurality of utility assets (i.e., a customer base or a portion of a customer base) available for transfer. For example, a first company 10 has a number of residential customers it wishes to dispose of by sale or trade. In order to facilitate the transfer of this customer base, the first company 10 posts via the internet 50 information regarding the customer group that is available for sale or trade on a server 330 of a third company 30 . A second company buyer 20 , wishing to acquire (i.e., purchase or trade) a group of customers, uses its computer 40 to access the internet 50 for the purpose of further accessing a third company server 330 that belongs to the third company 30 . When the second company 20 accesses the third company server 330 , the second company 20 accesses the third company main “home page” 530 . The second company 20 can now access the sub-web pages pertaining to the assets available for transfer by any first company who has posted such information. The second company 20 can search for assets available for transfer by location 532 (for example, by country 542 , state, region, city, county, etc.), by utility type 538 (for example, by water customers, gas customers, electricity customers, or any combination thereof 548 ), by the load characteristics of the assets available for transfer 536 (such as by time of use, by demand readings, or by other load characteristic criteria 546 ), by the load characteristics of each individual customer, by the customer demographic of each group of customers, or by the asset type 534 (by commercial type customers, industrial type customers, residential type customers, or any combination thereof 544 ). If the second company 20 wants to acquire a group of customers, the second company 20 clicks in the appropriate place to indicate its intention to acquire the customer asset 1030 . As a result, the first company 10 and the second company 20 will meet in a separate place to “close” on the sale or trade of the customer asset 1040 from the first company 10 to the second company 20 .
[0056] The above discussion is presented under the “Description of the Preferred Embodiment.” The following discussion is presented under the “Detailed Description of the Preferred Embodiment.”
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0057] The detailed specification set forth below discloses the details that would enable one skilled in the art to make the invention of this application. In the following detailed specification, the invention of this application as described above is part of an overall project, and the name of that project is: Blue Lightening.
[0058] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | An e-commerce based data processing system and associated method utilizes e-commerce technologies and a third company facilitator to facilitate the completion of a business transaction, which could involve the transfer, sale, or trade of utility-based commodity's customer base (or a portion of its customer base), the data processing system including a third server which is adapted for use by a third facilitator company, that third server being accessible via the internet to a first server that is adapted for use by one or more first company potential business partners and to a second server that is adapted for use by one or more second company potential business partners, the third company functioning as a facilitator for facilitating a culmination or a completion of a business transaction between any of the first company potential business partners and any of the second company potential business partners. | 6 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates to electrically powered devices and methods that employ one or more thermally responsive current-controlling elements to regulate current flow to an electrical component, particularly a light source.
BACKGROUND OF THE INVENTION
1. Introduction
The following description includes information that may be useful in understanding the present invention. It is not an admission that any such information is prior art, or relevant, to the presently claimed inventions, or that any publication specifically or implicitly referenced is prior art.
2. Background
Flashlights are popular devices, and have many applications. Traditionally, flashlights have employed an incandescent light bulb as the light source. Recently, flashlights have been introduced that use light emitting diodes (LEDs) as the light source. LEDs offer many advantages over traditional incandescent bulbs, including greater efficiency and durability and a longer useful life. As with traditional flashlights, however, the use of LED-based flashlights is also typically constrained by battery life. Also, the service life of a flashlight's light source, be it an incandescent bulb, LED, or other light source, can be radically affected by operating temperature. Accordingly, improvements in power usage and temperature control would advantageous.
3. Definitions
Before describing the instant invention in detail, several terms used in the context of the present invention will be defined. In addition to these terms, others are defined elsewhere in the specification, as necessary. Unless otherwise expressly defined herein, terms of art used in this specification will have their art-recognized meanings.
A “patentable” composition, process, machine, or article of manufacture according to the invention means that the subject matter satisfies all statutory requirements for patentability at the time the analysis is performed. For example, with regard to novelty, non-obviousness, or the like, if later investigation reveals that one or more claims encompass one or more embodiments that would negate novelty, non-obviousness, etc., the claim(s), being limited by definition to “patentable” embodiments, specifically exclude the unpatentable embodiment(s). Also, the claims appended hereto are to be interpreted both to provide the broadest reasonable scope, as well as to preserve their validity. Furthermore, if one or more of the statutory requirements for patentability are amended or if the standards change for assessing whether a particular statutory requirement for patentability is satisfied from the time this application is filed or issues as a patent to a time the validity of one or more of the appended claims is questioned, the claims are to be interpreted in a way that (1) preserves their validity and (2) provides the broadest reasonable interpretation under the circumstances.
A “plurality” means more than one.
SUMMARY OF THE INVENTION
The objects of this invention include the provision of patentable, electrically powered devices that use one or more thermally responsive current-controlling elements to regulate the flow of electricity from the device's power supply to an electrical component such as a light source. Such devices more efficiently utilize power supplies and also provide for greater service lives of the electrical components to which the supply of electric power is regulated.
Thus, in one aspect, the invention concerns patentable assemblies for inclusion in electrically powered devices. Such assemblies comprise a current-consuming electrical component and at least one thermally responsive current-controlling element in electrical communication with the current-consuming electrical component and positioned to regulate electrical current flowing from the power supply to the current-consuming electrical component. In preferred embodiments, the current-consuming electrical component is a light source, such as one or more light bulbs, optical fibers, and/or LEDs, alone or combination with other light sources. Representative examples of thermally responsive current-controlling elements include temperature-variable inductors and capacitors, and thermistors are particularly preferred. In preferred embodiments of the invention, the thermally responsive current-controlling elements are in thermal communication with the light source, such that heat from the light source can be transferred, directly or through one or more intermediate heat-conducting components, to the thermistor or other thermally responsive current-controlling element.
The light assemblies of the invention can be assembled with other components. In the context of a flashlight, for example, the light assembly can be associated with a component such as a reflector or heat sink. In some embodiments, the reflector also serves as a thermal mass, or heat sink, while in other embodiments, a non-reflective heat sink may be employed. In still other embodiments, a heat sink having one or more reflective elements (i.e., an element that reflects or refracts incident electromagnetic radiation) may be used, alone or in addition to a reflector.
In preferred embodiments of this aspect, the light assembly and reflector, as well as any other associated components (e.g., a lens or lens system) are configured for assembly into, or can otherwise be combined with, a flashlight bezel.
A related aspect of the invention relates to flashlights. Typically, such flashlights include a light assembly according to the invention, a flashlight bezel, and a flashlight body. Any such flashlight, regardless of the particular embodiment, also includes such other components, circuitry, and associated electronics and control logic, if any, as may be required for the device to operate as intended when a suitable power supply is included. Preferred power supplies include one or more rechargeable or non-rechargeable batteries, although the invention contemplates the inclusion or use any suitable portable or fixed DC, AC, or switchable AC/DC power supply to energize the particular light source(s) in the device.
Another aspect relates to methods of illuminating articles or spaces using a flashlight according to the invention. Still another aspects of the invention relate to methods of controlling current use, battery life, levels of light output, extending light source life, etc. through the use of a device, particularly a flashlight, that includes a light assembly according to the invention.
These and other aspects and embodiments of the invention are discussed in greater detail in the sections that follow.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows several views, FIG. 1A-FIG . 1 E, of a light assembly according to the invention.
FIG. 2 shows several views, FIG. 2A-FIG . 2 F, of a light assembly according to the invention.
FIG. 3 shows several views, FIG. 3A-FIG . 3 D, of a particular flashlight reflector.
FIG. 4 shows several views, FIG. 4A-FIG . 4 D, of a light assembly of FIG. 1 or 2 attached to a reflector as shown in FIG. 3 .
As those in the art will appreciate, the following description describes certain preferred embodiments of the invention in detail, and is thus only representative and does not depict the actual scope of the invention. Before describing the present invention in detail, it is understood that the invention is not limited to the particular assemblies, devices, systems, and methods described, as these may vary. Any suitable circuitry, components, and material now known or later developed can be used to produce the devices of the invention. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the invention defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be further described by reference to the drawings, which are described in detail below. This description shall in no way to be considered to limit the scope of the invention in any manner.
FIG. 1 shows a representative light assembly ( 10 ) according to the invention. This assembly ( 10 ) includes an LED ( 12 ; 3 watt; Luxeon) attached (in this embodiment, via a suitable epoxy) to a printed circuit board (PCB; 14 ; for a 3 watt LED). The leads of the LED are aligned with conductors that traverse the PCB in order to provide electrical communication between electrical components positioned on or adjacent to the opposite faces of the PCB. A thermistor ( 16 ) is attached (in this embodiment, via a suitable electrically conductive solder) via one surface to the PCB surface opposite the PCB surface to which the LED ( 12 ) is attached. A suitable electrically conductive solder ( 18 ) is also applied, as required, to a portion of the face of the thermistor ( 16 ) opposite that facing a surface of the PCB. In this embodiment, the components ( 12 , 14 , 16 , and 18 ) are each round, but of different diameters. Here, these components are concentrically aligned when assembled, although such alignment and component shape is not required, merely preferred.
Thermistors are electronic devices that change resistance depending on temperature. They can have linear and non-linear characteristics as well as negative and positive temperature coefficients. Some have a non-linear characteristic such that their resistance stays relatively constant until they reach a “switch temperature”. At this point, their resistance increases rapidly with temperature.
When connected in series with a lamp, for example, an electronic light-emitting device such as an LED, and thermally connected to the device, the series current will vary depending on the temperature of the assembly. A positive coefficient thermistor can be used to decrease the current as the assembly warms up. A thermistor with a switching characteristic can be used to regulate the temperature of such an assembly quite accurately.
In the context of LEDs, an LED is believed to heat up due to inefficiencies associated with light generation. The power loss associated with these inefficiencies can be expressed as heat. Depending on the particular embodiment, there is a limit to the allowable temperature of the junction of the LED and thermistor. To protect the LED, the temperature should be maintained below that temperature. By reducing the current flowing to the LED, in many embodiments the thermistor controls, and preferably reduces, the heat increase.
As will be appreciated, a particular assembly will reach a temperature equilibrium depending on factors such as heat loss, the absolute temperature of the assembly, and the heat introduced into the assembly during light emission as a result of the inefficiencies of the LED. In general, the heat introduced into the assembly comes from the I 2 R losses. Thus, holding constant the other parameters that influence the temperature equilibrium of the particular assembly, decreasing current should decrease the temperature, and the temperature is maintained at a value where these factors are in balance. In such embodiments, the negative feedback is provided by the thermistor.
Choosing a suitable thermistor depends on various factors, including the particular application, the type of light source, the desired amount of light to be emitted, etc., and is well within the ordinary skill of the art. In certain preferred embodiments, the thermistor allows use of a higher series current when the light assembly is cold and able to withstand more power, resulting in brighter light when the assembly is cold. When the temperature rises, the thermistor reduces the current flowing to the lamp(s) of the light assembly, thereby protecting the light source, which preferably is one or more LEDs, As those in the art will appreciate, selecting a thermistor with the desired nominal value for the particular application will protect the LED from too much initial current. Also, regulating the temperature of the assembly allows regulation of the current.
At equilibrium, the current is constant regardless of the voltage, provided the voltage does not exceed the maximum allowed for the particular components. Higher voltages will increase the amount of current until the light source, preferably one or more LEDs, heats up.
Heating of the assembly will decrease the current as the thermistor's resistance increases. As the voltage decreases, the temperature will decline, thereby reducing resistance, which, in turn, increases the current until equilibrium is once again established.
As compared to electrically powered devices that employ, for example, a battery circuit using a series resistor instead of a thermally responsive current-controlling element (e.g., a thermistor) and in which current, and hence light output, typically decrease as the voltage of the battery decreases and where initially high voltages could damage or stress a light source, e.g., an LED, in a device that employs a thermally responsive current-controlling element such as a thermistor, as the voltage decreases, the current, and therefore the light output, essentially remains constant until the batteries are depleted.
FIG. 2 shows another representative light assembly ( 20 ) according to the invention, which assembly is similar to that depicted in FIG. 1 . In FIG. 2 , light assembly ( 20 ) also comprises an LED ( 22 ; Luxeon, part LXK2-PW14-U00) bonded via epoxy to the upper face ( 23 ) of PCB ( 24 ). A thermistor ( 26 ) is attached (in this embodiment, via a suitable electrically conductive solder) to the lower face ( 25 ) of the PCB ( 24 ), and a suitable electrically conductive solder ( 28 ) is also applied, as required to provide electrical connectivity (i.e., electrical communication) with a terminal of a battery within the power supply (not shown), to a portion of the face of the thermistor ( 26 ) opposite that facing the lower face ( 25 ) of the PCB ( 24 ).
FIG. 3 shows several views of a representative flashlight reflector ( 30 ) for use in practicing certain embodiments of the invention. View A is a top down view, which clearly shows the hole ( 31 ) in the bottom of the reflector through which a light source, such as the LED shown in the light assemblies depicted in FIGS. 1 and 2 ( 12 and 22 , respectively), can be disposed when associated with the reflector ( 30 ). This reflector ( 30 ) has a parabolic curve to achieve a desired focal length. View B is a side view of the reflector ( 30 ) taken through the plane defined by the concentric diameters of the reflector's hole ( 31 ) and widest opening ( 32 ). Also shown is the apron ( 33 ) of the reflector ( 30 ) that engages an inner surface of a bezel (not shown). The parabolic shape of the reflector is clearly visible in this view, as it is in View D, as well. Also visible here is the portion at the bottom of the reflector intended to engage and retain a light assembly as shown in FIGS. 1 and 2 ( 12 and 22 , respectively), an enlarged cut-away view of which is shown in View C. As shown in View C, the lower portion ( 34 ) of the reflector ( 30 ) is machined to contain downward-extending lip ( 35 ) that defines a volume capable of accepting the PCB ( 14 or 24 ). The outer rim of the PCB (not shown) rests on the PCB base ( 36 ).
FIG. 4(A) shows an exploded view of a flashlight reflector ( 30 , as depicted in FIG. 3 ) assembled with a light assembly ( 10 or 20 ). Catalyst pellets ( 44 ), designed to absorb gases released from the batteries of the power supply (not shown) during flashlight operation, are spaced about in a groove ( 38 ) machined into the lower portion of the reflector ( 30 ). In this embodiment, the light assembly is retained in the reflector by swaging the lip ( 35 ) of the reflector ( 30 ) using a suitable tool adapted for this purpose. Prior to swaging the light assembly to the reflector, several catalyst pellets ( 44 ) are loosely placed into the groove ( 38 ).
The flashlight reflector and light assembly depicted in FIG. 4 can be assembled into a suitable bezel adapted to receive these items. The bezel preferably will contain a lens or lens system. The bezel may be assembled with a complementary flashlight body. The bezel may be attached or otherwise associated with the flashlight body using any suitable mating configuration, for example, a threaded male portion on a flashlight body adapted to receive a complementary female threaded portion of the flashlight. The flashlight body and bezel can be made of any suitable material, including metals and plastics. Particularly preferred are thermoplastics molded into the desired shapes. Preferably, the flashlight body will also contain a chamber for housing the power supplied, which in many embodiments will comprise one or more removable batteries.
* * *
All patents, patent applications, and publications mentioned in the specification are indicative of the levels of those of ordinary skill in the art to which the invention pertains. Each patent, patent application, and publication cited herein is hereby incorporated by reference in its entirety for all purposes regardless of whether it is specifically indicated to be incorporated by reference in the particular citation.
All of the compounds, compositions, and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. Moreover, it is intended to obtain rights which include alternative and/or equivalent embodiments to the extent permitted, including alternate, interchangeable, and/or equivalent structures, functions, ranges, or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges, or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter, as it is intended that all patentable subject matter disclosed herein eventually be the subject of patent claims.
The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Also, the invention illustratively described herein suitably may be practiced in the absence of any element(s) not specifically disclosed herein. Thus, for example, in each instance herein any of the terms “comprising”, “consisting essentially of”, and “consisting of” may be replaced with either of the other two terms. Furthermore, while the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and methods and in the steps or in the sequence of steps of the method described herein without departing from the spirit and scope of the invention. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims. | Methods and devices are described that use one or more thermally responsive current-controlling elements to regulate current flow to an electrical component, particularly a light source such as an LED. Examples of such thermally responsive current-controlling elements include thermistors, inductors, and capacitors. for treating conditions or disorders which can be alleviated by reducing food intake are disclosed which comprise administration of an effective amount of a purine analog, alone or in conjunction with other compounds or compositions that affect satiety. The methods are useful for treating conditions or disorders wherein appetite reduction would be beneficial, including obesity and binge-eating disorder. Pharmaceutical compositions for use in the methods of the invention are also disclosed. | 5 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a network system and a communication device. Particularly, the present invention relates to a network system with ATM (Asynchronous Transfer Mode) communication devices such as ATM-HUB/ATM handler/ATM router/ATM switching unit accomodating line interfaces (NNI/UNI) of the ATM layer such as SDH/SONET/E 3 /DS 3 (HEC/PLCP) for B-ISDN (Broadband-Integrated Service Digital Network).
[0002] In late years, as multi-media advances, B-ISDN receives attention as a leading part for next-generation communication network. Thus, it is expected that B-ISDN is used for a big and complicated network such as WAN (Wide Area Network) and OCN.
[0003] Accordingly, as for ATM communication device connected to B-ISDN, when it is expected that a communication failure occurs during the maintenance is operation, it is desirable to previously communicate contents of the communication failure to a transmission device (such as another ATM communication device and terminal) connected to another B-ISDN.
[0004] Here, in the conventional network system, concerning communication failures occurring between segments or end-to-end, the ATM communication device constituting a network notifies and detects line failures according to the following protocol so as to manage communication quality of NNI (Network Node Interface)/UNI (User Network Interface).
[0005] That is, in the conventional network system, when an ATM communication device to be a receiving device detects a communication failure such as LOS (Loss Of Signal)/LOF (Loss Of Frame)/OOP (Out Of Frame)/LOP (Loss Of Pointer)/LOP (Loss Of Cell) prescribed by SDH/SONET/E3/DS3 (HEC/PLCP), the ATM communication device transfers a failure alarm such as MS-RDI, P-RDI or P-YELLOW to an ATM communication device to be an opposing device. Then, the ATM communication device which receives a failure alarm performs the process corresponding to the failure alarm.
[0006] However, in the conventional network system, there are following problems. That is, in the conventional network system, for example, as to any ATM communication device constituting this network system, when there is a phenomenon independent of line quality such as stop by outage and a operator, an ATM communication device to be an opposite device to that ATM communication device detects a communication failure such as LOS/LOF/OOF/LOP/LOC.
[0007] However, LOS/LOF/OOF/LOP/LOC are information showing only a condition of the communication failure in the network but a cause of the communication failure. Thus, it is impossible for the ATM communication device which has detected the communication failure to know whether this communication failure is caused by quality deterioration of the network system (such as failure of ATM communication device and degradation of cable) or is caused by another cause (above-mentioned outage and stop of hand operated power supply). As the result, in the conventional network system, there is a case that it is impossible for an ATM communication device which has detected a communication failure and an administrator of the communication device (an administrator of the network system) to deal with the communication failure according to the cause thereof.
SUMMARY OF THE INVENTION
[0008] The present invention is achieved in view of the above-described problems, and has as its object the provision of a network system and a communication device capable of dealing with communication failures more suitably than the conventional network system and communication device.
[0009] The present invention introduces the following aspects to solve the above-described problems. That is, the first aspects of the present invention is network system in which a first communication device and a second communication device are connected through a communication line. The first communication device comprises a detection unit detecting an device failure caused in the first communication device, a notification unit gererating device failure information about the device failure detected by the detection unit and transmitting the device failure information to the second communication device, and the second communication device comprises the receiving unit receiving the device failure information from the first communication device, the memory unit memorizing the device failure information received by the receiving unit, and a display control unit displaying the failure alarm and the device failure information memorized in the memory means.
[0010] According to the first aspect of the present invention, when device failure causes in the first communication device, the first communication device transmits the device failure information to the second communication device. The second communication device makes a display unit display the device failure information. Thus, the administrator of the second communication device or the administrator of the network system, when the communication failure causes between the first communication device and the second communication device, can clearly know that the communication failure is caused by the device failure of the first communication device. Thus, the administrators can deal with the communication failure appropriately.
[0011] Here, the device failure is, for example, that power supply of the first communication device is stopped by human power, that electric power to be supplied to the first communication device by a power source lowers than a predetermined value, that a registration of the communication line connecting the first communication device and the second communication device is canceled by a operator and that the communication line is physically cut by external power as the device failure.
[0012] As to first aspect of the present invention, it is preferable that the detection unit detects communication failure caused between the first communication device and the second communication device, and the notification unit generates failure alarm information about the communication failure detected by the detection unit and transmits the failure alarm information to the second communication device, and the receiving unit receives the failure alarm information from the first communication device, and the memory unit memorizes the failure alarm information by the recceiving means, and the display control unit makes a display unit display the failure alarm information memorized in the memory means.
[0013] As to first aspect of the present invention, it is preferable that further comprises a another communication device connecting to the second communication device through the communication line, and the second communication device, when the device failure information is memorized in the memory unit, transmits information equal to the device failure information to the another communication device. In this case, it is possible to transmit the device failure information to another communication device downstream from the second communication device. As another communication device, a transmission unit or a terminal equipment is also used. In addition, when a plurality of other communication devices are connected to the second communication device, it is preferable that in-device failure information is multi-cast to these communication devices.
[0014] Further, in the first aspect of the present invention, it is preferable that the first communication device and the second communication device are ATM communication devices. As ATM communication devices, it is possible to mention an ATM-HUB, an ATM router, an ATM handler, an ATM switching unit and so on. In this case, it is preferable that the notification unit generates a operation and maintenance cell storing the device failure information and transmits the cell to the second communication device and that the memory unit memorizes the device failure information extracted from the operation and maintenance cell.
[0015] The second aspect of the present invention is a communication device connected to another communication device through a communication line. The communication device comprises a receiving unit receiving device failure information about device failure caused in the another communication device from the another communication device, a memory unit memorizing the device failure information received by the receiving means, and a display control unit making a display unit display the device failure information memorized in the memory unit.
[0016] The third aspect of the present invention is a communication device connected to another communication device through a communication line and making a display unit display device failure information. The communication device comprises a detection unit detecting device failure caused in the communication device, and a notification unit gererating device failure information about the device failure detected by the detection means and transmitting the device failure information to the second communication device.
[0017] According to the network system and the communication device of the present invention, it is possible to know that a communication failure occurring between communication devices is caused by the device failure of one communication device from the other communication device, therefore, it is possible to deal with the communication failure appropriately.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a whole block-diagram showing a network system according to Embodiment 1;
[0019] [0019]FIG. 2 is an operational explanatory view showing the network system shown in FIG. 1;
[0020] [0020]FIG. 3 is an operational explanatory view showing the network system shown in FIG. 1;
[0021] [0021]FIG. 4 is an operational explanatory view showing the network system shown in FIG. 1;
[0022] [0022]FIG. 5 is a whole block-diagram showing a network system according to Embodiment 2; and
[0023] [0023]FIG. 6 is an operational explanatory view showing the network system shown in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Hereinafter, explanations will be given of preferred embodiments of the present invention with reference to figures.
[0025] [Embodiment 1]
[0026] First, an explanation will be given of the Embodiment 1 according to the present invention.
[0027] [Whole Structure of Network System]
[0028] [0028]FIG. 1 is a whole block-diagram showing a network system according to Embodiment 1 of the present invention. In FIG. 1, the network system is structured as follows. That is, An ATM-HUB 1 accomodates an UNI (User Network Interface) 50 and a NNI (Network Node Interface) 6 . The NNI 6 is connected to a NNI 19 through a reception optical cable 27 and a transmission optical cable 28 . The NNI 19 is accepted by an ATM-HUB 14 . Then, the ATM-HUB 14 accepts an UNI 51 .
[0029] A plurality of user terminals not shown are connected to the UNI 50 . The UNI 50 transmits ATM cell (hereinafter, called cell) received from these user terminals not shown to the ATM-HUB 1 in accordance with a predetermined transmission speed. In this embodiment, the UNI 50 transmits cells to the ATM-HUB 1 at the transmission speed according to SDH (Synchonious Digital Hierarchy).
[0030] The ATM-HUB 1 , when receiving cells from the UNI 50 , performs routing to the cells, and then transmits the cells to the NNI 6 . On the other hand, the ATM-HUB 1 receives cells from the NNI 6 and performs routing to the received cells, thereafter, transmits each cell to the UNI 50 .
[0031] The NNI 6 transmits the cells received from the ATM-HUB 1 to the NNI 19 at the transmission speed according to SDH. Explanations are omitted of a NNI 19 , an ATM-HUB 14 and an UNI 51 , since theses are structured similarly to the above-described NNI 6 , ATM-HUB 1 and UNI 50 .
[0032] [Structure of ATM-HUB]
[0033] Next, explanations will be given of structures of the ATM-HUB 1 and the ATM-HUB 14 .
[0034] As shown in FIG. 1, the ATM-HUB 1 is provided with a switch (SW) 2 respectively connected to the UNI 50 and the NNI 6 , a switch controller (SW-CTL) connected to the SW 2 via a bus 9 , a micro processor (μP) 5 , a SRAM 35 , a GCR (General Control Register) 8 and an external I/O 55 mutually connected to the SW 2 via the bus 9 , and a power supply package (power supply PKG) 10 . The power supply package 10 is connected to an AC power source 13 , and the external I/O 55 is connected to a terminal for monitoring (Maintenance Console) 66 .
[0035] Additionally, the NNI 6 is provided with a framer 7 connected to the bus 9 in the ATM-HUB 1 . The framer 7 is connected to the SW 2 in the ATM-HUB 1 and is connected to the NNI 10 via the reception optical cable 27 and the transmission optical cable 28 .
[0036] Now, the ATM-HUB 14 and the NNI 19 are structured almost similarly to the above-described ATM-HUB 1 and NNI 6 . That is, the ATM-HUB 14 is provided with a SW 15 connected to an UNI 51 and a NNI 9 , a SW-CTL 16 connected to the SW 15 via a bus 22 , a micro processor 18 , a SRAM 57 , a GCR 21 and an external I/O 56 connected to the SW-CTL 16 via the bus 22 , and the power supply package 25 connected to the GCR 21 . Then, the power supply package 25 is connected to an AC power source 26 , and the external I/O 56 is connected to a terminal for monitoring (Maintenance Console) 67 .
[0037] Additionally, the NNI 19 is provided with a framer 20 connected to the bus 22 in the ATM-HUB 14 . The framer 20 is connected to the SW 15 in the ATM-HUB 14 and is connected to the NNI 6 via the reception optical cable 27 and the transmission optical cable 28 .
[0038] Each component of the ATM-HUB 14 and the NNI 19 functions similarly to each component of the ATM-HUB 1 and the NNI 6 , therefore, an explanations will be given of each component of the ATM-HUB 1 and the NNI 6 as a sample.
[0039] The SW 2 of the ATM-HUB 1 performs switching of cells received from the UNI 50 or the NNI 6 in accordance with instructions from the SW-CTL 3 . The SW-CTL 3 controls the switching of the SW 2 . The SW-CTL 3 is provided with a SAR (Segmentation and Reassembly) part 4 assembling and disassembling cells.
[0040] The SAR part 4 generates a OAM cell (Operation and Maintenance Cell) for network system maintenance in accordance with an order from the micro processor 5 or the SW-CTL 3 . The OAM cell is transmitted to the ATM-HUB 14 .
[0041] The micro processor 5 consists of a CPU (Central Processing Unit), a ROM (Read Only Memory) in which a control program is recorded, a RAM (Random Access Memory) to be a work area for the CPU, and so on. The micro processor 5 executes the control program recorded in the ROM, thereby controlling the SW-CTL 3 , the framer 7 , the GCR 8 , the SRAM 35 and the external I/O 55 . The GCR 8 stores information from the power supply package 10 . The SRAM 35 receives information from the SW-CTL 3 and kept it.
[0042] The external I/O 55 is an I/O (Input/Output unit) based on RS-232 or 10BASE-T. The external I/O 55 converts data in the ATM-HUB 1 into a data type so that the data can be transmitted to the terminal 66 , and transmits the data to the terminal 66 . Further, the external I/O 55 converts the data transmitted from the terminal 66 into a data type so that the micro processor 5 can utilize the data.
[0043] The power supply package 10 receives power supplied from the AC power source 13 , and functions as a +5V/E power source for each part of the ATM-HUB 1 . Moreover, the power supply package 10 , when the AC power source 13 cut off power to the power supply package 10 (the power supplied by the AC power source 13 is lower than a predetermined value), inputs an AC input interruption signal 12 into the GCR 8 . The power supply package 10 , when a not-shown the manual power supply switch of the ATM-HUB 1 becomes OFF, inputs a stop of hand operated power supply signal 11 into the GCR 8 .
[0044] The terminal 66 is a personal computer or a work station provided with a processor device, a display unit (such as a CRT display and a liquid crystal display) and an input device (such as a keyboard and a mouse), and is operated by an administrator of the ATM-HUB 1 (or an administrator of the network system).
[0045] The framer 7 provided in the NNI 6 converts cells received from the ATM-HUB 1 into the ATM frame interface of SDH. That is, the framer 7 crams a plurality of cells received from the ATM-HUB 1 into a predetermined SDH frame, and then transmits the frame to the DSU 29 .
[0046] Further, the framer 7 detects a communication failure occurring between the ATM-HUB 1 and the ATM-HUB 14 . That is, the framer 7 detects, as communication failures, LOS (a state that no signal is transmitted from the ATM-HUB 14 ), LOF (a state that no frame (SDH frame) is transmitted from the ATM-HUB 14 ), OOF (a state that frames are transmitted from the ATM-HUB 14 but synchronized), LOP (a state that no pointer indicating a top of the cell is found) and LOC (a state that no cell transmitted from the ATM-HUB 14 is found). The framer 7 is provided with a failure indicate register 7 a in which information showing communication failures (failure information), and stores the information showing the detected communication failure into the failure indicate register 7 a for using the information as a failure indicator.
[0047] The micro processor 5 accesses the failure indicate register 7 a regularly and monitors whether a communication failure occurs between the ATM-HUB 1 and the ATM-HUB 14 (between segments).
[0048] [Operation in Network System]
[0049] Next, explanations will be given of operations (processes by the ATM-HUB 1 and the ATM-HUB 14 ) in the network system according to Embodiment 1 in a plurality of states.
[0050] <Case that Hand Operated Power Supply of ATM-HUB is Stopped>
[0051] First, an explanation is given of an operation in the network system when a hand operated power supply of the ATM-HUB 1 or the ATM-HUB 14 is stopped by a operator et al. In FIG. 1, the micro processor 5 in the ATM-HUB 1 (the micro processor 18 in the ATM-HUB 14 ) regularly accesses the failure indicate register 7 a in the framer 7 (the failure display register 20 a in the framer 20 ), and monitors whether a communication failure occurs between the ATM-HUB 1 and the ATM-HUB 14 (between segments) or not.
[0052] For example, as shown in FIG. 2, it is assumed that the not-shown hand operated power supply switch in the ATM-HUB 14 is turned OFF. Then, the ATM-HUB 14 becomes a state that the hand oprated power supply is a stop, and then cut off power after a predetermined time passes.
[0053] On the other hand, when the not-shown hand operated power supply switch of the ATM-HUB 14 is turned OFF, the power supply package 25 notifies a hand operated power supply stop signal 23 to the GCR 21 . The GCR 21 , when receiving the hand operated power supply stop signal 23 , generates a break signal (IRQ in FIG. 2) indicating that the hand operated power supply switch is turned OFF and transmits it to the micro processor 18 .
[0054] The micro processor 18 , when receiving IRQ, generates a massage (a hand operated power supply stop message: corresponding to the device failure information of the present invention) indicating that the ATM-HUB 14 stops by a stop of the hand operated power supply after a predetermined time passes, and transmits the message to the SAR part 17 in the SW-CTL 16 . Then, as shown in FIG. 3, the SAR part 17 generates an OAM cell in accordance with a command from the micro processor 18 , and stores the hand operated power supply stop message into the OMA cell. Then, the generated OAM cell is transmitted to the NNI 19 via the SW 15 .
[0055] Thereafter, the OAM cell is transmitted to the ATM-HUB 1 via the NNI 6 . In the ATM-HUB 1 , the OAM cell is transmitted to the SAR part 4 of the SW-CTL 3 via the SW 2 . The SAR part 4 takes out the hand operated power supply stop massage containing the OAM cell received from the NNI 6 , and transmits the massage to the micro processor 5 . The micro processor 5 stores the hand operated power supply stop massage into the SRAM 35 .
[0056] Thereafter, the ATM-HUB 14 stops by the stop of the hand operated power supply. Then, the ATM-HUB 14 stops transmitting output signals outputted from the NNI 19 , the framer 7 in the NNI 6 respectively detects LOS, LOF, OOF, LOP and LOC which are failure information in the ATM-HUB 14 . Then, the framer 7 stores each information indicating these communication failures in the failure indicate register 7 a.
[0057] The micro processor 5 of the ATM-HUB 1 regularly accesses the failure indicate register 7 a , thereby reading storage contents in the failure indicate register 7 a . At that time, the micro processor 5 reads storage contents in the SRAM 35 . Then, the micro processor 5 makes a display unit of the terminal 66 display an image on the basis of these contents as alarm logging.
[0058] With this arrangement, the display unit of the terminal 66 displays that a communication failure such as LOS occurs in the ATM-HUB 14 and that the ATM-HUB 14 stops by the stop of hand operated power supply cut. Accordingly, it is possible for the administrator for the ATM-HUB 1 (the administrator of the network system) to know that a communication failure occurs in the ATM-HUB 14 caused by that the power supply for the ATM-HUB 14 is manually cut.
[0059] Additionally, when the not-shown hand operated power supply switch in the ATM-HUB 1 is turned OFF, the network system operates similarly to the above operation. Thus, the terminal 67 for the ATM-HUB 14 displays that a communication failure occurs and that the ATM-HUB 1 stops caused by the stop of the hand operated power supply cut.
[0060] <Case that ATM-HUB is Stopped by Outage or the Like>
[0061] Next, an explanation is given of the action of the network system, when the ATM-HUB 1 or the ATM-HUB 14 is stopped by outage or the like. In FIG. 1, the micro processor 5 of the ATM-HUB 1 (the micro processor 18 of the ATM-HUB 14 ) regularly accesses the failure indicate register 7 a containing the framer 7 (the failure indicate register 20 a of the framer 20 ), and monitors whether a communication failure occurs between the ATM-HUB 1 and the ATM-HUB 14 (between segments) or not.
[0062] For example, as shown in FIG. 2, it is assumed that power supply to the power supply package 25 of the ATM-HUB 14 stopped by a outage and the like. Then, since power supply stops to the ATM-HUB 14 , the ATM-HUB 14 stops acting after a predetermined time passes.
[0063] Now, when power supply from the AC power source 26 to the power supply package 25 is stopped (when power to be supplied is lower than a predetermined value), the power supply package 25 notifies the GCR 21 of an AC input interruption notification signal 24 . The GCR 21 , when receiving the AC input interruption notification signal 24 , generates a break signal (IRG in FIG. 2) indicating that power supply from the AC power source 26 stops and transmits the signal to the micro processor 18 .
[0064] The micro processor 18 , when receiving the IRQ, generates a message (AC input interruption message: corresponding to the device failure information of the present invention) indicating that the ATM-HUB 14 stops by the AC input interruption after a predetermined time passes and transmits the message to the SAR part 17 of the SW-CTL 16 . Then, as shown in FIG. 3, the SAR part 17 generates a OAM cell in which the AC input interruption message is stored. Then, the generated OAM cell is transmitted to the NNI 19 via the SW 15 .
[0065] The sequent action is almost similar to that of the hand oprated power cut as above described, therefore, an explanation thereof is omitted. Finally, the display unit of the terminal 66 displays that a communication failure such as LOS occurs in the ATM-HUB 14 and that the ATM-HUB 14 stops acting caused by the AC input interruption.
[0066] Accordingly, it is possible for the administrator of the ATM-HUB 1 (the administrator of the network system) to know that power supply to the ATM-HUB 14 is cut off by outage, thereby stopping the ATM-HUB 14 , and that a communication failure occurs between the ATM-HUB 1 and the ATM-HUB 14 , based on contents displayed by the terminal 66 .
[0067] Additionally, when power supply to the ATM-HUB 1 is stopped, the network system acts similarly to the above-described action. With this arrangement, the terminal 67 of the ATM-HUB 14 displays that a communication failure occurs and that the ATM-HUB 1 stops caused by outage.
[0068] <Case that Line Registration Between ATM-HUBs is Canceled>
[0069] Next, an explanation is given of the operation of the network system in a case that a line registration between the ATM-HUB 1 and the ATM-HUB 14 is canceled. For example, it is assumed that the administrator of the ATM-HUB 14 inputs a line blockade command from the terminal 67 of the ATM-HUB 14 so as to erase the line registration connecting the ATM-HUB 1 and the ATM-HUB 14 .
[0070] Then, the line blockade command is transmitted to the micro processor 18 via the external I/O 56 . The micro processor 18 generates a message (a line blockade message: corresponding to the device failure information of the present invention) indicating that the line blockade command is input into the ATM-HUB 14 , and transmits the message to the SAR part 17 of the SW-CTL 16 . The SAR part 17 generates an OAM cell in which the line blockade message is stored. Then, the generated OAM cell is transmitted to the NNI 19 via the SW 15 .
[0071] The OAM cell is transmitted to the ATM-HUB 1 via the NNI 6 . In the ATM-HUB 1 , the OAM cell is transmitted to the SAR part 4 of the SW-CTL 3 via the SW 2 . The SAR part 4 takes the line blockade message out of the OAM cell received from the NNI 6 and gives the massage to the micro processor 5 . The micro processor 5 stores the line blockade message into the SRAM 35 .
[0072] Thereafter, in the ATM-HUB 14 , the micro processor 18 performs a line registration erasion process between the ATM-HUB 1 and the ATM-HUB 14 . As the result, no output signal from the ATM-HUB 14 is transmitted to the NNI 6 , therefore, the framer 7 of the NNI 6 respectively detects LOS, LOF, OOF, LOP and LOC between the ATM-HUB 1 and the ATM-HUB 14 . Then, the framer 7 stores each of information indication these communication failures into the failure indicate register 7 a.
[0073] The micro processor 5 of the ATM-HUB 1 regularly accesses the failure indicate register 7 a , thereby reading contents in the failure indicate register 7 a . At the same time, the micro processor 5 reads the contents of the SRAM 35 . Then, the micro processor 5 makes the display unit of the terminal 66 display an image on the basis of these contents as alarm logging.
[0074] With this arrangement, the display unit of the terminal 66 displays that a communication failure such as LOS occurs in the ATM-HUB 14 and that a line blockade command between the ATM-HUB 1 and the ATM-HUB 14 is input into the ATM-HUB 14 . Therefore, it is possible for the administrator of the ATM-HUB 1 (the administrator of the network system) to know that a line between the ATM-HUB 1 and the ATM-HUB 14 is blockaded, whereby a communication failure occurs, based on the contents displayed by the terminal 66 .
[0075] In addition, the network system acts similarly to the above-described action when no line blockade command is input from the terminal 66 in the ATM-HUB 1 . With this arrangement, the terminal 67 of the ATM-HUB 14 displays that a communication failure occurs and that a line blockade command is input into the ATM-HUB 1 .
[0076] <Case that Optical Cable is Removed from NNI>
[0077] Next, an explanation is given of the operation of the network system in a case that the optical cable (the reception optical cable 271 and the transmission optical cable 28 ) connecting the NNI 6 and the NNI 19 is removed from the NNI 6 or the NNI 19 .
[0078] For example, it is assumed that the administrator of the ATM-HUB 14 removes the reception optical cable 27 connected with the NNI 19 . At that time, the administrator of the ATM-HUB 14 , before removing the cable, inputs a command (cable cut command) indicating that the cable is removed via the terminal 67 .
[0079] Then, the cable cut command is given to the micro processor 18 through the external I/O 56 . The micro processor 18 generates a message (cable cut message) indicating that the reception optical cable 27 is removed from the NNI 19 , and gives the message to the SAR part 17 in the SW-CTL 16 . Then, the SAR part 17 generates an OAM cell in which the cable cut message. The generated OAM cell is transmitted to the NNI 19 through SW 15 .
[0080] Then, the OAM cell is transmitted to the ATM-HUB 1 through the NNI 6 . In the ATM-HUB 1 , the OAM cell is given to the SAR part 4 in the SW-CTL 3 through the SW 2 . The SAR part 4 takes the cable cut message out from the OAM cell received from the NNI 6 , and gives it to the micro processor 5 . The micro processor 5 stores the cable cut message in the SRAM 35 .
[0081] Thereafter, the administrator of the ATM-HUB 14 removes the reception optical cable 27 from the NNI 19 . As a result, since the output signal from the ATM-HUB 16 is not transmitted to the NNI 6 , the framer 7 in the NNI 6 respectively detects LOS, LOF, OOF, LOP and LOC in the ATM-HUB 14 . Then, the framer 7 stores respective information showing theses communication failures in the failure display register 7 a.
[0082] The micro processor 5 of the ATM-HUB 1 reads contents stored in the failure indicate register 7 a by periodical accesses to the failure indicate register 7 a . At the same time, the micro processor 5 reads the contents stored in the SRAM 35 . Then, the micro processor 5 makes the display unit of the terminal 66 show the image on the basis of these as alarm logging.
[0083] Consequently, the display unit of the terminal 66 shows that a communication failure such as LOS occurs in the ATM-HUB 14 , and that the thee reception optical cable 27 is received from the NNI 19 . Accordingly, the administrator of the ATM-HUB 1 (the administrator of the network system) can know that a communication failure occurs in the ATM-HUB 14 since the reception optical cable 27 is removed from the NNI 19 , based on the contents displayed on the terminal 66 .
[0084] In addition, when the transmission optical cable 28 is removed from the NNI 6 , the administrator of the ATM-HUB 1 inputs a cable cut command through the terminal 66 , whereby the network system operates similarly to the above described case. As a result, the terminal 67 of the ATM-HUB 14 displays that a communication failure occurs and the transmission optical cable 28 is removed from the NNI
[0085] [Effective of Embodiment 1]
[0086] According to the network system of the above described embodiment 1, it is possible to notify a in-device failure occurring by a stop of hand oprated power supply of the ATM-HUB 1 and the ATM-HUB 14 , AC input interruption, cancel of line registration or removing an optical cable of the administrator for ATM-HUB to be an opposite device (the administrator for the network system).
[0087] Accordingly, the administrator of the ATM-HUB 1 , 14 can precisely know that a communication failure occurs because of the in-device failure, therefore, the administrator of the ATM-HUB 1 , 14 can deal with the communication failure appropriately. That is, the administrator of the ATM-HUB 1 , 14 can know that the communication failure is not caused by communication quality deterioration of the network system (a trouble of the cable and the communication device in the network system, therefore, it is possible to avid an useless inspection or the like for the cable and the communication device.
[0088] [Embodiment 2]
[0089] Next, explanations will be given of the network system of the embodiment 2 according to the present invention.
[0090] [Whole Structure of Network System]
[0091] [0091]FIG. 5 is a whole block-diagram showing a network system of the embodiment 2 according to the present invention. In FIG. 5, the network system of the embodiment 2 is structured as follows. That is, the ATM-HUB 1 accepts an UNI 50 . The UNI 50 is respectively connected to an ATM-HUB 60 , an ATM router 70 and an ATM switch 80 through communication cables. Each of the ATM-HUB 60 , the ATM router 70 and the ATM switch 80 connects a plurality of user terminal units (hereinafter, called terminal) SUN.
[0092] The ATM-HUB 1 accomodates a NNI (Network Node Interface) 6 . The NNI 6 is connected to a DSU (Digital Service Unit) 29 through the reception optical cable 27 and the transmission optical cable 28 . The DSU 29 is connected with a WAN (Wide Area Network) 31 through the communication line.
[0093] The WAN 31 is connected with a DSU 30 through a communication line. The DSU 30 is connected to the NNI 19 through a optical cable, and the NNI 19 is accepted by an ATM-HUB 14 . The ATM-HUB 14 accepts an UNI 51 , and the UNI 51 is connected with a plurality of terminals SUN.
[0094] The ATM-HUB 60 , the ATM router 70 and the ATM switch 80 respectively receive cells from the terminals SUN connected to themselves and transmits the cells to the UNI 50 . Then, each of the ATM-HUB 60 , the ATM router 70 and the ATM switch 80 transmits the cell received from the UNI 50 to one corresponding terminal in accordance with the header information thereof.
[0095] The UNI 50 transmits the cells received from the ATM-HUB 60 , the ATM router 70 and the ATM switch 80 to the ATM-HUB 1 at a predetermined transmission speed. Here, the UNI 50 transmits cells at a transmission speed according to SDH.
[0096] The ATM-HUB 1 , when receiving a cell from the UNI 50 , performs routing to the received cell and then transmits the cell to the NNI. The ATM-HUB 1 , when receiving a cell from the NNI 6 , performs routing as to the received cell and transmits the cell to the UNI 50 .
[0097] The NNI 6 transmits the cell received from the ATM-HUB 1 to the DSU 29 at the transmission speed according to SDH. The NNI 6 also receives a cell from the DSU 29 and transmits this cell to the ATM-HUB 1 . The DSU 29 transmits the cell received from the NNI 6 to the WAN 31 . The DSU 29 also receives a cell from the WAN 31 , and transmits the received cell to the NNI 6 .
[0098] The WAN 31 is a digital public network (B-ISDN) consisting of plural nodes and plural lines. The WAN 31 transmits a cell received from the DSU 29 to the DSU 30 and transmits a cell received from the DSU 30 to the DSU 29 . No explanation is given of the NNI 19 , the ATM-HUB 14 and the UNI 51 , since each of them functions similarly to each of the NNI 6 , the ATM-HUB 1 and the NNI 50 which are above described.
[0099] In addition, the ATM-HUB 1 , the NNI 6 , the ATM-HUB 14 and the NNI 19 shown in FIG. 5 are structured almost similarly to those of Embodiment 1 , therefore, explanation of them are omitted.
[0100] [Operation in Network System]
[0101] Next, explanations will be given of the operation in the network system according to the Embodiment 2 (process by the ATM-HUB 1 and the ATM-HUB 14 ) as to plural situations. In the network system shown in FIG. 5, when data is transmitted between one terminal SUN connected to one of the ATM-HUB 60 , the ATM router 70 and the ATM switch 80 and one terminal SUM connected to the UNI 51 (end-to-end), a signaling procedure is executed. As a result, a connection establishes between terminals, and a call establishes. Then, cells are transmitted between terminals, whereby data is communicated between terminals.
[0102] <Case that Hand Operated Power Supply of ATM-HUB is Stopped>
[0103] First, an explanation is given of the operation in the network system when power supply to the ATM-HUB 1 or the ATM-HUB 14 is stopped by hand during data communication between end-to-end.
[0104] In FIG. 5, the micro processor 5 of the ATM-HUB 1 (the micro processor 18 of the ATM-HUB 14 ) periodically accesses the failure indicate register 7 a in the framer 7 (the failure indicate register 20 a in the framer 20 a ), thereby monitoring whether a communication failure occurs between the ATM-HUB 1 and the ATM-HUB 14 (between segments) or not.
[0105] For example, a hand oprated power supply switch not shown of the ATM-HUB 14 is turned OFF, the power supply package 25 notifies the GCR 21 of the hand oprated power supply stop signal 23 . The GCR 21 , when receiving the hand oprated power supply stop signal 23 , gives a break signal (IRQ) indicating that the not shown hand oprated power supply switch is turned OFF to the micro processor 18 .
[0106] The micro processor 18 , when receiving the IRQ, generates the above described hand oprated power supply cut message and gives it to the SAR part 17 of the SW-CTL 16 . Then, the SAR part 17 generates an OAM cell in which the hand oprated power supply cut message is stored. The generated OAM cell, as shown in FIG. 6, is transmitted to the NNI 19 through the SW 15 .
[0107] Thereafter, the OAM cell is transmitted to the ATM-HUB 1 through the NNI 19 , the DSU 30 , the WAN 31 , the DSU 29 , the reception optical cable 27 and the NNI 6 . In the ATM-HUB 1 , the OAM cell is given to the SAR part 4 in the SW-CTL 3 through the SW 2 .
[0108] The SAR part 4 , when receiving an OMA cell, generates three copies from the OAM cell. Successively, the SAR part 4 determines the ATM-HUB 60 , the ATM router 70 and the ATM switch 80 as destinations for generated OAM cells. Then, theses three OAM cells are transferred to the UNI 50 through the SW 2 , and then are respectively transmitted to the ATM-HUB 60 , the ATM router 70 and the ATM switch 80 .
[0109] In this way, the OMA cell received by the ATM-HUB 1 is broadcasted to the ATM-HUB 60 , the ATM router 70 and the ATM switch 80 .
[0110] Then, the SAR part 4 takes out the hand oprated power supply cut message from the OAM cell received from the NNI 6 and transmits it to the micro processor 5 . The micro processor 5 stores the hand oprated power supply cut message in the SRAM 35 .
[0111] Now, the ATM-HUB 14 stops operating by a stop of the hand oprated power supply after a predetermined time passes. Thus, since the transmission of the output signal of the ATM-HUB 14 via the NNI 19 stops, the DUS 30 detects LOS in the ATM-HUB 14 . Then, the DSU 30 stops outputting a signal to the DSU 29 . Thus, the DSU 29 detects LOS in the DSU 30 . The DSU 29 , when detecting LOS, transmits an AIS (Alarm Indication Signal) to the NNI 6 .
[0112] The framer 7 in the NNI 6 , when receiving the AIS from the DSU 29 , stores information indicating that the AIS is received in the failure indicate register 7 a . Then, the micro processor 5 of the ATM-HUB 1 periodically accesses the failure indicate register 7 a , thereby reading the contents stored in the failure indicate register 7 a . At the same time, the micro processor 5 reads the contents stored in the SRAM 35 . Then, the micro processor 5 makes the display unit of the terminal 66 display an image on the basis of these contents as alarm logging.
[0113] With this arrangement, the display unit of the terminal 66 displays that the AIS is received from the DSU 29 and the ATM-HUB 14 stops by a stop of the hand oprated power supply. Thus, the administrator of the ATM-HUB 1 (the administrator of the network system), based on the displayed contents of the terminal 66 , can know that the AIS is transmitted from the DSU 29 by a stop of the hand oprated power supply of the ATM-HUB 14 .
[0114] Each of the ATM-HUB 60 , the ATM router 70 and the ATM switch 80 , when receiving the OAM cell from the UNI 50 , makes a display unit not shown of the terminal connected to each of them display an image on a basis of the hand oprated power supply cut message contained in the OAM cell. Thus, each administrator of the ATM-HUB 60 , the ATM router 70 and the ATM switch 80 can know that the communication failure occurs by the hand oprated power supply cut between the ATM-HUB 1 and the ATM-HUB 14 .
[0115] In addition, when power supply is stopped by outage and so on, when the line registration between ATM-HUBs is canceled and when the optical cable is removed, the operation of the network system is almost similar to that of the network system of the embodiment 1, therefore, no explanation is given.
[0116] [Effect of Embodiment 2]
[0117] The effect of the network system according to the embodiment 2 is almost similar to the effect of the network system according to the embodiment 1. That is, it is possible to clearly know a cause of communication failure occurrence at the side of the communication device (ATM-HUB 1 ) which detects the communication failure, therefore, the administrator of the ATM-HUB 1 (the administrator of the network system can appropriately deal with this communication failure.
[0118] Each administrator of the ATM-HUB 60 , the ATM router 70 and the ATM switch 80 can clearly know a cause of the communication failure occurring in the network system, therefore, it is possible to deal with the communication failure appropriately.
[0119] In addition, each of the UNI 50 , the NNI 6 , the NNI 19 and the UNI 51 transmits cells at a transmission speed according to SDH (digital hierarchy), however, each of them may transmits cells at a speed according to SONET (Synchronous Optical Network), E3 or DS-3 (Digital Signal Level-3) instead of SDH.
[0120] Further, in the embodiments 1 and 2, the network system is provided with ATM-HUB 1 and the ATM-HUB 14 , however, a network system may be provided with an ATM router, an ATM handler or an ATM switch instead of the ATM-HUB 1 or the ATM-HUB 14 only when the network system is provided with one of the ATM-HUB 1 and the ATM-HUB 14 .
[0121] Moreover, in the embodiments 1 and 2, the explanations are given of the ATM network system, however, the present invention may be applied to another type of network system such as frame relay network system and packet network system. | A network system comprises a first communication device and a second communication device. When device failure caused in the first communication device, the first communication device ganerates the device failure information and transmits the device failure information to the second communication device. The second communication device receives the device failure information, and memorizes the device failure information, and makes a display unit display the device failure information. | 7 |
RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/270,483 filed Feb. 21, 2001.
FIELD OF THE INVENTION
The present invention relates to a nonwoven material suitable for use as a battery separator. More particularly, the invention is directed to a nonwoven material formed from a laminate of nonwoven webs.
BACKGROUND OF THE INVENTION
Various kinds of battery constructions utilize a porous battery separator material disposed between the battery electrodes for positioning the electrodes in a spaced apart relationship and to maintain the battery electrolyte in contact with the electrodes. For example, one known construction consists of a wound anode interleaved with a wound cathode, with the wound anode and cathode being spaced apart from one another by a nonconductive porous separator material which is impregnated with electrolyte. Various battery separators have been produced from nonwoven webs of fibrous materials. For example, Williams et al. U.S. Pat. No. 6,174,826 describes a nonwoven battery separator material which is formed from a blend of polypropylene staple fibers and polyethylene/polypropylene sheath/core bicomponent fibers. Published PCT Application WO 00/41254 describes a nonwoven battery separator material which includes thermoplastic polymeric fibers blended with a hydrophilic melt additive.
Although nonwoven webs of this type offer many advantageous features, the need exists for greater control over the uniformity, strength, dimensional stability, electrolyte transport properties and other characteristics of a nonwoven battery separator. For example, it is important that the battery separator have uniformity in thickness and basis weight, avoiding holes or thin areas that could produce short circuits or variations in the resistance or other electrical properties.
SUMMARY OF THE INVENTION
The present invention provides a material having a laminated construction formed of multiple nonwoven web layers. The material has utility as a battery separator material. The laminated battery separator material of the present invention comprises a first layer of nonwoven fibers defining a first surface of the battery separator; a second layer of nonwoven fibers defining the opposite surface of the battery separator; and a third layer of nonwoven fibers located between the first and second layers. The layers are bonded together to form a laminate. At least one of the nonwoven layers comprises a nonwoven web of meltblown fibers. Additionally, one or more of the layers has been rendered permanently hydrophilic by forming the nonwoven web from fibers of a normally hydrophobic polymer having a hydrophilic melt additive incorporated therein.
Preferably, at least one of the nonwoven web layers of the laminate contains binder fibers having a melting or fusing point lower than the fibers of the other layers. The binder fibers of this layer can be activated by heating so as to bond the layers of the laminate together while preserving the integrity of the other layers.
Preferably, at least the web formed of meltblown fibers is made from a normally hydrophobic polymer having a durable hydrophilic melt additive incorporated therein. The hydrophilic melt additive may comprise at least one member selected from the group consisting of monomer or dimer fatty acids having a carbon chain length in the range of 6 to 50, hydroxy phenols, polyethylene glycol, polyvinyl alcohol, and polyvinyl formal. One or more of the other layers of the separator may also be made permanently hydrophilic in this manner.
The nonwoven webs used in the laminated battery separator may be formed by various processing techniques known in the nonwovens industry. For example, the webs may comprise an air-laid web of staple fibers, a carded web of staple fibers, a wet-laid web of staple fibers, a web of meltblown fibers or a spunbonded web of substantially continuous filaments. The various nonwoven layers may be arranged in various configurations to provide the desired mechanical, electrical and electrolyte transport properties.
For example, in one specific embodiment, the laminated battery separator material comprises a first layer formed of meltblown nonwoven fibers defining a first surface of the battery separator; a second layer formed of nonwoven fibers defining the opposite surface of the battery separator; and an intermediate third layer of wet-laid nonwoven fibers located between said first and second layers and bonded to said first and second layers to form a laminate. At least one of the first and third layers comprises permanently hydrophilic fibers formed of a normally hydrophobic polypropylene polymer having a hydrophilic melt additive incorporated therein. In one preferred specific embodiment, both outer layers of the laminated battery separator material are formed of meltblown nonwoven fibers formed of a normally hydrophobic polypropylene polymer having a hydrophilic melt additive incorporated therein. In another preferred specific embodiment, the first layer is formed of meltblown fibers containing a hydrophilic melt additive, so that this surface of the separator is hydrophilic and promotes wicking and retention of the electrolyte, and the opposite surface of the separator is hydrophobic and is formed from meltblown fibers of a normally hydrophobic polymer. Between the two outer meltblown layers, there is provided a bonding layer, preferably a wet-laid nonwoven formed of staple fibers, at least some of which are formed of or contain a relatively lower melting polymer so as to function as binder fibers. The fibers of this layer may be hydrophobic, permanently hydrophilic, or a blend of hydrophobic and hydrophilic fibers.
Other exemplary constructions include a wet-laid-meltblown-carded laminate; a meltblown-spunbond-wet-laid laminate; a meltblown-wet-laid-carded laminate, a meltblown-wet-laid-wet-laid laminate and a wet-laid-meltblown-wet-laid laminate. The separator material can also contain more than three layers. At least one of the outer layers is rendered permanently hydrophilic by incorporating into a normally hydrophobic polyolefin polymer, at least one hydrophilic melt additive.
The nonwoven webs used in the laminated battery separator of the present invention may include multicomponent fibers which include a first component formed of a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive. This second component is disposed at the surface of the fibers. The hydrophilic melt additive-modified polyolefin component can be arranged in various configurations in the cross-section of the fiber and the fibers can have various cross-sections. For example, the hydrophilic component can occupy a portion of the surface of the fiber, as would occur for example with a side-by-side or segmented pie multicomponent fiber cross-sectional configuration.
There are various melt additives available which can be melt blended with a hydrophobic polyolefin composition to impart durable hydrophilic properties to the polyolefin. Melt additives suitable for the present invention must not undesirably alter the melt-spinability of the multicomponent fibers and should be relatively compatible with the polyolefin composition such that the additive will not prematurely leach out and lose the hydrophilic properties. Certain suitable melt additives useful in the present invention will be at least partially immiscible with the polyolefin polymer composition and will tend to bloom to the fiber surface over time or with application of heat to impart a prolonged hydrophilic surface modification. Particularly suitable are compounds with a molecular structure which includes at least one functional group which is tethered to the olefin polymer structure, with other functional groups which provide reactive hydrophilic sites. Suitable hydrophilic melt additives for use in the present invention include monomer or dimer fatty acids, hydroxy phenols, polyethylene glycol, fluorohydrocarbons, polyvinyl alcohol and polyvinyl formal.
One particularly suitable class of melt additives is an admixture of hydroxy phenols and polyethylene glycols. The hydroxy phenol is characterized in that it contains the functional group HOC 6 H 4 —.
Another particularly suitable class of melt additives are monomer and dimer fatty acids having a carbon chain length in the range of 6 to 50, preferably 18 to 36.
According to one embodiment of the invention, the nonwoven web is fabricated employing wet laid and/or carded thermal bonding processes. It is possible to use combinations of hydrophobic and hydrophilic fibers in the web. In other words, all fibers in the web need not be permanently wettable.
In one specific preferred embodiment, the web includes bicomponent fibers in which the melt additive is incorporated into the sheath constituent of the fiber. Use of bicomponent fibers, as well as combinations of hydrophobic and hydrophilic fibers, reduces costs and permits optimization of the web for diverse applications. In another of the embodiments of the present invention, the wettable fibers are blended with non-wettable binder fibers. Preferably these binder fibers are polyethylene/polypropylene bicomponent fibers having a polyethylene sheath and a polypropylene core. In still another embodiment of the invention, the nonwoven web includes both non-wettable binder fibers and wettable binder fibers. The wettable binder fibers are preferably polyethylene/polypropylene bicomponent fibers where the hydrophilic melt additive is incorporated into the polyethylene sheath of the bicomponent fiber. The non-wettable binder fibers may comprise polyethylene/polypropylene bicomponent fibers. In yet another embodiment, the nonwoven web is formed substantially entirely of wettable binder fibers of the type described.
In general, laminated battery separator materials of the invention have enhanced wetability and strength and provide good permeability to gases. More particularly, the laminated materials of the present invention can provide the very fine average pore sizes and bubble points (largest pore measurement) desired in many kinds of battery separators which maintaining excellent burst strength, tensile strength and dimensional stability. The laminates also provide the capability of imparting a gradient wettability to the material for better control over the wetting characteristics. For example, for certain end-use applications, the laminated material can have wettability on one surface and barrier properties on the opposite
The invention also includes the related process for making laminated nonwoven material which can be used as a battery separator which require durability and wettability. In general, wettable fibers with at least one hydrophilic melt additive are produced and formed into a nonwoven web by meltblowing, spunbonding other nonwoven formation methods. In one embodiment the fibers are further mixed with binder fibers which are then laid on a papermaking machine to form a wet-laid web. The water is removed from the wet-laid web, thermal bonded and calendered to form the nonwoven.
The laminated nonwoven materials of the present invention have particular utility as battery separator materials. However, the materials also can be advantageously employed in other end uses. For example, in the field of filtration, the various web layers can be selected to produce filtration media with various desired fluid transport and separation characteristics.
BRIEF DESCRIPTION OF THE DRAWING
Some of the features and advantages of the invention having been generally described, others will become apparent from the description which follows, and from the accompanying drawing, in which:
The FIGURE is a schematic cross-sectional view illustrating a laminated nonwoven material in accordance with the present invention.
DETAILED DESCRIPTION
The present invention will be described more fully hereinafter with reference to the accompanying drawing, in which one specific embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments illustrated or described herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
The hydrophilic melt additives are incorporated into the thermoplastic olefin polymer and are converted into a nonwoven web using any of various forming technologies available for the production of nonwoven webs. The material can be converted directly from the polymer into a nonwoven web by spunbonding or meltblowing or a combination of the two. Alternatively, the material may be first formed into fibers and the fibers may thereafter be converted into a nonwoven web by techniques such as wet-laying, air-laying or carding. By combining the melt additives and the nonwoven process, a durably hydrophilic nonwoven web is produced.
In one embodiment of the invention, the hydrophilic melt additives are blended with polypropylene and formed into multicomponent staple fibers to form a wettable fiber matrix. This matrix is then further combined with non-wettable binder fibers and wet-laid to form one of the layers of the nonwoven material of the invention. The non-wettable binder fibers used may include a bicomponent fiber comprising a polyethylene sheath and a polypropylene core, available as Chisso fibers from Chisso, Japan. The nonwoven material formed has both discrete hydrophobic and hydrophilic regions due to the different types of fibers used in making the web.
In an alternate embodiment the hydrophilic melt additives are blended with bicomponent fibers comprising a polypropylene sheath and a polypropylene core to form the wettable fiber matrix. The bicomponent sheath/core fiber proportions used in the invention may vary over a wide range, with from 50/50 sheath/core to 60/40 sheath/core being exemplary. Essentially the melt additives are incorporated into the outer sheath of the fibers. Use of bicomponent fibers having 60/40 sheath/core permit higher incorporation of the melt additive into the sheath portion. The wettable fibers may be then further combined with non-wettable binder fibers to form the nonwoven web.
In all embodiments, the durable hydrophilic web is manufactured by blending a concentrate of hydrophilic melt additives with the thermoplastic polymer and converting the polymer into fibers, and into a nonwoven web directly or through an intermediate fiber formation process. The type of melt additive and proportion can be varied as required to control the wettability of the particular nonwoven web layer.
In one embodiment, the melt additives used in the invention are selected from the group consisting of monomer and dimer fatty acids having a carbon chain length in the range of 6 to 50, preferably 36. In a preferred composition of this embodiment, the blend contains 2 to 15% Acintol® tall oil fatty acid, Acintol® distilled tall oils (monomer acids) and Sylvadym® dimer acids, which are all commercially available from Arizona Chemical Company, Panama City, Fla. and are fully described in the Technical Data Sheets for these materials, which are incorporated herein by reference. These are polar liquid materials which migrate to the surface of the polyolefin and remain as liquid on the surface thereof. Uniform mixing of the components is important to achieve effective hydrophilic properties. In another embodiment, the hydrophilic melt additives are fluorohydrocarbons, such as 3M FC 1296.
In another embodiment, the melt additives used in the invention are an admixture of hydroxy phenols and polyethylene glycols. Examples of melt additives used are commercially available from Techmer PM, California under the product designations PPM 11211, PPM 11249, PPM 11212, PPM 11267 and PPM 11268. This active or functional chemical is provided in a carrier resin, preferably polyolefin such as polypropylene or polyethylene, of a given melt flow rate (MFR) suitable for meltblowing, spunbonding or staple fiber manufacture. Accordingly, the formulations have different melt flow rates depending on the end use applications. The MFR listed in the formulations below were measured at 230° C., 2.16 kg. Melt blown grade polypropylene resins typically have a much higher melt flow rate (MFR 800–1200), whereas spunbond and staple fiber grade polypropylene resins have a lower melt flow rate (MFR 7–35). The base chemicals in the formulations include durable hydrophilic materials or non-durable hydrophilic materials depending on the desired wettability properties and end use applications. The non-durable hydrophilic materials provide initial wetting of the fibers to enhance and maximize incorporation of the durable hydrophilic materials. The durable hydrophilic materials impart the wettability and strength properties to the fiber materials.
For melt blown nonwoven structures, the fiber-forming polymer suitably contains from about 1% to about 20% by weight of the active durable hydrophilic additive. For spunbond webs and nonwoven webs containing staple fibers, the fibers can suitably contain from about 1% to about 15% by weight of the active durable hydrophilic additive. A small proportion of a non-durable hydrophilic additive may optionally also be included. The hydrophilic melt additives can be used in the following exemplary forms of nonwovens, namely meltblown, spunbond, wet-laid, dry-laid or a combination of these forms. Fiber deniers for melt blown structures typically range from 0.1 to 2.0 deniers, with less than 1.0 most preferred. In the case of staple fiber and spunbond filaments deniers, fiber deniers of less than 3.0 are used, but less than 2.0 are most preferred.
The fibers can be produced by blending the unmodified hydrophobic polyolefin resin, in chip or flake form as supplied by the resin supplier, with a melt additive masterbatch formulation which contains the active hydrophilic melt additive chemical in a polyolefin resin carrier. The following are exemplary melt additive masterbatch formulations:
Melt Additive 1 contains approximately 30% by weight of a durable active hydrophilic chemical with the balance being polypropylene, and is a commercially available composition sold as PPM 11211 from Techmer PM, California.
Melt Additive 2 contains approximately 30% by weight of a non-durable hydrophilic active chemical, with the balance being polypropylene, and is a commercially available composition sold as PPM 11212 from Techmer PM, California.
Melt Additive 3 contains approximately 25% of the same durable hydrophilic materials as in Melt Additive formulation 1. This additive has a MFR of 54 grams/10 minutes and is commercially available as PPM 11267 from Techmer PM.
Melt Additive 4 contains approximately 20% of the active chemical and includes the same non-durable hydrophilic materials as in Melt Additive formulation 2. This additive has a MFR of 109 grams/10 minutes and is commercially available as PPM 11268 from Techmer PM, California.
EXAMPLES
To understand the present invention more fully, several illustrative examples of the invention are described below. These examples are for purposes of illustration only and this invention should not be considered to be limited by any recitation used therein. The examples demonstrate the preparation of various laminated nonwoven materials in accordance with the present invention.
Test Procedures:
In the examples below, unless otherwise specified, the following test procedures were used:
Air Permeability. Air Permeability was measured in accordance with ASTM Test Method D737–96.
Tensile Strength. Machine direction (MD) and cross-machine direction (CD) tensile strength were measured an accordance with ASTM Procedure D5035.
Wicking. Wicking refers to the ability of a fabric to absorb a liquid through capillary action. Wicking values are obtained by determining the distance a solution of potassium hydroxide (KOH) is absorbed (wicked) by a fabric specimen held vertically. Specifically, three (3) specimens from each sample are cut 1 inch CD×7 inch MD (2.54 cm×17.8 cm). The specimens are conditioned by drying in an oven at 70° C. (158° F.) for 1 minute, removed from the oven, and conditioned to the lab environment for 15 minutes prior to testing. Each specimen of the fabric is suspended vertically in a 31% solution of KOH and the distance the liquid is absorbed by the specimen is measured after 30 minutes.
The 31% KOH solution was prepared as follows: Ingredients: Distilled water and potassium hydroxide pellets (KOH). Procedure: The distilled water is freed of dissolved carbon dioxide by boiling and covering with a watch glass. The boiled water is allowed to cool to room temperature. The solution should be 31% KOH by weight. Since solid KOH contains approximately 10% water, 34.5 g of solid KOH is used for every 100 g of solution required. The solution is made by slowly adding the 34.5 g of KOH to 65.5 g of water.
Bubble Point and Mean Pore Size. The mean pore size and bubble point (maximum pore size) measurements are from a Porous Materials Inc (PMI) Automated Capillary Flow Porometer. The company is located at 83 Brown Road, Ithaca, N.Y. 14850. The test method used is the standard supplied by the manufacturer.
Absorbency Under Pressure. Die cut 20 layers of fabric into 1 inch (2.54 cm) diameter circles. Stack the 20 circular samples, place in a heat-sealable plastic pouch and place the pouch assembly between two square plexiglass plates that can be tightened with bolts/wing-nuts on each of the four comers. Add sufficient 31% KOH to the pouch to saturate the samples and soak for 5 minutes, then drain the excess KOH. Vacuum fill the assembly two times to remove any trapped air and completely saturate the samples. Again drain any excess KOH. Weigh the sample and measure thickness after the 5-minute soak and after the second vacuum. Compress the assembly to 50 psi (345 kPa), adjust wing-nuts to maintain compression, drain excess KOH and then heat-seal the open end of the plastic pouch. Place the entire assembly in an oven at 60° C. for a minimum of 3 hours. Allow to cool, cut open bag and drain excess KOH. Compress assembly to 100 psi (690 kPa) and again adjust wing-nuts to maintain compression. Drain excess KOH. Measure weight and thickness of assembly after 50 psi compression, after 3+ hour heat treatment and after 100 psi compression. Calculate the absorbency at 100 psi in g/cc=grams of KOH absorbed at 100 psi /(thickness of 20 layers at 100 psi×area of the 2.54 cm diameter sample).
Hi Pot. Place rectangular fabric sample approximately 2⅝ inch×3¼ inch (6.7 cm×8.3 cm) between two aluminum test plates. Compress sample to 50 psi (345 kPa). Apply electrical potential across plates and increase voltage steadily until electrical arc occurs. Report voltage at which arcing begins. Measure 20 samples and report average voltage.
Ionic Resistance. Cut twenty one inch (2.54 cm) diameter samples from the sheet. Place in heat sealable pouch, cover with 31% KOH solution and seal pouch. Heat in 60° oven for 3 hours, cool for one hour before testing. Stack a 1″ diameter Ni disk+1″ diameter metal hydride electrode disk+two 1″ diameter separator samples (add few drops of 31% KOH)+1″ metal hydride electrode disk+1″ diameter nickel disk. Compress the assembly with a 50 psi (345 kPa) load. Measure the impedance between the two nickel disks using an Agilent Impedance Meter (Model HP4338B). Add two more fabric sample disks and measure the impedance with 4 layers of separator. Continue testing two additional layers at a time until all 20 layers are tested. Plot the measured impedance versus the number of layers. Calculate ionic resistance (ohm-cm)=slope×area of 1 inch diameter sample/thickness of 1 sample layer under compression.
Preparation of Nonwoven Webs
The nonwoven webs used in the laminated wettable battery separator materials described in Table 1 below were prepared as follows:
Meltblown webs having an average fiber diameter of 1 to 5 μm, preferably 1 to 2 μm are produced by blending polypropylene resin flake with the following masterbatch compositions: 2½ percent of the nondurable hydrophilic Melt Additive 2 and 20 percent of the durable hydrophilic Melt Additive 1. Thus, the fibers contain 6 percent of the active durable hydrophilic melt additive.
Wet-laid webs are produced from a blend of durably hydrophilic bicomponent fibers and unmodified, hydrophobic bicomponent fibers. The hydrophilic bicomponent fibers are 16.6 μm diameter fibers ½ inch (1.3 cm) staple length, and of a 50/50 sheath/core configuration, including a polyethylene sheath and a polypropylene core. The polyethylene sheath component contains 20% by weight of the durable hydrophilic Melt Additive 3 and 2½% of Melt Additive 4. The non-modified hydrophobic fibers are 17.5 μm diameter, 10 mm staple length fibers which are 50/50 concentric sheath/core polyethylene/polypropylene bicomponent fibers.
The carded thermal bond webs are produced from hydrophobic polypropylene fibers 1½ denier, 15 μm diameter, 1½ inch (3.8 cm) staple length.
The spunbond webs are produced from hydrophobic polypropylene filaments 15–20 μm in diameter.
The netting is produced from polypropylene strands 100–150 μm in diameter.
The nylon web is form from a blend of 10 μm and 19 μm nylon 6 fibers.
The various separately produced webs were arranged in stacked relation and directed through a heated calender equipped with smooth rolls to form laminates. The nip pressure and roll temperature and speed are adjusted to provide sufficient heat to activate the polyethylene component of the fibers so as to effect bonding without overly affecting the structure of the other web layers. An exemplary roll temperature for bonding polyethylene is 225° F. (107° C.). The physical properties of the laminates were measured, and are reported in Table 1.
TABLE 1
Trilaminate Physical Data & Description
Air
MD
CD
Perm
Ten-
Ten-
KOH
Ex-
Outer
Intermed.
Outer
Total
cm3/
sile
sile
Wick-
KOH
Bubble
Mean
am-
Wt.
Layer 1
Wt.
Layer 3
Wt.
Layer 2
Wt.
Caliper
cm2/
kg/
kg/
ing
Retenti-
Point
Pore
ple
gsm
Description
gsm
Description
gsm
Description
gsm
mm
sec
5 cm
5 cm
(mm)
vity (%)
microns
microns
1
10
PP
25
PE/PP
10
PP
47.3
0.15
17.4
10.8
5.9
80
301
22.4
12.7
Meltblown*
Wet Laid*
Meltblown*
2
46
PP
25
PE/PP
50
PP
121
0.257
1
16
8.5
118
156
9.8
4.2
Meltblown
Wet Laid*
Meltblown*
Liquid
Barrier
3
20
PP
25
PE/PP
5
PP
49
0.133
23.5
10.8
4.7
41
109
52.3
30
Thermalbond
Wet Laid
Meltblown*
4
10
PP
15
PP
30
PE/PP
55
0.115
12.4
16
7
35
125
39
21
Meltblown*
Spunbond
Wet Laid*
5
5
PP
25
PE/PP
10
PP
42
0.095
11.5
8.9
5.3
76
146
255
14.3
Meltblown
Wet Laid*
Meltblown*
6
30.5
PP Netting
21
PE/PP
10
PP
57.6
0.176
31
12.6
10.3
105
228
25.3
13.6
Wet Laid*
Meltblown*
PP = polypropylene
PE = polyethylene
*Polymer contains wettable melt additive
Example 2 has a hydrostatic head of 26 cm
As shown in the drawing FIGURE, the laminate includes outer layers 1 and 2 and an intermediate layer 3 located therebetween. The product of Example 1 was designed to promote wicking of the electrolyte. All three layers of the laminated battery separator are formed from fibers containing a hydrophilic melt additive, and both outer layers are meltblown webs. Example 2 was designed with a relatively heavy basis weight hydrophilic meltblown on one outer surface, and this outer layer together with the intermediate wet laid layer function as an electrolyte reservoir. The opposite outer surface is formed from a relatively heavy basis weight hydrophobic meltblown web and serves as a liquid barrier. The laminated separator has hydrostatic head of 26 cm. Example 3 is a laminated construction designed to provide higher MD tensile strength. The crimped staple fiber contained in the thermal bond layer, coupled with the thermal bond pattern of the layer contribute to providing flow channels within the separator material. The laminate of Example 4 is designed for enhanced strength while maintaining sufficient electrolyte wicking and retention. The laminate of Example 5 has limited hydrophobic properties on one surface and hydrophilic properties on the opposite surface. The laminate of Example 6 utilizes a polypropylene netting material for strength and to provide channels in the machine direction contributing to enhanced gas transport within the separator material.
A further example of a multi-layer nonwoven laminate structure is a trilaminate structure including PP Meltblown outer layer containing a durable hydrophilic melt additive, a wet-laid inner layer of PE/PP sheath/core bicomponent fibers in which the PE sheath component contains a durable hydrophilic melt additive, and an outer layer of wet-laid nylon fibers. This laminate exemplifies how two different kinds of fibers can be incorporated into different layers. One surface layer is formed of wet laid web of nylon fibers, while the opposite surface is formed of hydrophilic polypropylene meltblown fibers. Still another example is a trilaminate structure in which all three layers contain a durable hydrophilic melt additive, and arranged as follows: two wet-laid outer layers of PE/PP bicomponent fibers containing hydrophilic melt additive in the PE sheath component on opposite sides of a middle layer of PP meltblown fibers containing a hydrophilic melt additive.
Examples 7 and 8 illustrate products that are similar to Example 1, but differ in weight. Additional test data illustrating the utility of these materials for battery separators are available for these samples: KOH absorbency under pressure (which measures electrolyte retention under compression, such as would be found in a cell), ionic resistance (measures resistance to ion flow through electrolyte saturated separator), and hi-pot (resistance to shorting).
Preferably, nonwoven materials of the present invention intended for use as battery separators have the following physical properties:
hi-pot greater than 400 volts, and desirably greater than 500 volts;
ionic resistance less than 25 ohm-cm, more desirably less than 20 ohm-cm, and most preferably less than 15 ohm-cm; and
absorbency at 100 psi (690kPa) between 0.50 and 0.70 g/cm 3
Example 9 illustrates how a conventional grafting technology can be utilized in one of the layers in another embodiment of the invention. In this case, one outer layer contains acrylic acid grafted polypropylene. Similarly, a sulfonated or fluorinated fabric could be used as one of the layers.
The use of acrylic acid grafted or sulfonated polyolefin fabric as a separator is known to provide better self-discharge performance in a cell. It is thought that the grafted functional groups on the surface of these fabrics are able to capture trace metal ion and ammonia contaminants present in the positive electrode. These contaminants could migrate through a non-grafted separator and “poison” the surface of the negative electrode. Ammonia absorption capacity of the fabrics of examples 7 and 9 was measured by the following test: each fabric was soaked in 31% KOH containing 0.1M ammonium nitrate for 12 hours, then thoroughly rinsed in distilled water and dried. The amount of nitrogen absorbed by the fabric is then measured by the Kjeldahl method. Example 9, containing a grafted layer is seen to absorb 17 times as much nitrogen as Example 7. The Kjeldahl method is a well-known method for determining nitrogen content. The method involves treating the sample with concentrated H 2 SO 4 , KMnO 4 , and HClO 4 to convert the nitrogen into ammonium sulfate. The solution is diluted, excess alkali is added and the ammonia formed is distilled into a known quantity of standard acid. The amount of ammonia generated is determined by titrating the excess acid.
According to the present invention, melt additives containing anionic functional groups, such as —COO − , —SO 4 = , —SO 3 = , —PO 4 −3 , —CO 3 = , can be used to provide the same kind of improved self-discharge performance in polyolefin fabrics at lower cost than grafting. The melt additive can be incorporated in one or more of the laminate layers. An example of a melt additive that provides both hydrophilic and anionic functionality is Sylvadym® dimer acid, commercially available from Arizona Chemical Company.
TABLE 2
Example 7
Example 8
Example 9
Outer Layer 1
10
gsm PP meltblown*
15
gsm PP meltblown*
10
gsm PP meltblown*
Intermediate Layer
20
gsm PE/PP Wetlaid*
28
gsm PE/PP Wetlaid*
20
gsm PE/PP Wetlaid*
Outer Layer 2
10
gsm PP meltblown*
15
gsm PP meltblown*
55
gsm PP Spunbond**
Basis Wt., g/m 2
40.0
58.0
85
Caliper, mm
0.14
0.15
0.21
Air Perm, cm 3 /cm 2 /sec
22.0
5.0
5.0
Bubble Pt, μ
27
14
16.5
Mean Pore Size, μ
18
8
9
MD Tensile, kg/50 mm
9.3
16.1
29.6
CD Tensile, kg/50 mm
4.3
6.9
—
KOH Wicking, mm
84
69
96
KOH Retentivity, %
351
203
134
Absorb at 100 psi, g/cm 3
0.62
0.53
0.61
Ionic resistance, ohm-cm
10.9
12.8
12.2
Hi pot, volts
559
782
1114
Ammonia absorption (% N)
.009
—
.16
*Polymer contains wettable melt additive
**Spunbond surface grafted with acrylic acid
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 and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | A nonwoven material having a laminated construction and including a first layer of nonwoven fibers defining a first surface of the material; a second layer of nonwoven fibers defining the opposite surface of the material; and a third layer of nonwoven fibers located between the first and second layers. The layers are bonded together to form a laminate. At least one of the nonwoven layers comprises a nonwoven web of meltblown fibers. Additionally, one or more of the layers has been rendered permanently hydrophilic by forming the nonwoven web from meltspun fibers of a normally hydrophobic polymer having a hydrophilic melt additive incorporated therein. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
Not applicable.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to pumps and in particular to compact piston pumps.
Pumps for medical applications, such as used in oxygen concentrators, generally need to be compact and quiet to operate indiscreetly in homes and hospitals. It is thus important to properly muffle the working air as wells as reduce vibration during operation of the pump.
One problem with conventional pumps is that they can create excessive noise and vibration as the piston(s) are reciprocated, especially if they are improperly balanced. One reason for this in opposed piston pumps is that the pistons may be coupled to the drive shaft by a single retainer or eccentric element between the connecting rods of the piston. Ordinarily, an eccentric element is mounted to the drive shaft and two nibs or bosses extend axially from each side of the eccentric element to mount the pistons to the drive shaft. A moment, or shaking couple, arises as the drive shaft is turn because of the axial spacing between the pistons.
Another problem with conventional pumps is sealing the crankcase and cylinder(s). Improper sealing of the cylinders to the crankcase or the valve head(s) can cause pressurized air to leak to the outside of the pump, which both reduces pumping efficiency and makes noise. Typical sealing arrangements are either prone to leakage or require costly machining operations on the valve plate. Also, many crankcases are make with open necks to allow the pistons to be slid into the crankcase easily during assembly. Typically, the openings in the neck terminate at the cylinders, which have curved exterior surfaces. This makes sealing the crankcase difficult and typically requires separate seals in addition to that sealing the end of the crankcase, thus increasing assembly complexity and creating a potential leak path between the neck seals and the end seal.
Another problem with conventional pumps is that the valve stops can create excessive noise during operation. Typically, thin flapper valves are used to control the intake and exhaust ports of the valve heads. Because of the exhaust port opens under the force of the compressed air, a valve stop is used to support the valve and prevent it from being hyper-extended beyond its elastic range. Usually the stops have undersides that ramp up from the valve plate to support the tip of the valve farther from the valve plate than the neck of the valve. The valves are usually metal and the stops can be metal or plastic, however, in either case the rapid contact between the two surfaces can generate tapping or clicking sounds that are unacceptable in medical applications. Another problem here is that the thin flat flapper valve can succumb to surface attraction between the flapper and the stop and essentially “stick” to the stop and thus remain open.
Yet another problem confronting the design of low-noise pumps is properly muffling the intake and/or exhaust chambers of the valve heads. This can be done by attaching a muffler element to the valve head either direction or via suitable hoses. Another technique is to run the exhaust air into the crankcase on the non-pressure side of the piston head. In this case, if the crankcase is closed and the pistons are in phase, the crankcase will usually be vented through a muffler to avoid generating pulsations in the pump. Even using the later technique, the valve heads are usually exhausted through hoses leading to the crankcase, which is vented through a muffler directly mounted to the crankcase or at the end of a hose.
Accordingly, an improved pump is needed which addresses the aforementioned problems.
SUMMARY OF THE INVENTION
In accordance with one aspect, the invention provides a piston and drive shaft assembly for a pump. The assembly has first and second pistons each having a head and a connecting rod. The connecting rods have respective first and second openings. First and second bearings are fit into the respective first and second openings of the connecting rods. First and second eccentric elements are fit into the open centers of the respective first and second bearings. The eccentric elements each have an axial through bore and extend axially to one side substantially no further than a face of the corresponding piston connecting rod such that the pistons can be mounted on the drive shaft with the connecting rods axially offset and substantially adjacent one another.
In preferred forms, the eccentric elements are disk shaped and they each have an axial dimension no more than substantially the axial dimension of the connecting rods. Preferably, the piston connecting rods are mounted to the drive shaft spaced apart no more than {fraction (1/16)}″. The eccentric elements are preferably press-fit into centers of inner races of the bearings. In the event that the pistons have different masses, for example when one piston has a larger piston head, cup retainer elements can have differing masses weighted to bring the moments effected on the drive shaft by the pistons near equilibrium. The heavier retainer is used with the lighter piston connecting rod and pan to equalize the total mass of each piston assembly. One way to accomplish this is to make the retainers of different sizes and/or materials. For example, one retainer can be zinc and the other magnesium or aluminum.
In another aspect the invention provides a cylinder seal assembly. The cylinder has a circular end defining an oblique circumferential surface tapering radially. The oblique surface has a circumferential groove sized to receive the seal, preferably a resilient o-ring. The assembly preferably attaches to a valve plate having a circular recess defining a circular surface at an oblique angle corresponding to the oblique surface of the cylinder against which the seal can seat.
In yet another aspect the invention provides an assembly for enclosing an open-necked crankcase, having an open end and a neck opening extending from the open end to a cylinder extending essentially perpendicularly to the neck. The assembly includes a resilient seal backed by a rigid backing plate. The seal contacts the open end of the crankcase and has a plug section extending into the neck opening and having a contoured sealing surface abutting the cylinder. The backing plate covers the open end of the crankcase and has a plug support contacting the plug section of the seal.
In preferred forms, the seal is open at its center and extends into the crankcase to seal off the open face of the crankcase. The seal is preferably resilient, but the depth of the seal gives it some rigidity. The seals has a plug section for each opening in the neck of the crankcase. The sealing surface of the plug section(s) are concave and the plug sections are each formed with a ledge facing opposite the sealing surface which is engaged by the plug support of the backing plate. In opposed two cylinder pumps, the seal and cover have two plug sections and two plug supports spaced apart 180 degrees. The seal can also include one or more channel plug portions which align with open ended channels formed in the crankcase and the backing plate would then have radially extending tabs for backing the channel plugs. The channel plugs not only close of the channels but also aid in properly centering and orienting the seal on the face of the crankcase.
In still another aspect the invention provides a valve stop for retaining and supporting a flapper valve. The valve stop includes a body for attachment to a valve plate or to be cast as part of the valve head, an arm of decreased dimension extending from the body and a hand at the end of the arm having an underside spaced from an underside of the body and having at least two spaced apart lobes. Preferably, the valve stop has two arms each with a three lobed hand the undersides of which taper away from their respective arms. The lobes are preferably spaced apart equiangularly. The body further defines an alignment tab extending between the arms.
A further aspect of the invention provides a pump with one or more transfer tubes for passing air from one or more valve heads to the crankcase or to another valve head. In particular, the pump is a 180 degree opposed piston pump with both pistons located to one side of the motor. The pump has a crankcase defining a chamber, a cylinder and a transfer opening. A valve plate is mounted to the cylinder. The valve plate has intake and exhaust ports in communication with the working air inside of the cylinder. The intake and exhaust ports are opened and closed by valves mounted to the valve plate. A valve head is mounted to the valve plate to separate the intake port from the exhaust port and define respective intake and exhaust chambers. The valve plate further has a transfer port located in one of the chambers. The transfer tube is connected between the valve plate transfer port to the crankcase transfer opening.
Multi-cylinder pumps can have multiple transfer tubes connected to one or more transfer ports in the valve plate for each cylinder. For example, the transfer tubes can couple the intake or exhaust chambers to the inside of the crankcase, or they can couple multiple exhaust chambers together and/or multiple intake chambers together or the exhaust chamber of one valve head to the intake chamber of another valve head.
The crankcase can form integral passageways leading from one or more transfer openings at which the transfer tube(s) are connected. The passageway can open into the crankcase chamber in phase or run between transfer openings to join one or more chambers of one valve head with the chamber(s) of another valve head.
In preferred forms, the passageways and transfer tubes have opposing flat side walls. The transfer tube can be separate from the valve plate and the crankcase or formed as a unitary part of either the crankcase or the valve plate or both. Resilient seals can be disposed between the ends of the transfer tubes and a transfer opening in the crankcase and/or the intake and exhaust transfer ports in the valve plates as needed. The transfer tube(s) can be made of a resilient material and have stepped ends sized to fit into transfer ports. Preferably, the transfer tube(s) are clamped between the valve plate(s) and the crank case.
The invention thus provides a compact pump with considerable noise reduction and improved efficiency. These and other advantages of the invention will be apparent from the detailed description and drawings. What follows is a description of the preferred embodiments of the present invention. To assess the full scope of the invention the claims should be looked to as the preferred embodiments are not intended as the only embodiments within the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view an opposed piston pump of the present invention;
FIG. 2 is a perspective view of the pump showing its piston assemblies exploded;
FIG. 3 is another perspective view of the pump showing one of its cylinder and valve head assemblies exploded;
FIG. 4 is an exploded perspective view showing one valve assembly in isolation;
FIG. 5 is an enlarged partial cross-sectional view taken along arc 5 — 5 of FIG. 9 showing a cylinder seal in a circumferential groove in an angled end of the cylinder;
FIG. 6 is an enlarged partial cross-sectional view taken along line 6 — 6 of FIG. 9 showing an assembly for sealing the open neck of the pump housing;
FIG. 7 is a cross-sectional view taken along line 7 — 7 of FIG. 1 showing the pump (without the intake and exhaust valves) with its pistons 180° out of phase and one piston at top dead center and the other at bottom dead center and with the valve heads coupled;
FIG. 8 is a cross-sectional view similar to FIG. 7 albeit with the pistons in a position 180° from that of FIG. 7;
FIG. 9 is a cross-sectional similar to FIG. 7 showing the pump with its pistons in phase at bottom dead center and with one valve head exhausted to the crankcase and the other exhausted to the load;
FIG. 10 is a cross-sectional view similar to FIG. 9 albeit showing the pistons at top dead center;
FIG. 11 is a cross-sectional view taken along line 11 — 11 of FIG. 9;
FIG. 12 is a cross-sectional view taken along line 12 — 12 of FIG. 9;
FIG. 13 is an enlarged partial cross-sectional view showing one valve assembly;
FIG. 14 is a cross-sectional view taken along line 14 — 14 of FIG. 9;
FIG. 15 is a cross-sectional view taken along line 15 — 15 of FIG. 14 with an exhaust side flapper valve closed;
FIG. 16 is a view similar to FIG. 15 albeit with the valve shown open;
FIG. 17 is a cross-sectional view taken along line 17 — 17 of FIG. 12;
FIG. 18 is an enlarged partial cross-sectional view taken along arc 18 — 18 of FIG. 17;
FIGS. 19-21 are enlarged partial cross-sectional view taken along line 19 — 19 of FIG. 17 showing various alternate constructions of a transfer tube;
FIG. 22 is a perspective view of an alternate embodiment of the pump of the present invention with different sized cylinders and pistons;
FIG. 23 is a cross-sectional view taken along line 23 — 23 of FIG. 22 showing the pump (without the intake and exhaust valves) operating as a pressure-vacuum pump with its pistons in phase at bottom dead center and with the larger valve head exhausted to the crankcase;
FIG. 24 is a cross-sectional view similar to FIG. 23 albeit showing the pistons at top dead center; and
FIG. 25 is a cross-sectional view taken along line 25 — 25 of FIG. 22 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-4 illustrate a pump 30 according to the present invention. Generally, the pump 30 has a motor 32 mounted in an inverted manner in a top opening 34 of a housing or crankcase 36 containing two piston assemblies 38 and 39 . Two cylinders 40 and 41 are mounted to the crankcase 36 in respective side openings 42 and 43 . Valve plates 44 and 45 and valve heads 46 and 47 are mounted to the outer ends of the respective cylinders 40 and 41 . A cover/seal assembly 48 is mounted to the open neck 50 of the crankcase 36 over a bottom end opening 52 so that the interior of the crankcase is completely enclosed when the pump is assembled.
Referring to FIGS. 1, 3 and 5 , more specifically, to improve the seal between the cylinders 40 and 41 and valve plates 44 and 45 , the outer rims of each cylinder are tapered radially inward to define an angled surface 54 (one shown in FIG. 5) with a circumferential groove 56 therein sized to a retain seal 58 , preferably a resilient o-ring. Each of the valve plates 44 and 45 have an underside with a circular angled surface 60 against which the seal 58 can seat when the pump is assembled. The cylinders 40 and 41 are clamped to the crankcase 36 by fasteners 63 connecting the valve heads 46 and 47 to the crankcase 36 which compresses the seals between the grooves and the respective seats of the valve plates. This assembly provides a good seal as well as promotes serviceability in that the angled surfaces reduce the occurrence of the o-ring sticking to the valve plate over time and locking the valve plate to the cylinder. Also, the inwardly angled seat can be formed during casting of the valve plate without the need for additional machining.
Referring to FIGS. 2 and 6, the cover/seal assembly 48 improves the seal at the bottom opening 52 and open neck 50 of the crankcase 36 . The unique cover/seal assembly 48 includes a resilient seal 64 and a rigid backing plate 66 . In particular, the seal 64 is a generally ring shaped structure defining a central opening 68 and sized to fit onto the open end 52 of the crankcase 36 . The seal 64 defines two axially extending neck plugs 70 and 71 at opposite locations on the ring, for example at the 12 and 6 o'clock positions. The neck plugs 70 and 71 are sized and shaped to fit into the openings 72 and 73 in the neck 50 of the crankcase 36 . The neck plugs 70 and 71 define concave sealing surfaces 74 and 75 shaped to fit against the convex contour of the outside of the cylinders 40 and 41 . The sealing surfaces 74 and 75 have pointed ends that fit snugly against the intersecting surfaces of the neck 50 and the cylinders 40 and 41 (see FIG. 6 ). The seal 64 also defines two channel plugs 76 and 77 extending radially outward from the ring at the 3 and 9 o'clock positions. These channel plugs 76 and 77 fit into the end of channels 78 and 79 formed in the crankcase 36 (as discussed below). The seal 64 is retained by the backing plate 66 , which is generally a circular plate with four openings 80 through which four fasteners 82 are disposed to fasten the cover/seal assembly 48 to the crankcase 36 . The backing plate 66 has axially extending plug supports 84 and 85 aligned with the neck plugs 70 and 71 with curved edges 86 and 87 contacting ledges 88 and 89 defined by the neck plugs 70 and 71 . The backing plate 66 also has two tabs 57 and 59 located and sized to support respective channel plugs 76 and 77 of the seal 68 .
The plug supports 84 and 85 help maintain the seal of the neck plugs 70 and 71 . However, the pointed corners of the neck plugs 70 and 71 can flex away from the crankcase and cylinders somewhat to allow a leak path to relieve transient high pressure situations. The seal is designed primarily for low pressure applications to seal off air leaks for noise reductions. The corners of the neck plugs will unseat slightly when the internal pressure reaches about 15 psi as a pressure relief. The assembly could, of course, be used in higher pressure applications by using a more rigid elastomer or modifying the backing plate to prevent the seal from unseating.
Referring to FIG. 2, the piston assemblies 38 and 39 each include pistons 90 and 91 and with heads 92 and 93 , forming pan sections having pistons seals 94 and 95 mounted by retainers 96 and 97 (shown in phantom), and connecting rods 98 and 99 defining circular openings 100 and 101 , respectively. Bearings 102 and 103 (having inner races 104 and 105 rotatable with respect to outer races 106 and 107 , respectively) press-fit into the respective openings 100 and 101 to fix the outer races to the connecting rods 98 and 99 . Circular eccentric elements 108 and 109 are then press-fit into respective openings 110 and 111 of the bearings to fix them to the respective inner races 104 and 105 . The eccentric elements 108 and 109 have through bores 112 and 113 radially offset from their centers.
Referring to FIGS. 7, 8 , 11 and 12 , the piston assemblies 38 and 39 are press-fit onto a drive shaft 114 of the motor 32 one at a time in the through bores 112 and 113 of the eccentric elements 108 and 109 , respectively. The drive shaft 114 is journalled to the crankcase 36 by bearing 116 . The crankcase openings 42 and 43 and cylinders 40 and 41 are offset somewhat to account for the different axial locations of each piston assembly 38 and 39 so that piston 90 reciprocates along the centerline of cylinder 40 and piston 91 reciprocates along the centerline of cylinder 41 allowing the piston seals 94 and 95 of each assembly creating a sliding seal with the inner surfaces of the cylinders.
Importantly, the connecting rods 98 and 99 of the pistons 90 and 91 are mounted on the drive shaft 114 so that the connecting rods 98 and 99 are substantially adjacent to one another, that is within ⅛ inches (preferably less than {fraction (1/16)}″) or as close as possible. Preferably, the pistons are mounted on the drive shaft as close as possible with only air space between the connecting rods. This is to reduce the moment or shaking couple about the drive shaft 114 caused by the axial displacement of the piston assemblies 38 and 39 . While some moment remains, this arrangement provides a significant improvement over the prior art in that there is no other element (eccentric or otherwise) on the shaft between the pistons so that their axial displacement is minimized.
As shown in FIGS. 7 and 8, the pump 30 can operate as a parallel pressure or parallel vacuum pump in which the pistons reciprocate 180 degrees out of phase. FIG. 5 shows piston 90 at top dead center while piston 91 is at bottom dead center. FIG. 6 shows the pistons when the drive shaft is rotated 180 degrees so that piston 90 is at bottom dead center when piston 91 is at top dead center. This configuration of the pump results from the eccentric elements 108 and 109 being mounted to the drive shaft 114 so that the through bores 112 and 113 in positions opposite 180 degrees with respect to their pistons. For example, the through bore 112 would be at a 12 o'clock position (toward the piston head) and the through bore 113 would be at a 6 o'clock position.
FIGS. 9 and 10 show an alternate configuration in which the pump operates as a pressure-vacuum pump with the pistons reciprocating in phase (i.e., moving in and out of the cylinders in unison). In this case, the eccentric elements would be mounted to the drive shaft when both are in the same orientation with respect to their piston, for example, both through bores being at 12 o'clock. This version of the pump can be otherwise identical to that shown in FIGS. 1-4.
Air flow through the cylinders is controlled by the valving on the valve plates 44 and 45 . Referring to FIGS. 3, 4 , and 13 - 16 , the valve plate 44 includes pairs of intake ports 120 and exhaust ports 122 . The pairs of intake 120 and exhaust 122 ports are separated by a partition 124 of the valve head 46 defining two intake 126 and exhaust 128 chambers. A specially shaped head seal 130 lies between the valve plate 44 and the valve head 46 to seal and isolate the two chambers 126 and 128 .
The intake 120 and exhaust 122 ports are controlled by respective flapper valves 130 and 132 . The flapper valves 130 and 132 are identically shaped thin, metal valves. The valves 130 and 132 each have a middle section 134 defining an opening 136 and an alignment tab 139 as well as two identical paddles 140 extending from the middle section 130 in opposite directions approximately 30 degrees from vertical. The paddles 140 have narrow necks 142 and relative large flat heads 144 . The heads are sized slightly larger than the intake and exhaust ports and the necks are narrow to let the valves flex more easily under the force of the pressurized air, and thus reduce power consumption. Each flapper valve 130 and 132 is mounted to the valve plate 44 by a fastener 146 inserted through the opening 136 in the middle section 134 of the valve and threaded into bores in the valve plate. The intake valve 130 is mounted at the inside of the cylinder 40 and the exhaust valve 132 is mounted in the exhaust chamber 128 .
Referring to FIGS. 4 and 13 - 16 , because the exhaust valve 132 opens under the force of the compressed air in the cylinder, it is backed by a valve stop 138 preferably made of a rigid plastic. No valve stop is used (besides the piston) for the intake valve which opens during the expansion stroke. In particular, the valve stop 138 has a middle body 148 with an alignment tab 149 and an opening therethrough for the fastener 146 . Two arms 150 extend out from the body 148 at the same angles as the valve paddles 140 . Two hands 152 have fingers or lobes 154 , preferably three, extending outward and spaced apart at equal angles. The underside of the arms 150 and hands 152 tapers away from the valve plate, preferably with a slight convex curve, so that the lobes 154 are spaced away from the valve plate 44 enough to allow the valve paddles 140 to move sufficiently to open the ports. As shown in FIG. 16, the paddles follow the contour of the underside of the arms and lobes when opened and are supported along their entire length (except at the tips). The arms 150 are approximately the width of the valve paddle necks 142 and the lobes 154 are sized to support the entire paddle heads 144 to prevent them from hyper-extending at the narrow necks. Collectively, the underside of the lobes 154 are of less surface area than the paddle heads 144 and end inside of the boundaries of the heads. This design limits the surface contact between the paddles and thus reduces or eliminates valve chatter. This valve stop design has two main advantages: first, it reduces the surface attracting forces or “stiction” between these elements which could cause the valves to stick to the stop and remain open, and second, it reduces noise/vibration in the valves that would otherwise be present were the valve tips to contact the stops. It should also be noted that the valves are mounted to the valve plates with their middle sections disposed over recesses 156 shaped like the middle sections only larger. This allows the valves to be assembled and aligned by a fixture having pins that extend below the underside of the valves and into the recesses 156 . The alignment tabs 139 and 149 ensure that the valve and stop are in the proper orientation.
Another feature of the pump 30 is the use of transfer tubes 158 with air passageways formed in the body of the crankcase 36 (outside of the internal chamber) to either couple an intake or exhaust chamber to the inside of the crankcase or to couple the valve heads together (in parallel between exhaust chambers and/or between intake chambers or in series with the exhaust chamber of one valve head connected to the intake chamber of the other valve head) without the need for hoses. Referring now to FIGS. 11, 12 and 17 - 21 , the pump 30 includes small tubular members 158 , preferably having two opposite flat sides, extending from intake 160 and exhaust 162 transfer ports through the valve plates outside of the cylinders. In one preferred form, these transfer tubes 158 are formed as a unitary part of the valve plates (see FIGS. 17 and 19 ). The free ends of the transfer tubes 158 are coupled to two sets of transfer openings 164 and 165 in the crankcase 26 preferably with a special resilient seal 166 therebetween having a flange 168 that fits inside the transfer openings 164 and 165 in the crankcase. It should be noted that the transfer tubes need not be integral with the valve plates but instead could be as shown in FIGS. 20 and 21 in which they are entirely separate elements. In FIG. 20, each transfer tube 158 A is a separate rigid member with (or without) stepped ends mounting resilient seals 166 A. Or, as shown in FIG. 21, each transfer tube 158 B could be made of a entirely of a resilient material so that no separate seals are needed. Preferably, it would have stepped ends that fit inside the corresponding openings in the crankcase and valve plate.
As mentioned, the crankcase 36 has two sets of interior passageways 170 and 171 in the walls of the crankcase opening at the transfer openings 164 and 165 . Depending on the desired operation of the pump, there can be only one of these passageways 170 and 171 or one set of these passageways in one side of the crankcase. One or both of these passageways may also open to the channels 78 and 79 , which open to the interior of the crankcase. This can be done by boring through section 174 or by casting the crankcase to block off or connect passageways as needed. In the parallel pressure embodiment of the pump shown in FIGS. 11, 17 and 18 , preferably the passageways 170 and 171 couple the exhaust chambers of each valve head and the intake chambers of each valve head. In this way, the load can be connected at a hose barb or socket of either of the intake chambers (to pull a vacuum) or either of the exhaust chambers (to provide pressure) or both, without connecting to both of the intake chambers and/or exhaust chambers. A suitable muffler (not shown) can be connected to either the intake or exhaust side if not otherwise connected to a load.
FIGS. 22-25 show another preferred pressure-vacuum embodiment of the pump 30 C such as can be used in a medical application, such as an oxygen concentrating apparatus. This embodiment of the invention is identical to that described above, with the following exceptions. Here, cylinder 40 C, valve plate 44 C, valve head 46 C and the head of piston assembly 38 C are of a lesser size (diameter) than cylinder 41 C, valve plate 45 C, valve head 47 C and the head of piston assembly 39 C, respectively. Preferably, the smaller side is the pressure side and the cylinder 40 C has a 1.5 inch diameter and the larger side is the vacuum side with the cylinder 41 C having a 2 inch diameter. Preferably, in this embodiment, the piston assemblies 38 C and 39 C are in phase as shown in FIGS. 23 and 24 (although they could be out of phase as well), the pressure side providing roughly 5 to 10 psi of pressure and the vacuum side drawing a vacuum of about −10 to −5 psi, which is preferred for oxygen concentrator devices.
Since the pistons are of different sizes, they have different masses. The difference in masses will make the pistons out of balance and thus effect unequal moments on the drive shaft, which would cause vibration, noise and lower pump efficiency. Preferably, the retainers 96 C and 97 C are selected to have different masses, substantially equal to the difference in the masses of the other parts of the pistons (such as the connecting rods and the heads/pans). This can be accomplished by making the retainers 96 C and 97 C from disparate materials or of different thicknesses. For example, the retainer 96 C could be made of a suitable zinc composition so that it has a greater mass (despite its smaller diameter) than retainer 97 C, which could be made of an aluminum. Thus, the heavier retainer 96 C would make up the difference in mass of the smaller piston 90 C. The result is equally balanced piston assemblies and improved operation of the pump when the application requires different flow volumes in the cylinders.
The pump also differs from that described above in that it has only one transfer tube 158 C connecting the exhaust side of valve head 47 C to passageway 171 C (through a transfer opening) in the crankcase 36 C. Passageway 171 C intersects with channel 78 C (as shown in FIG. 25 ). The crankcase 36 C has no other internal passageways as did the previously described embodiment.
This embodiment of the pump is thus constructed so that air can be drawn from the load (through a hose (not shown) connected to barb 200 ) and into the intake chamber of valve head 47 C. Surrounding air can also be brought in through barb 202 (to which preferably a muffler (not shown)) is mounted. Air from the higher pressure side valve head 46 C exhaust chamber will be exhausted through barb 204 to the load (after passing through hoses and valves as needed). The exhaust chamber of the vacuum side valve head 47 C will exhaust through the transfer tube 158 C and the crankcase passageway 171 C to the non-pressure side of the inside of the crankcase 36 C, which is vented through barb 206 and another muffler (not shown). Passing the exhaust through the crankcase prior to the muffler provides further (two-stage) sound attenuation beneficial in low-noise applications, such as when used with medical devices.
It should be appreciated that preferred embodiments of the invention have been described above. However, many modifications and variations to these preferred embodiments will be apparent to those skilled in the art, which will be within the spirit and scope of the invention. For example, while only two-cylinder embodiments were shown, the principles of the invention could apply to a single-cylinder pump or to three or four cylinder pumps, such pumps having a double shafted motor and additional crankcases, cylinders, pistons and valve heads. For multi-cylinder pumps, the valve heads of all of the cylinders could be coupled in series or parallel through the transfer tubes and integral crankcase passageways, like those described above. Shared valve heads for multiple cylinders could also be incorporated into such a pump. The pump of the present invention could also include transfer tubes which connect directly to the valve heads/plates to join air chambers without connected to passageways in the crankcase.
Therefore, the invention should not be limited to the described embodiments. To ascertain the full scope of the invention, the following claims should be referenced. | A compact 180° opposed piston pump/compressor minimizes axial spacing between its pistons on the drive shaft and thereby reduces the shaking couple and noise from reciprocation. Each piston has its own eccentric element press-fit into the connecting rods so as not to occupy space between the pistons. The shaking couple can be further reduced for pistons of different masses by selecting the mass of the cup retainers to compensate for the difference in overall piston masses. The pump also includes an improved cylinder sealing arrangement having a circumferential groove in an angled surface at the end of the cylinder. The pump also has a special cover and seal for closing the open neck of the pump crankcase and an improved multi-lobed valve stop. The pump further uses tubular transfer members for transferring intake and/or exhaust air into the crankcase and/or between valve heads. | 5 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government for governmental purposes without the payment of any royalty thereon.
BACKGROUND OF THE INVENTION
This invention is for a unique prefabricated storage building in which all of the components are interlocked without the use of fasteners. The building is intended primarily for use by the military for ammunition storage and is designed to withstand high forces applied both from within the building and from without. Provisions are included for covering the structure with earth to provide the building with additional integrity and security. The building can be erected on a prepared site within a matter of a few days, whereas erection time for previous designs for similar uses was measured in months, and at much higher costs. While the disclosed modular storage building is intended for storage of munitions, it is useful for general storage when military security is important.
BACKGROUND OF THE INVENTION
No relevant art is known that is comparable to the disclosed invention. Prior art patents revealed by a search of related art include the following U.S. Pat.: Barker patent No. 3,353,315, Ziegelman et al patent No. 3,461,633, Rhyne patent No. 3,591,212, Pilish patent No. 3,706,168, Wainshal patent No. 3,830,025, and Johnston patent No. 3,990,197. Only Wainshal, Johnston, Pilish and Ziegelman et al relate to prefabricated buildings. The remaining patents do not relate to modular buildings.
Ziegelman et al disclosed a building comprised of a welded steel frame which is enclosed by wall, roof and floor panels. The present invention is frameless.
Pilish uses precast panels, but he assembles his building by means of footings which support the various elements in alignment. The present invention requires no footings.
Johnston's building is made up of a unitary "tunnel" structure into which a "flat bed" is slid to form the floor. Applicant's modular building essentially uses all planar panels which are assembled by various interlocking mechanisms.
SUMMARY OF THE INVENTION
This invention is a prefabricated modular building constructed of a plurality of panels which are readily assembled and locked together without the need for tools (other than material handling and earth moving equipment) at the assembly site. The building is constructed entirely of sets of panels, the panels in each set being identical. Thus, for a standard module there are 4 identical floor panels, 4 identical side wall panels, 4 identical roof panels, 1 rear wall panel and 1 front wall panel which is fitted with all of the hardware for mounting the doors. The vertical panels are interlocked by sliding a built in flange on each panel into a built in channel member on an abutting panel. Projecting beams at the tops and bottoms of the vertical panels are received by corresponding spaced receptacles in the horizontal ceiling and floor panels. The roof is "finished" with two identical quarter ceiling panels, one for over the front door panel, and 1 over the rear wall panel. In addition, there is an earth barricade for mounting on either the front or the rear quarter panel, or both, depending on site conditions. Interlocking wings provide stability under extreme conditions, and the entire building, is covered with earth.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a partially assembled modular building;
FIGS. 2 and 3 illustrate the reinforced concrete side walls panels;
FIGS. 4 and 5 are views of the reinforced concrete floor panels;
FIG. 6 is a view of the rearmost floor panel;
FIG. 7 and 8 show the rear wall assembly;
FIGS. 9 to 12 are various views of the door frame;
FIGS. 13 and 14 are views of the left and right door assemblies, respectively;
FIGS. 15 and 16 show one of the four identical roof panels;
FIGS. 17 and 18 show one of the two quarter panel roof caps mounted over the front door and rear wall, respectively; and
FIGS. 19 and 20 show the earth barricade;
FIG. 21 shows the triangular brace used to brace the building walls and the wing walls.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a perspective view of a partially assembled modular building 10 consisting of a floor 12, side walls 14, roof 16, rear wall 18 and front door assembly 20. The assembly of these components is self-supporting without the use of fasteners, and it requires no tools for assembly, except those needed to lift and put the various components in place. Wing wall panels 23, 25, 27 and 29 serve to brace the building and to provide retention for the earth (not illustrated) which covers the top and sides of the building. This configuration is especially useful for military applications as an ammunitions storage building.
Referring to FIGS. 2 and 3, each side wall 14 comprises two steel reinforced concrete panels 21 in which a plurality of spaced steel I-beams 22 are anchored along the length thereof. As seen in FIG. 2, one flange 24 of each I-beam 22 is embedded within the concrete panel 21, while the other flange 26 extends out of the panel and lies in a plane essentially parallel to the side walls 14. The I-beams 22 are equally spaced, and each extends above and below the panel 21.
To join the side wall panels 21 together, the flange 32 of an I-beam 30 is embedded in and along the entire height of one edge 34 of each panel 21, while the other flange 36 projects from it. A complimentary C-shaped channel member 38 is embedded in the other end 40 of the panels 21. When two such wall panels 21 are assembled, the panels are locked together by sliding the flange 36 into the channel of an adjacent channel member 38. FIG. 1 shows two such side wall panels interconnected between the rear wall 18 and the door assembly 20. It will be understood that the length of the building is determined by the number and length of such panels, and that any number may be used.
The wing wall panels 23 and 25 are identical to the panels 21. Wing panels 27 and 29 are essentially identical to the panels 21, but as shown, are half size.
The floor 12 of the building 10 comprises four panels 12a and d. Three of the panels 12a are identical and are used for all the floor panels except the rear floor panel 12d. One of the three identical floor panels 12a is shown in FIGS. 4 and 5 and it consists of a steel reinforced concrete slab 42 which is provided with four rectangular openings or receptacles 44 adjacent each side. Each of the openings is lined with a steel box 46 which is open at its top and which is dimensioned to snugly receive the bottom ends of the I-beams 22 of the side wall slabs 21.
The rearmost panel 12d is shown in FIG. 6 and it is identical to the panels 12a-c in all respects, except for the provision of rectangular openings or receptacles 48 which extend across the panel from side wall to side wall. The opening 48 are also lined with steel boxes 50 to accommodate I-beams of the rear panels. The floor slabs 12a-d are laid side by side on a prepared level site.
The rear wall assembly, shown in FIGS. 7 and 8, comprises a single steel reinforced concrete panel 52 in which a plurality of spaced steel I-beams 54 are anchored along the length thereof. As best seen in FIG. 8, one flange 56 of each I-beam 54 is embedded within the concrete panel 52, while the other flange 58 extends out of the panel and lies in a plane parallel to the end walls 18. The I-beams 54 are equally spaced, and as may be seen in FIG. 7, each of them extends above and below the panel 52. For reasons hereinafter to be explained, angle iron members 60 attached to several of the flanges 58, extend therefrom at the height of the top edge 62 of the panel 52. In addition, a flange 64 secured to the rear panel 52 adjacent an end 66 extends from the slab, while a complementary c-channel member 68 is secured to the panel 2 at the other end 70.
The door frame for the door assembly 20 is shown in FIGS. 9 to 12. As seen in FIG. 9, the frame is comprised of structural steel base member 72, structural steel uprights 74 and 76, and upper frame member 78.
The cross sections of the uprights 74 and 76 are shown in FIGS. 11 and 12. The beam 74 has a number of elements welded to it, including four hinge plates 80 each provided with a hole 82 (See FIG. 11) sized to retain a hinge pins affixed to the doors (not shown in FIGS. 9 to 12). Similarly the beam 76 has four hinge plates 90 welded to it. The hinge plates 90 are provided with hinge pin holes 93. For purposes hereinafter to be explained an elongated channel member 97 is welded to the side of beam 74, while a complimentary flange 95 is welded to the side of beam 76. In addition, the rear of I-beams 74 and 76 are provided with an elongated flange 99 and a complementary channel member 101. For reasons to be explained, a plurality of I-beams 103 are welded to the member 78 and a plurality of equi-spaced flanges 105 are welded to the upper door frame member 78.
The door assemblies comprise left and right doors 20a and 20b, shown respectively in FIGS. 13 and 14, and are generally conventional. Both doors are shown as having four hinge pins 98 which are positioned to be received by the holes 82 in the hinge plates 80. The door assembly 20a also includes a conventional lock bar and handle assembly 105.
The roof panels 16 comprise 4 identical panels. One of the panels 16 is shown in FIGS. 15 and 16, and it consists of a plurality of steel reinforced concrete slabs 100 which are provided with five openings 102 on each side. These openings do not penetrate the tops of the slabs 100, and each of the openings is lined with a steel liner 104 closed at its top and which is dimensioned to snugly receive the top ends of the I-beams 22 of the side wall sections 21. As shown in FIGS. 15 and 16, the slabs 100 are rectangular and are intended to be mounted side by side with their complementary lap joints 106 and 108 seated in the lap joints of an abutting panels.
Referring again to FIG. 1, concrete reinforced quarter panels 110 and 112 are used to cap off the front and rear ends of the roof, respectively. The panels 110 and 112 are identical, so that only panel 110 is illustrated in FIGS. 17 and 18. The panels are provided with steel lined openings 114 into which the I-beams 103 of the door frame and the top of the I-beams 54 of the end wall 18 are received.
The quarter panel 110 and 112 are each provided with a lap joint 116 so that the panels can be interlocked with the adjacent lap joint of an abutting roof panel 16.
The earth barricade 120 is shown in FIGS. 19 and 20. It comprises a slab 122 of triangular cross section. It has a plurality of I-beams 124 projecting from its bottom and spaced to be inserted into the recesses 114 of quarter panel 110.
As seen in FIG. 21, corner braces 130 are used to brace the various walls and to provide earth retention. Although only one brace can be seen in FIG. 1, it will be understood that four are used, one in each corner. The braces 130 each comprises a generally right triangular structure on which channel members 132 are positioned to mate with the flanges of the various corner panels.
ASSEMBLY OF THE BUILDING
The described components can now be assembled. First the ground is leveled to 2 feet below the grade of the floor and 18 inches of sand are added before the floor panels are set in side by side. The lower ends of the sidewall I-beams 22 are then inserted into the steel lined openings 44, the adjacent side wall panels being assembled by sliding the flange 36 located at one edge into the channel member 38 of an adjacent edge. Similarly, the lower ends of the I-beams 54 of the rear wall panel are retained in the steel lined openings 48 in the rear floor panel 12d.
The door frame can then be erected by sliding the flange 99 on the back of I-beam 74 into the channel 38 of side wall 21, while the channel 101 on the I-beam 76 is slid over the flange 36 on the side wall 21. The doors 20a and 20b are then assembled by inserting the hinge pins 98 into the holes 82 in the respective hinge plates 80.
The wall extensions 23, 25, 27 and 29 can now be installed. First, the wall 25 is erected by sliding channel 38 over the flange 95 on the door frame. Next, the wall 29 is installed by sliding its flange 36 into the channel 97 on the other side of the door frame. Similarly, the wall 23 is erected by sliding its flange 36 into the channel 70 of end wall 18, while the channel 38 of wall 27 is slid over the flange 64 on the other side of the end wall 18.
The roof panels 16 are put in place by inserting the upper ends of the I-beams 22 into the steel lined openings 102. The rearmost edge of the rear roof panel is additionally supported by the flanges 60 on the end wall I-beam 54. To provide insulation and to prevent water leakage, various cavities in the assembly may be filled with an insulation foam.
The roof is then capped by the quarter panels and then the earth barricade 120 , and the building is covered with earth extending over the roof and between the wall extensions.
IN SUMMARY
This invention provides a building, the premanufactured components of which can be assembled on site, and which by its nature provides very high integrity of the assembly in the event of explosions occurring within or without the building. The invention is subject to many variations and modifications, and it is intended, therefore, that it be limited only by the scope of the following claims as interpreted in the light of the prior art. | A prefabricated modular building is constructed of a plurality of panels which are readily assembled and locked together without the need for tools (other than material handling and earth moving equipment) at the assembly site. The building is constructed of sets of panels, most of the panels in each set being identical.
All of the vertical panels are interlocked by sliding a built in flange on each panel into a built in channel member on an adjacent panel. The vertical structural beams of each panel projects above and below the panels and these projecting ends are received by corresponding spaced receptacles in the horizontal ceiling and floor panels. In addition, an earth barricade on the roof of the building plus wall extensions provide for the covering of the roof and sides of the building with earth. | 4 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a concrete embedded insert, called an anchor bolt locator, for properly locating and supporting a bolt or anchoring member during the pouring and curing of a concrete member, such that bolt will be properly placed in the cured concrete.
[0002] A concrete slab member is a common structural element of modern buildings. Horizontal slabs of steel-reinforced concrete are used to construct slab foundations, floors, ceilings, decks and exterior paving.
[0003] Concrete slabs are built using formwork - a type of boxing into which the wet concrete is poured. Typically, if the slab is to be reinforced, steel reinforcing rods are used, and these are positioned within the formwork before the concrete is poured. This steel reinforcing is often called rebar. Plastic tipped metal, or plastic bar chairs are typically used to hold the reinforcing rods away from the bottom and sides faces of the formwork, so that when the concrete sets it completely envelops the reinforcing rods. For a slab resting on the ground, the formwork may consist only of sidewalls pushed into the ground. For a suspended slab, the formwork is shaped like a tray, often supported by a temporary scaffold until the concrete sets. The formwork is commonly built from wooden planks and boards, plastic, or steel. After the concrete has set the formwork can be removed or remain in place. In some cases formwork is not necessary - for instance, a ground slab surrounded by brick or block foundation walls, where the walls act as the sides of the tray and the hardcore earth acts as the base.
[0004] Concrete slab members are also typically built in a manner that allows for anchor members and fasteners to be built into the slab so that other building elements can be easily and securely anchored to the concrete member. It is very common to see a slab with many different bolts and fasteners protruding from the slab after it has cured and the formwork has been removed. These preset anchors or inserts are typically used for securing pipes or conduits to concrete ceilings, or for securing framing to a concrete foundation or floor.
[0005] When anchors such as bolts and threaded rod are to be embedded in a concrete slab, they must be supported during the concrete pour. It is important that the anchors are located properly in the slab and remain undisturbed during the pour, so that subsequent building elements can be attached to them properly. The proper location of anchors in slabs is especially important for decks where the anchor will fasten a safety railing to the deck and for lateral force resisting systems where the anchors must be placed carefully to provide the proper anchorage without interfering with other structural members. Proper location is also important for the integrity of the anchor and the strength of the anchorage. If the anchor is set too close or at an improper angle so that it is too close to the sides of the slab water penetrating into the slab can degrade the anchor, and the strength of the anchorage is also compromised if there is insufficient concrete surrounding the anchor.
[0006] Typically, certain of the anchors located in the slab will be located close enough to the edges of the slab that they can be supported by a member attached to the side formwork during the pour. Other anchors will be located sufficiently far away from the sides of the form that they must be supported in some other manner. Sometimes the anchors can be tied to and supported by the reinforcing rods. Other times it is preferable to support the anchor on the underlying surface of the formwork. The present invention is a free-standing anchor bolt locator that attaches to the underlying formwork and holds an anchor or bolt during the concrete pour. Many such devices appear in the patent literature, including: U.S. Pat. No. 5,957,644, granted Sep. 28, 1999, to James A. Vaughan, U.S. Pat. No. 5,050,364, granted Sep. 24, 1991, to Michael S. Johnson et. al., and U.S. Pat. No. 5,205,690, granted Apr. 27, 1993, to Steven Roth.
[0007] The present invention improves upon the prior art by providing an anchor bolt locator that is inexpensively manufactured on automatic die-press machines from sheet steel and a structural nut that does not require any welding, while also being easy to use and install with current, commonly-used building practices and anchor designs.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention is to provide an anchor bolt locator, and a method for making an anchor bolt locator that is economically efficient to produce. It is also an object of the present invention to provide an anchor bolt locator that is easy to use and install. These objects are achieved by forming the chair of the anchor bolt locator out of sheet metal, and forming the anchor bolt locator in such a way that a structural nut can be permanently attached to the sheet metal chair without having to weld the nut to the chair. In this manner an anchor bolt locator is formed that can receive a piece of threaded rod in the nut in the typical fashion currently used for creating threaded rod anchorages with the nut at the proper height for such an anchorage. This type of anchorage is typical in the industry and uses two structural nuts sandwiching a structural plate washer between them. The structural nut of the present invention is designed to serve as the lower nut for a double-nut and plate washer anchorage. By avoiding welding the nut to the chair the structural integrity of the nut is better preserved, and the process does not need to include a welding station. Welding can crack nuts, especially if they are heat treated.
[0009] It is also an object of the present invention to provide an anchor bolt locator where the connection between the threaded rod and the locator is easily made. This object is achieved by providing a central opening in the anchor bolt chair that allows the user to precisely position the anchor bolt locator, while also providing tongues that serve as stop to prevent the anchor from being inserted too far into the structural nut. The threaded rod is rotated into the nut and tongues or prongs stop the threaded rod from being inserted farther than is necessary into the nut. If the anchor is threaded too far into the nut, the bottom of the anchor may be placed too close to the bottom of the concrete form which can lead to degradation of the anchor, and it will also mean that less of the anchor protrudes from the top of the form for attaching other devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1A is a perspective view of the anchor bolt locator of the present invention.
[0011] FIG. 1B is an alternate perspective view of the anchor bolt locator of the present invention.
[0012] FIG. 1C is an exploded, perspective view of the anchor bolt locator of the present invention, showing the placement of fasteners to secure the anchor bolt locator.
[0013] FIG. 1D is a perspective view of the anchor bolt locator of the present invention, attached to and set in a concrete slab form.
[0014] FIG. 1E is a side view of the anchor bolt locator of the present invention, attached to and set in a concrete slab form, showing the concrete in the form.
[0015] FIG. 2A is a plan view of the blank of the chair of an anchor bolt locator of the present invention.
[0016] FIG. 2B is a plan view of a chair of an anchor bolt locator of the present invention, after openings have been cut in the chair, and the depression and the legs bent from the bridge of the chair.
[0017] FIG. 2C is a plan view of an anchor bolt locator of the present invention. The structural nut has been attached to the chair.
[0018] FIG. 2D is a sectional view of a chair of an anchor bolt locator of the present invention taken along line 2 D- 2 D of FIG. 2B .
[0019] FIG. 2E is a sectional view of a chair of an anchor bolt locator of the present invention taken along line 2 E- 2 E of FIG. 2B , with a structural nut shown above the chair and ready for placement in the chair.
[0020] FIG. 2F is a partial sectional view of an anchor bolt locator of the present invention similar to FIG. 2E , with the structural nut now set in place on the chair, and the chair having been modified to frictionally engage the nut, securing it in place.
[0021] FIG. 3A is a plan view of a blank of a chair of an anchor bolt locator of the present invention. The anchor bolt locator shown in FIGS. 3A-3F is similar to the anchor bolt locator shown in FIGS. 2A-2F , except the anchor bolt locator shown in FIGS. 3A-3F receives a smaller structural nut.
[0022] FIG. 3B is a plan view of a chair of an anchor bolt locator of the present invention, after openings have been cut in the chair, and the depression and the legs bent from the bridge of the chair.
[0023] FIG. 3C is a plan view of the anchor bolt locator of the present invention. The structural nut has been attached to the chair.
[0024] FIG. 3D is a sectional view of the chair of the anchor bolt locator of the present invention taken along line 3 D- 3 D of FIG. 3B .
[0025] FIG. 3E is a sectional view of the chair of the anchor bolt locator of the present invention taken along line 3 E- 3 E of FIG. 3B , with the structural nut shown above the chair and ready for placement in the chair.
[0026] FIG. 3F is a partial sectional view of the anchor bolt locator of the present invention similar to FIG. 3E , with the structural nut now set in place on the chair, and the chair having been modified to frictionally engage the nut, securing it in place.
[0027] FIG. 4A is a plan view of a blank of a chair of an anchor bolt locator of the present invention. The anchor bolt locator shown in FIGS. 4A-4F is similar to the anchor bolt locator shown in FIGS. 2A-2F and FIGS. 3A-3F , except the anchor bolt locator shown in FIGS. 4A-4F receives an even smaller structural nut.
[0028] FIG. 4B is a plan view of a chair of an anchor bolt locator of the present invention, after openings have been cut in the chair, and the depression and the legs bent from the bridge of the chair.
[0029] FIG. 4C is a plan view of the anchor bolt locator of the present invention. The structural nut has been attached to the chair.
[0030] FIG. 4D is a sectional view of the chair of the anchor bolt locator of the present invention taken along line 4 D- 4 D of FIG. 4B .
[0031] FIG. 4E is a sectional view of the chair of the anchor bolt locator of the present invention taken along line 4 E- 4 E of FIG. 4B , with the structural nut shown above the chair and ready for placement in the chair.
[0032] FIG. 4F is a partial sectional view of the anchor bolt locator of the present invention similar to FIG. 4E , with the structural nut now set in place on the chair, and the chair having been modified to frictionally engage the nut, securing it in place.
[0033] FIG. 5A is a plan view of a blank of a chair of an anchor bolt locator of the present invention. The anchor bolt locator shown in FIGS. 5A-5F is similar to the anchor bolt locator shown in FIGS. 2A-2F , FIGS. 3A-3F and FIGS. 4A-4F , except the anchor bolt locator shown in FIGS. 5A-5F receives an even smaller structural nut.
[0034] FIG. 5B is a plan view of a chair of an anchor bolt locator of the present invention, after openings have been cut in the chair, and the depression and the legs bent from the bridge of the chair.
[0035] FIG. 5C is a plan view of the anchor bolt locator of the present invention. The structural nut has been attached to the chair.
[0036] FIG. 5D is a sectional view of the chair of the anchor bolt locator of the present invention taken along line 5 D- 5 D of FIG. 5B .
[0037] FIG. 5E is a sectional view of the chair of the anchor bolt locator of the present invention taken along line 5 E- 5 E of FIG. 5B , with the structural nut shown above the chair and ready for placement in the chair.
[0038] FIG. 5F is a partial sectional view of the anchor bolt locator of the present invention similar to FIG. 5E , with the structural nut now set in place on the chair, and the chair having been modified to frictionally engage the nut, securing it in place.
DETAILED DESCRIPTION OF THE INVENTION
[0039] FIG. 1A , shows the preferred, non-welded anchor bolt locator 1 of the present invention made from a galvanized sheet metal chair 2 and a structural nut 3 attached to the chair 2 by way of a friction fit.
[0040] As shown in FIG. 1A , preferably the chair 2 of the anchor bolt locator 1 is a u-shaped body having a bridge 4 that connects two legs 5 and 6 . Preferably, the bridge 4 is substantially rectangular with pairs of opposed sides and the legs 5 and 6 of the chair 2 are connected to the bridge 4 at one pair of opposed sides. Preferably, the legs 5 and 6 of the chair 2 depend from the bridge 4 at right angles to the bridge 4 . Preferably, the plurality of legs 5 and 6 extend away from the top surface 7 of the of the bridge 4 .
[0041] As shown in FIGS. 1 E and 2 D- 2 F, the bridge 4 is formed with a depression 8 that receives the structural nut 3 . The structural nut 3 is connected to the bridge 4 by frictional engagement and is held securely in place. The inner surface 9 of the side wall 10 of the depression 8 in the bridge 4 frictionally engages with the outer surface 11 of the outer side wall 12 of the nut 3 . Preferably, the outer side surface 11 of the nut 3 is made with flat faces 13 to have a polygonal, preferably hexagonal, cross-section. As shown in FIGS. 1B , 2 C and 2 D, edge openings 14 may be formed in the side wall 10 of the depression 8 where the flat faces 13 of the outer surface 11 of the polygonal nut 3 meet at nut side edges 15 . These edge openings 14 are particularly needed when a deep depression 8 must be made for a tall structural nut 3 , and the metal of the side walls 10 must be particularly stretched to make the depression 8 . The edge openings 14 may also be formed in the side wall 10 to extend into the bottom floor 16 of the depression 8 where the nut side edges 15 meet the bottom end 17 of the nut. The side wall 10 of the depression 8 extends away from the top surface 7 of the bridge 4 .
[0042] As shown in FIGS. 2B and 2C , the depression 8 in the bridge 4 is formed with a bottom floor 16 that has a top surface 18 . As shown in FIGS. 1A-1E , the structural nut 3 is received in the depression 8 of the bridge 4 . As best shown in FIGS. 2C and 2E , the structural nut 3 has a top end 19 , a bottom end 17 , an internal, threaded bore 20 forming an internal, threaded side wall 21 , and an outer side wall 12 defining an outer surface 11 of the nut 3 . The bottom end 17 of the structural nut 3 rests on the top surface 18 of the bottom floor 16 of the depression 8 , and portions of the outer surface 11 of the outer side wall 12 of the structural nut 3 are in contact with and in frictional engagement with portions of the inner surface 9 of the side wall 10 of the depression 8 such that the structural nut 3 is secured to the chair 2 .
[0043] As shown in FIGS. 1A and 2E , preferably, the outer side wall 12 of the nut 3 extends at a right angle to the top and bottom ends 19 and 17 of the nut 3 . Preferably, the side wall 10 of the depression 8 in the bridge 4 extends at right angle to the generally planar portion 22 of the bridge 4 surrounding the depression, and the generally planar portion 22 of the bridge 4 surrounding the depression 8 extends at a right angle to the outer side wall 12 of the structural nut 3 .
[0044] Since the anchor bolt locator 1 is preferably made from thin sheet steel the bridge 4 and legs 5 and 6 are, preferably, generally planar, thin members. See FIGS. 2C and 2F . Preferably, a portion 22 of the bridge 4 surrounding the depression 8 in the bridge of the chair 2 is a substantially planar and relatively thin member. As such, the structural nut 3 between the top end 19 and the bottom end 17 will have a thickness that is substantially greater than the relatively thin portion 22 of the bridge 4 surrounding the depression 8 . Similarly, the depression 8 in the bridge 4 to accommodate the structural nut 3 will have a depth from the top surface 7 of the bridge 4 to the bottom floor 16 of the depression 8 , with portions of the side wall 10 of the depression 8 extending from the top surface 7 of the bridge to the bottom floor 16 of the depression 8 , and that depth of the depression 8 will be substantially greater than the relatively thin portion 22 of the bridge 4 surrounding the depression 8 .
[0045] As shown in FIGS. 1B and 2B , preferably, the depression 8 in the bridge 4 of the anchor bolt locator 1 is formed with an opening 23 in the bottom floor 16 . Preferably, the opening 23 is located at the center of the depression 8 and will align with the center of the internal bore 20 in the nut 3 . This allows for accurate placement of the anchor or threaded rod 24 . The opening 23 is preferably an irregular opening 23 that creates a plurality of tongues 25 that extend underneath and support the structural nut 3 at is bottom end 17 . Preferably, at least one of the tongues 25 that make up the bottom floor 16 of the depression 8 extends sufficiently inward from the side walls 10 of the depression 8 to extend past the internal side wall 21 of the structural nut 3 , so as to block the passage created by the internal bore 20 so as to interfere and stop the travel of any threaded rod or anchor 24 received and threaded into the internal passage 20 of the nut 3 past the bottom end 17 of the structural nut 3 .
[0046] As shown in FIGS. 1A and 1E , each leg 5 and 6 of the chair 2 is formed with a flow passage 40 to ensure that concrete 26 flows around and under the anchor bolt locator 1 and the threaded rod 24 attached to the nut 3 .
[0047] Mounting holes 27 are provided in the bridge 4 , preferably at all four corners of the bridge 4 . As shown in FIGS. 1C , 1 D and 1 E, fasteners 28 , preferably nails when the form board bottom 29 is wood, are inserted through the mounting holes 27 and fastened to the form board decking 29 , securing the anchor bolt locator 1 to the form 30 in the desired location.
[0048] The anchor bolt locator 1 is preferably formed from galvanized, stainless-steel formed in a sheet. Steel is sufficiently rigid, and can be cold-formed to grip the structural nut 3 after it has been placed in the depression 8 . In the preferred method of making the anchor bolt locator 1 , any openings that are to be made in the bridge 4 are formed first, usually with or right after the blank for the chair 2 is cut from the sheet stock. See FIGS. 2A , 3 A, 4 A and 5 A. Then, the depression 8 in the bridge 4 for receiving the nut 3 is formed and the legs 5 and 6 are bent down from the bridge 4 along bend lines 31 . See FIGS. 2B , 2 D, 3 B, 3 D, 4 B, 4 D and 5 B, 5 D. At the same time, embossments 32 are formed in the bridge 4 outwardly from the depression 8 . The depression 8 of the chair 2 is then ready to receive the nut 3 which is placed in the depression 8 . See FIGS. 2E , 3 E, 4 E and 5 E. The structural nut 3 is placed in the depression 8 so that portions of the outer surface 11 of the outer side wall 12 of the structural nut 3 are in alignment and in close proximity to portions of the inner surface 9 of the side wall 10 of the depression 8 . Once the nut 3 is received the embossments 32 formed outwardly from the depression 8 are clampingly pressed back into the original plane of the bridge 4 of the chair 2 . See FIGS. 2C , 2 F, 3 C, 3 F, 4 C, 4 F and 5 C, 5 F. This causes a spreading flow of the material of the embossments 32 toward the depression 8 which causes the side walls 10 of the depression 8 to be pressed against the outer side surface 11 of the nut 3 , causing frictional engagement that holds the structural nut 3 in place.
[0049] As shown in FIGS. 1B and 1C , preferably, the attachment between the anchor 24 and the nut 3 is made by means of corresponding threads in the internal cavity 20 of the structural nut 3 and threads 33 on the outer surface 34 of the anchor 24 . As shown in FIG. 1E , the anchor 24 is formed with an elongated shank 35 that can protrude above the top level 36 of the concrete slab 26 . FIG. 1E shows the top level 36 of the form 30 and the side wall 41 of the form 30 .
[0050] FIGS. 1D and 1E illustrate use of the invention. The anchor bolt locator 1 shown is used with a wood form 30 upon which concrete 26 will be poured. In FIG. 1D , rebar members 37 , a specific type of steel concrete reinforcing member, are shown placed in the form 30 . In FIG. 1D , chalk lines 38 are also shown on the bottom member 29 of the form 30 to aid in locating the anchor bolt locator 1 . The installer need merely look through the opening 20 in the nut 3 and line up the center of the opening 20 with the intersection of the chalk lines 38 . The installer then nails or screws the anchor bolt locator 1 to the bottom 29 of the form 30 by running the fasteners 28 through the mounting holes 27 in the anchor bolt locator 1 . Once the anchor bolt locator 1 is firmly fastened to the bottom 29 of the formwork 30 , the appropriate anchor 24 or threaded rod is inserted and threaded onto the nut 3 , until the tongues 25 of the depression 8 stop its further downward travel. As shown in FIG. 1E , typically a washer 38 will then be placed over the anchor 24 so that it rests on the top surface 19 of the structural nut 3 and a second structural nut 39 will be threaded onto the anchor 24 so that it engages the top surface of the washer 38 . This type of double-nut-washer anchorage is commonly used in the industry, because the components are readily available and inexpensive, and yet well documented for their performance as anchors. Concrete 26 is then poured into the formwork 30 , so that the anchor bolt locator 1 , the structural nuts 3 and 39 , the washer 38 , and the threaded rod 24 are all surrounded and embedded in the concrete 26 with the top of the threaded rod 24 or anchor protruding from the top surface 36 of the concrete 26 . When the concrete 26 hardens the form 30 can be removed. If there is access to the bottom 29 of the form 30 , it can be removed as well and the ends of the fasteners 28 that were driven into the bottom formwork 29 can be broken off where they protrude from the concrete foundation 26 . | An anchor bolt locator is provided that is inexpensively manufactured on automatic die-press machines from sheet steel and a structural nut that does not require any welding, while also being easy to use and install with current, commonly-used building practices and anchor designs. The anchor bolt locator is made from a galvanized sheet metal chair and a structural nut attached to the chair by way of a friction fit. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates generally to mesh networks, and more specifically in one embodiment to interrupt drive commissioning of nodes in a sleeping mesh network.
LIMITED COPYRIGHT WAIVER
[0002] A portion of the disclosure of this patent document contains material to which the claim of copyright protection is made. The copyright owner has no objection to the facsimile reproduction by any person of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office file or records, but reserves all other rights whatsoever.
BACKGROUND
[0003] Although computer networks have become relatively common both in office and in home networking environments, such networks are typically fairly sophisticated and require significant processing power, electrical power, and infrastructure to work well. Some networking applications do not require so robust a network environment, but can benefit from the ability to provide electronic communications between devices.
[0004] One such example is the Bluetooth technology that enables a cell phone user to associate and use an earpiece in what is sometimes referred to as a personal area network or PAN. Another example is a mesh network, in which a number of devices work together to form a mesh, such that data can be sent from a source device to a destination device via other devices in the mesh network.
[0005] Mesh networks often include multiple links from a network node to other network nodes nearby, and can thereby provide routing around broken links or paths by discovering other routes through the mesh to a destination node. New nodes to a mesh network are typically able to automatically discover the mesh network when they are activated in the vicinity of a compatible mesh network, and can easily join the network.
[0006] But, joining a mesh network becomes somewhat more complex in network environments where different frequencies or network identifiers are used. In ZigBee mesh networks, for example, different frequencies or channels can be used for different networks, such as to prevent nodes from one network from interfering with another network. A new node wishing to join a network must therefore find the appropriate frequency or channel being used by the intended network before it can join the intended network. This is performed in one example by searching among the various available channels until a mesh network is found, but confirming that the node has joined the intended network is difficult.
[0007] In addition to searching various frequencies or channels, some wireless mesh network technologies also sleep, or become inactive, to conserve power. For example, an array of battery powered sensors might be configured to wake up once every two hours and take a measurement, report the measurement via the mesh network, and go back to sleep. Use of sleeping nodes typically includes allowing end devices with reduced functionality to sleep, such as between taking and reporting measurements via router nodes that do not sleep. In other embodiments sleep times are synchronized between nodes in the network during configuration, so that all nodes are awake and able to contribute to mesh network communication at the same time.
[0008] But, in environments where mesh network nodes sleep for extended periods of time, it becomes difficult to add new nodes to the network or perform certain other node or network operations. There exists a need to provide wireless mesh network technology that addresses management of a mesh network with sleeping nodes.
SUMMARY
[0009] Some example embodiments of the invention comprise a mesh network of nodes having a set sleep period coordinated among the nodes to conserve power. A neighbor wireless mesh network node in proximity to a second node to be added to the mesh network is actuated, causing the neighbor wireless mesh network to be woke from a sleep state. The second node is added to the wireless mesh network by exchanging data with the neighbor wireless mesh network node to join the network
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIG. 1 shows an example wireless mesh network environment, consistent with an example embodiment of the invention.
[0011] FIG. 2 is a flowchart illustrating a method of actuating a neighboring node to add a node to a wireless mesh network, consistent with an example embodiment of the invention.
DETAILED DESCRIPTION
[0012] In the following detailed description of example embodiments of the invention, reference is made to specific examples by way of drawings and illustrations. These examples are described in sufficient detail to enable those skilled in the art to practice the invention, and serve to illustrate how the invention may be applied to various purposes or embodiments. Other embodiments of the invention exist and are within the scope of the invention, and logical, mechanical, electrical, and other changes may be made without departing from the subject or scope of the present invention. Features or limitations of various embodiments of the invention described herein, however essential to the example embodiments in which they are incorporated, do not limit the invention as a whole, and any reference to the invention, its elements, operation, and application do not limit the invention as a whole but serve only to define these example embodiments. The following detailed description does not, therefore, limit the scope of the invention, which is defined only by the appended claims.
[0013] Mesh networks are often used to route data between various elements or nodes in a network made up of a number of loosely assembled nodes. Many mesh networks are designed such that a compatible node can easily join the network and receive and send data, including passing received data along a route to an intended destination node. Mesh networks are therefore often self-healing, in that if a node becomes inoperable or loses a connection to another node, data can be easily routed around the broken network link.
[0014] Many mesh network technologies use wireless communication, further enhancing the ease of use of mesh networking for certain applications. Because mesh network nodes are typically stationary, wireless connections between various nodes can be formed and characterized by searching a known frequency or radio band for other mesh network nodes as new wireless nodes are added to the mesh network. Recent reductions in cost and advancement in wireless networking technology has made use of mesh networking for a variety of applications a desirable alternative to using a more structured network such as a TCP/IP network.
[0015] One example of a mesh network standard using wireless radio communication is the ZigBee mesh network, which was developed by an industry alliance and is related to IEEE standards including 802.15.4. The retail price of ZigBee-compliant transceivers is nearly a dollar, and a transceiver, memory, and processor can be bought for a few dollars in quantity, making integration of mesh network technology into inexpensive electronic devices economically practical. The standard is intended to support low power consumption at reasonably low data rates, and provides a self-organizing network technology that works well for applications such as control, monitoring, sensing, and home automation.
[0016] In this example of wireless mesh technology, one node operates as a coordinator, forming the root of the mesh network and performing other functions such as bridging to other networks and handling encryption keys. Most nodes are router nodes, which can receive and send data, including passing data along to other nodes. In some embodiments, end device nodes contain just enough functionality to receive and send data, but cannot route or pass data from a sending node to a different receiving node. While this preserves battery life and reduces the cost of the node, end device nodes are unable to contribute to the routing functions of the mesh network, and so will typically not make up a large percentage of a mesh network's nodes.
[0017] Nodes in some mesh networks can also conserve power by entering a sleep mode, or becoming inactive for extended periods of time when operation is not necessary. For example, a mesh network of ground moisture sensors may only need to take and report measurements every two hours, and need only be awake for a few milliseconds every two hour period. The sleeping nodes in a further embodiment of such a network are desirably synchronized during configuration of the network so that they wake at the same time, enabling the nodes to communicate with each other while awake and route data from neighboring nodes.
[0018] New nodes are typically able to join an existing network by searching known radio channels on which the mesh network technology operates, and in further examples by looking for other mesh network nodes broadcasting data having a PAN ID that matches the PAN ID of the network that the new node wishes to join. But, this becomes more difficult if the other nodes in the network are asleep, and if it is unknown when or for how long the nodes will be awake. Further, the sleep timing of the network can be several hours or longer as illustrated by the previous example, which is likely longer than an installer will be willing to wait to install a new node or perform other network functions such as replacing or reconfiguring a node.
[0019] This is solved in some embodiments by leaving at least one node powered, such as the coordinator node of the mesh network. The new node can join the network and synchronize its sleep schedule from the coordinator node, and will link to neighboring nodes in the mesh once placed in the mesh during the next wake cycle. Another option is to have all nodes in the mesh network remain awake after a certain wake cycle, so that the nodes remain awake while the installer works. This requires planning the service before the preceding wake period, and requires that all nodes remain on for an extended period of time which may significantly impact battery life. A third option includes powering on a new node in range of the sleeping network and keeping it fully awake until the rest of the network wakes up and the nodes can exchange synchronization information. This technique has the disadvantage that the newly added node can deplete a significant portion of its batteries in the time it waits to join the network.
[0020] Some embodiments of the invention improve upon prior methods by providing one or more nodes that can be woken during the coordinated sleep period, such as by toggling an I/O or interrupt line to wake a network node near the node being serviced. For example, a failed mesh network node can be replaced by removing the failed node, powering on a replacement node, and toggling an interrupt line by actuating a switch on a neighboring node such that the neighboring node wakes up for a predetermined amount of time. This enables the neighboring node to communicate with the replacement node, exchanging information such as the PAN ID, encryption keys, sleep timing, and other information to incorporate the new node into the mesh network.
[0021] FIG. 1 illustrates an example mesh network environment, such as may be used to practice some embodiments of the invention. A mesh network gateway or controller device 101 in this example includes a mesh network radio such that it is operable to communicate with mesh network nodes 102 , and a network connection such that it is operable to bridge the mesh network to an external network 105 . The mesh network nodes 102 are distributed about an area within radio contact of one another, such as security monitoring devices within a store or warehouse, water monitoring devices distributed about a golf course or farm, or military surveillance devices distributed about a hostile area. One of the mesh network devices 103 is undergoing a service operation, such as being newly installed or replacing a failed mesh network device.
[0022] The gateway device 101 bridges the wireless mesh network to the Internet 105 , which couples the mesh network to various devices such as a computer system 104 that is operable to access and control the mesh network. A mobile wireless device 106 such as an Internet-enabled cell phone can also be used to configure and control the mesh network, enabling control of the mesh network nodes from remote locations such as locations within the mesh network.
[0023] FIG. 2 is a flowchart of a method of adding new devices to a sleeping mesh network, consistent with an example embodiment of the invention. In this example, a gateway controller such as 101 of FIG. 1 is powered by an external power connection, but the mesh network nodes 102 are battery powered and sleep for extended periods coordinated between nodes. The nodes all wake at the same time, so that information can be communicated throughout the network, passed between neighboring nodes until the information reaches its desired destination. Because the wake period is in many embodiments only several milliseconds long and occurring every several hours, performing maintenance functions such as adding a new mesh network node during the brief period when the network is awake will often require waiting for hours until the next wake period.
[0024] Here, a node 103 has failed and is being replaced with a new node that has no knowledge of the mesh network or its coordinated sleep schedule. Although the network node is within communication distance of several other network nodes, it is not within communication distance with the gateway device 101 , which is the only device in the network that does not sleep to conserve battery power.
[0025] To perform the service operation, a service technician first removes the failed mesh network device, and places and powers on a new mesh network node device at 201 . The technician then actuates a neighboring mesh network node located near the new node, such as by triggering an interrupt or performing another monitored I/O function operable to wake up the sleeping neighbor node at 202 . The actuation can take place using a separate device such as an attached service or configuration device, by pushing a button or other actuation of a part of the node device, or any other such function. In an alternate embodiment, steps 201 and 202 are performed in opposite order, such that the new mesh network device is powered on after the neighboring network node is actuated.
[0026] The neighboring mesh network node wakes as a result of the actuation, and becomes operable to communicate with other devices such as the new network node device at 203 . The new mesh network node joins the wireless mesh network by exchanging network configuration information with the awake neighboring node, including information such as adding the replacement node to the neighboring node's node list, and sending network identification information and sleep timing data from the neighboring node to the new mesh network node device.
[0027] This results in the new network node device joining the network at 204 , after which the new and neighboring network nodes return to their sleep states at 205 until the next coordinated wake period. The new device in a further example provides an indication that it has successfully communicated with the neighboring node and joined the network, such as by flashing an indicator light.
[0028] These examples illustrate how actuation of a sleeping mesh network node can be used to awaken the node, enabling installation of new or replacement nodes into the mesh network without waiting until the next scheduled time the entire network is awake. This facilitates faster configuration and service of new network node devices, enabling service operations to be performed at any time. It also provides significantly improved power savings and battery life over prior solutions requiring the entire mesh network to be left in a powered on state for long periods of time to perform service functions.
[0029] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiments shown. This application is intended to cover any adaptations or variations of the example embodiments of the invention described herein. It is intended that this invention be limited only by the claims, and the full scope of equivalents thereof. | A set sleep period is coordinated among a plurality of mesh network nodes to conserve power. A neighbor wireless mesh network node in proximity to a second node to be added to the mesh network is actuated, causing the neighbor wireless mesh network to be woke from a sleep state. The second node is added to the wireless mesh network by exchanging data with the neighbor wireless mesh network node to join the network. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is an original patent application based on provisional application Ser. No. 60/519,099, filed Nov. 12, 2003, and derives its priority therefrom.
TECHNICAL FIELD
[0002] The present invention relates generally to a communications system for transmission and reception of voice and/or data over a wireless network using conventional land-line telephone equipment.
BACKGROUND
[0003] Cellular, Personal Communications Systems (PCS) and other types of wireless telephones that receive and transmit telephone calls on wireless networks have become commonplace. Indeed, wireless telephones have become so popular that some people have discontinued their conventional land-line home telephone service in favor of just having a wireless telephone service. In this way, users reduce their costs by eliminating their conventional land-line telephone service. However, drawbacks to eliminating the conventional home land-line service exist. For example, health concerns may be associated with extended periods of using a wireless telephone in close proximity to a user's body. Further, some users find it inconvenient not to have multiple telephones in various places of their home, as with conventional land-line telephone systems. Additionally, wireless telephone signals sometimes experience interference in various places of a house as the wireless telephone is moved from place to place. For these and other reasons, many people continue to maintain both a wireless telephone service (primarily for use outside of the home) and a conventional land-line telephone service for use at home.
[0004] The embodiments described hereinafter were developed in light of these and other disadvantages of existing communication systems.
SUMMARY
[0005] A converter device is disclosed for enabling conventional land-line communication equipment, including land-line telephones, modems, etc., to place and receive calls over a wireless telephone network.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] These and other features and advantages will be apparent from the following detailed description and the appended claims, taken in conjunction with the accompanying drawings, in which:
[0007] FIG. 1 is a diagram of a communications system, according to an exemplary embodiment, having a converter device that enables conventional land-line communication devices to place and/or receive calls on a wireless network; and
[0008] FIG. 2 is an exemplary block diagram of the communications device of FIG. 1 , according to an embodiment.
DETAILED DESCRIPTION
[0009] Referring to FIG. 1 , a communications system 10 is illustrated that includes a land-line network 12 and a wireless network 14 . As described in detail below, land-line network 12 is connected to wireless network 14 through converter 24 . Land-line network 12 is the hard-wired telephone network that is commonplace in most residential homes. In FIG. 1 , land-line network 12 is illustrated as having two conventional telephone wall jacks 18 and a telephone 16 plugged into one of the wall jacks 18 via conventional telephone wire 26 ( a ). Of course, land-line network 12 may include any number of wall jacks 18 distributed throughout the home and networked in a conventional manner. Any number of land-line telephones 16 (corded or cordless), modems (not shown) or other types of communication devices can be plugged into wall jacks 18 .
[0010] Wireless network 14 may be a cellular, PCS, or any other type of wireless communication network used for wireless telephone communications. In a conventional manner, wireless telephone 22 communicates with other wireless telephones, e.g., wireless telephone 23 , through a base station 20 . Specifically, wireless telephone 22 can be used to send and receive telephone calls with other wireless telephones and with conventional land-line phones on the plain old telephone system (POTS), in manners known in the art, when the wireless telephone 22 is not connected to converter 24 . When wireless telephone 22 is connected to converter 24 (as shown in FIG. 1 ), wireless telephone 22 and converter 24 together enable conventional land-line communication equipment (e.g., telephones) to place and receive telephone calls over the wireless network 14 .
[0011] Converter 24 provides an interface between the hard-wired telephone network 12 in a user's home to a wireless network 14 . Converter 24 is illustrated in FIG. 1 as being connected to the hard-wired home telephone network by simply connecting a line interface 24 ( d ) of converter 24 to a conventional wall jack 18 via telephone wire 26 ( b ), though other means for connecting converter 24 to the hard-wired home telephone network are envisioned and within the scope of the invention. An input/output port 24 ( a ) of converter 24 is detachably connected to wireless telephone 22 via wire 27 to provide a communication path between wireless telephone 22 and converter 24 . In some embodiments, converter 24 is connected to wireless telephone 22 through an existing data input/output connection on the wireless telephone 22 . Wire 27 may be a serial, USB, or other appropriate connecting cable. Preferably, converter 24 is located within a building (e.g., residential home) where the wireless signal is strongest and the wireless telephone 22 receives the clearest signal.
[0012] Referring now to FIG. 2 , a detailed block diagram of converter 24 is shown. As illustrated, converter 24 includes an input/output (I/O) port 24 ( a ), a central processing unit (CPU) 24 ( b ), RAM and ROM memory 24 ( c ) and 24 ( d ), an analog-to-digital (A/D) converter 24 ( e ), a line interface 24 ( f ), radio frequency (RF) transceiver 24 ( g ), data bus 24 ( h ), and power supply 24 ( i ). Other embodiments of the converter 24 are envisioned and within the scope of the invention. In this embodiment, CPU 24 ( b ) provides the processing capabilities of converter 24 . For example, CPU 24 ( b ) converts wireless telephone signals to conventional analog telephone signals and vice versa. CPU 24 ( b ) communicates with RAM memory 24 ( c ) and ROM memory 24 ( d ) in conventional manners to store and retrieve data and operating instructions. CPU 24 ( b ) communicates with wireless telephone 22 via I/O port 24 ( a ) over two-way data bus 24 ( h ). Specifically, CPU receives wireless telephone communications from wireless telephone 22 and sends wireless telephone communications to wireless telephone 22 via data bus 24 ( h ) and I/O port 24 ( a ). Similarly, CPU 24 ( b ) communicates with the hard-wired telephone network 12 through A/D converter 24 ( e ) and line interface 24 ( f ). Specifically, line interface 24 ( f ) provides the interface connection to connect a telephone wire 26 ( b ) between converter 24 and wall jack 18 . A/D converter 24 ( e ) converts analog voice/data signals from the hard-wired telephone network 12 to digital signals used by the CPU 24 ( b ) and visa versa. As shown in FIG. 2 , CPU 24 ( b ) may additionally communicate to the hard-wired telephone network 12 in a wireless manner via RF transceiver 24 ( g ). Either as a supplement to or in place of hard-wiring converter 24 to hard-wired network 12 (via line interface 24 ( f )), converter 24 may communicate directly to cordless land-line telephone devices (not shown) through RF transceiver 24 ( g ). Specifically, RF transceiver 24 ( g ), if employed, can receive and transmit wireless radio frequency signals to/from cordless hand-held telephone units in much the same manner that known 900 Mhz, 2.4 Ghz, and 5.8 Ghz base units currently communicate with cordless hand-held telephone units. Power supply 24 ( i ) powers the circuitry of converter 24 and further provides the line voltage and ringing current used by the line interface 24 ( f ) to generate rings in the land-line network 12 .
[0013] Now, exemplary methods of processing telephone calls using converter 24 will be discussed. First, the situation where a phone call is initiated from a third-party (e.g., telephone 23 ) to a residence using a converter 24 is described. A call initiated from telephone 23 is routed through base station 20 and received by wireless telephone 22 in a conventional manner. Though FIG. 1 shows telephone 23 as a wireless telephone, a call initiated from a conventional land-line telephone would similarly be routed through base station 20 to wireless telephone 22 in a known manner. When wireless telephone 22 receives the call, wireless telephone 22 generates a ring signal, which is conveyed to converter 24 via I/O port 24 ( a ). Converter 24 converts the wireless ring signal to a conventional ring signal for a land-line telephone system, which is output via line interface 24 ( f ) and/or RF transceiver 24 ( g ). This causes land-line telephones (e.g., telephone 16 ) connected to the hard-wired land-line network 12 to ring. When the user answers one of the land-line phones, an off-hook signal is generated. Converter 24 receives the off-hook signal through line interface 24 ( f ) and/or RF transceiver 24 ( g ) and converts it to a wireless telephone format, which is conveyed to wireless telephone 22 . Then, wireless telephone 22 is placed into off-hook mode and the call is connected. Wireless voice/data signals are received from the calling party by wireless telephone 22 . Converter 24 converts those wireless voice/data signals to analog voice/data signals and conveys them to land-line network 12 . Similarly, land-line telephone 16 sends analog voice/data signals to converter 24 , which converts them to wireless voice/data signals and conveys them to wireless telephone 22 . Wireless telephone 22 sends the wireless voice/data signals to the third-party caller in a conventional wireless manner. In this way, two-way communication is established between a conventional land-line telephone and a third-party caller (calling from either a wireless telephone or conventional land-line phone) via a wireless network.
[0014] Now, a method where a user of the land-line network 12 initiates a call to a third-party will be described. When a user initiates a call by picking up a land-line telephone (e.g., telephone 16 ) (either corded or cordless phone), a conventional off-hook signal is generated. Converter 24 receives the off-hook signal through line interface 24 ( f ) and/or RF transceiver 24 ( g ). Converter 24 converts the off-hook signal to a wireless network format compatible with the wireless network 14 . Wireless telephone 22 receives the off-hook signal and goes into an off-hook mode. The user then dials the desired number on the land-line phone 16 , which is also converted to the wireless network format by converter 24 . Wireless telephone 22 , in response to the signals, dials the corresponding number that is routed through base station 20 to the called party (e.g., wireless telephone 23 ). When the called party picks up, the call is completed between the land-line phone 16 and the called party via the wireless network.
[0015] In an alternative embodiment, a cell phone cartridge or “clone” cartridge can be used in place of wireless telephone 22 in the system to achieve the same end result. A clone cartridge is a device that is capable of sending and receiving wireless voice/data signals like a normal wireless telephone. However, a clone cartridge does not have any buttons, so the only means of input and output with a clone cartridge is through an I/O interface of the clone cartridge, which, when used with converter 24 , is connected to I/O port 24 ( a ) through wire 27 . The use of a clone cartridge would allow the converter 24 to have the full functionality described hereinabove without the need to connect the user's wireless telephone 22 to the system. This arrangement would provide the benefit of maintaining the functionality of the land-line system as described above while the wireless telephone 22 is away from the house. Moreover, it provides the additional convenience of not having to constantly plug and unplug the wireless telephone 22 into the system.
[0016] The above-described embodiment provides a system where conventional land-line telephones and other communication devices can place and receive calls via a wireless network. In the described system, the user does not have to directly use the wireless telephone 22 , thereby reducing some of the possible health concerns associated with wireless telephones. Further, the system allows a user to locate converter 24 where the wireless signal reception is strongest, thereby consistently providing a strong connection to third-party callers. In this way, users can enjoy many of the benefits of a land-line telephone without the expense of two telephone service billings. The user is billed only for use of wireless which connects to the non-user party and is not billed for use of user's landline telephone which connects only to the user's wireless telephone or clone. One skilled in the art, in light of this disclosure, will recognize other benefits associated with the described embodiments.
[0017] Various other modifications to the present invention may occur to those skilled in the art to which the present invention pertains. Other modifications not explicitly mentioned herein are also possible and within the scope of the present invention. For example, the foregoing description refers to communications received and/or initiated by the user utilizing a telephone as the land-line device 16 . It is recognized however, that the above systems and processes are equally applicable to communications received and/or initiated by a computer or any other device capable of communicating on the land-line network 12 . Accordingly, it is the following claims, including all equivalents, which define the scope of the present invention. | A telecommunications converter module is disclosed. The telecommunications converter module includes a connection port configured to connect to a wireless communication device and an interface to a land-line communication network. The telecommunications converter module further includes a processor, in communication with said data port and said interface, that is configured to convert wireless telecommunication signals to land-line telecommunication signals and to convert land-line telecommunication signals to wireless telecommunication signals. | 7 |
TECHNICAL FIELD
[0001] The present invention is related generally to semiconductor integrated circuits, and more specifically to a method and system for electrically coupling a semiconductor chip to a chip package.
BACKGROUND OF THE INVENTION
[0002] During the manufacture of integrated circuit devices, such as memories and microprocessors, a semiconductor die or chip must be physically and electrically attached to a chip package. A chip is a small piece of semiconductor material, such as silicon, in which an integrated circuit is formed, and a chip package as used herein is a protective container, such as a plastic dual-in-line package (DIP), or printed circuit board to which the chip is coupled, as will be appreciated by those skilled in the art.
[0003] To electrically couple a chip to a chip package, electrical connections are formed between regions on the chip known as bonding pads, and leads or corresponding bonding pads on the chip package. This process can entail the creation of hundreds of electrical connections between the chip and chip package. Three techniques are generally relied on to accomplish this task: (1) wire bonding; (2) flip chip/bump bonding; and (3) tape automated bonding.
[0004] [0004]FIG. 1 is a diagram illustrating a chip 2 that is wire-bonded to a chip package 4 . Generally, in a wire bonding process a thin wire 6 (commonly between 0.7 to 1.0 mil) is used to connect a chip bonding pad 8 to an inner lead 10 on the chip package 4 . Each inner lead 10 is coupled to an outer lead (not shown) which, in turn, provides electrical connections to external circuits (not shown). Each wire 6 must be placed individually, which is time consuming, and each wire results in increased electrical resistance in the connection. In addition, the use of wires mandates the observance of minimum spacing requirements to avoid short circuiting wires and performance problems resulting from wires being too close to one another.
[0005] [0005]FIG. 2 shows a chip package 4 that is electrically coupled with a chip 2 through flip chip/bump bonding. With flip chip/bump bonding, metal bumps 12 placed on each bonding pad 8 on the chip 2 are soldered to the inner leads 14 of the chip package 4 . This is usually done by placing the chip 2 in position on the chip package 4 and melting the metal bumps 12 to solder the bonding pads 8 to the inner leads 14 . In this way, all of the bonds necessary to electrically connect a chip 2 to a chip package 4 can be done essentially simultaneously, which reduces the time required to interconnect the chip 2 and chip package 4 when compared to wire bonding. Flip-chip bonding, however, requires precise alignment of the chip 2 and the chip package 4 to ensure proper interconnection. Moreover, great care must also be exerted to prevent soldered metal from causing short circuits by propagating from one bonding pad 8 to adjacent bonding pads. Additionally, given the orientation of the chip 2 and the chip package 4 , after bonding an efficient visual inspection of the bonds is not possible, and the nature of the bonding procedure mandates that the chip 2 be heated and exposed to pressure.
[0006] Tape automated bonding (TAB) is accomplished through the use of a flexible strip of tape on which a metal lead system has been deposited. Initially a conductive layer is deposited on the tape, usually by methods including sputtering and evaporation. This conductive layer is then formed by mechanical stamping or patterning techniques, such as fabrication patterning, resulting in a continuous tape with multiple individual lead systems. In order to bond the tape to the chip, the chip is then placed on a holder and the tape is positioned over the chip with the inner leads of a lead system on the tape being situated exactly over corresponding bonding pads located on the chip. The inner leads and the bonding pads are then pressed together, creating physical and electrical bonds between the inner leads and the bonding pads. TAB requires very precise positioning of the tape and the chip. Even slight misalignment can result in multiple short circuits and missed connections between inner leads and chip pads, thus compromising the electrical connection of the chip to the chip package.
[0007] In view of the above-mentioned processes, it is desirable to develop a new process for electrically interconnecting a chip and chip package.
SUMMARY OF THE INVENTION
[0008] According to one aspect of the present invention, a chip and a chip package can transmit information to each other by using a set of converters capable of communicating with each other through the emission and reception of electromagnetic signals. Both the chip and the chip package have at least one such converter physically disposed on them. Each converter is able to (1) convert received electromagnetic signals into electronic signals, which it then may relay to leads on the device on which it is disposed; and (2) receive electronic signals from leads on the device on which it is disposed and convert them into corresponding electromagnetic signals, which it may transmit to a corresponding converter on the other device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is a cross-sectional view of a chip wire-bonded to a chip package.
[0010] [0010]FIG. 2 is a cross-sectional view of a chip bonded by flip chip/bump technology to a chip package.
[0011] [0011]FIG. 3 is a functional and cross-sectional view of a chip that is coupled to a chip package through electromagnetic signals.
[0012] [0012]FIG. 4 is a functional and cross-sectional view of a chip and chip package placed into communication according to another embodiment of the invention.
[0013] [0013]FIG. 5 is a block diagram of a memory device including a semiconductor memory chip coupled to a chip package through electromagnetic signals.
[0014] [0014]FIG. 6 is a block diagram of a computer system including the memory devices of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
[0015] [0015]FIG. 3 is a functional and cross-sectional view of a microelectronics package 30 including a chip 32 that is coupled to a chip package 34 through electromagnetic signals 42 , as will now be explained in more detail. By coupling the chip 32 to the chip package 34 through electromagnetic signals 42 , a direct physical connection between the two is eliminated, which can simplify the fabrication of the package 30 and reduce the adverse inductive and capacitive effects associated with conventional bonding techniques. The chip 32 includes electronic circuitry 36 coupled to bonding pads 38 which, in turn, are coupled to first converters 40 . It is also possible for the circuitry 36 to be directly coupled to the converters 40 without the use of intervening bonding pads 38 . The circuitry 36 in the chip 32 may be a memory device, a processor, or any other type of integrated circuitry.
[0016] Each first converter 40 receives a corresponding electric signal 41 from the circuitry 36 via the bonding pad 38 , and converts the electric signal into an electromagnetic signal 42 . The converter 40 then transmits the electromagnetic signal 42 to a corresponding second converter 44 located on the chip package 34 . The second converter 44 receives the electromagnetic signal 42 and converts it to a corresponding electric signal 45 that is applied to an inner lead 46 . The first and second converters 40 and 44 may also communicate in the opposite direction, with the second converter 44 converting the electric signal 45 received from the inner lead 46 to the electromagnetic signal 42 which the second converter 40 receives and converts into the electric signal 41 that is applied to the circuitry 36 . The first and second converters 40 and 44 may transmit and receive the electromagnetic signals 42 having a wide range of frequencies, including visible light and infrared frequencies. Furthermore, even though FIG. 3 only illustrates a pair of first converters 40 and a pair of second converters 44 , more or fewer converters may be employed as desired.
[0017] The microelectronics package 30 includes an intermediate layer 48 disposed between the chip 32 and the chip package 34 . The intermediate layer 48 has suitable physical characteristics to allow the electromagnetic signals 42 to propagate through the intermediate layer, and may be air, an adhesive layer physically coupling the chip 32 to the chip package 34 , or other suitable materials, as will be appreciated by those skilled in the art. The intermediate layer 48 may include regions 49 disposed between the converters 40 and 44 , that are formed from different materials than the other portions of the intermediate layer 48 . In another embodiment, the intermediate layer 48 is omitted and the chip 32 is physically positioned on the chip package 34 with the converters 40 , 44 adjacent one another. An encapsulation layer 51 is typically formed over the chip 32 once the chip is attached to the chip package 34 , sealing the chip and chip package to prevent moisture and other contaminants from affecting the operation of the package 30 .
[0018] [0018]FIG. 4 is a functional and cross-sectional view of a microelectronics package 400 including a silicon chip 402 and a chip package 404 that are electrically coupled through infrared signals 406 according to another embodiment of the invention. Though not shown in FIG. 4, the silicon chip 402 includes circuitry and bonding pads and the chip carrier 404 includes inner leads as previously described for the corresponding components in FIG. 3. A first converter 407 is disposed on a first side 408 of the chip 402 , opposite a second side 410 of the adjacent side 412 of the chip package 404 . The first converter 407 operates as previously described for the converters 40 of FIG. 3 to convert the infrared signals 406 to electrical signals and visa versa. The second side 410 of the silicon chip 402 may physically contact the side 412 of the chip package 404 or an intermediate layer (not shown) may be disposed between the two.
[0019] With the first converter 407 disposed on the first side 408 of the chip 402 , the infrared signals 406 propagate though the silicon chip 402 to a second converter 414 disposed on the side 412 of the package 404 . Because the chip 402 is silicon, which is substantially transparent to infrared signals, the infrared signals 406 propagate through the chip with a relatively low signal loss. If an intermediate layer is disposed between the silicon chip 402 and the chip package 404 , this layer must, of course, have suitable physical characteristics to allow the propagation of infrared signals. In the embodiment of FIG. 4, the chip 402 may be formed from materials other than silicon and the frequency of the signals 406 varied accordingly to allow the signals to propagate through the chip, as will be appreciated by those skilled in the art.
[0020] [0020]FIG. 5 is a block diagram of a memory device 99 including a semiconductor memory circuit 101 formed on a chip 100 and coupled to a chip package 102 through electromagnetic signals 104 , 105 , and 107 that include address, control, and data signals, respectively, for transferring data to and from the memory circuitry, as will now be explained in more detail. The memory circuitry 101 includes an address decoder 106 , a control circuit 108 , and read/write circuitry 110 , all of which are conventional and known in the art. The address decoder 106 , control circuit 108 , and read/write circuitry 110 are all coupled to a memory cell array 112 and are also coupled to an address bus 114 , a control bus 116 , and a data bus 118 , respectively. The memory device 99 may be a synchronous or asynchronous dynamic random access memory or static random access memory, as well as a packetized memory, such as an SLDRAM or RAMBUS device. Moreover, the device 99 need not be a memory device, but may be another type of integrated circuit.
[0021] An address converter 120 receives electromagnetic address signals 104 and converts these signals into corresponding electric address signals that are applied to the address decoder 106 over the address bus 114 . A control converter 122 receives electromagnetic control signals 105 and converts these signals into corresponding electric control signals that are applied to the control circuit 108 over the control bus 116 . A read/write converter 124 operates during write operations of the memory device 99 to receive electromagnetic data signals 107 and convert these signals into corresponding electric data signals that are then applied to the read/write circuitry 110 over the data bus 118 . The read/write converter 124 also operates during read data transfers of the memory device 99 to receive electric data signals on the data bus 118 and convert these signals into corresponding electromagnetic data signals 107 . A package address decoder 126 is mounted on the chip package 102 adjacent the address decoder 106 , and receives electric address signals 133 and converts these signals into the electromagnetic address signals 104 , and a package control converter 128 mounted on the chip package adjacent the control converter 122 operates in the same way to generate the electromagnetic control signals 105 in response to electric control signals 132 applied to the chip package. A package read/write converter 130 is mounted on the chip package 102 adjacent the converter 124 and operates during write operations to receive electric data signals 131 and generate the corresponding electromagnetic data signals 107 . During read operations, the package read/write converter 130 receives the electromagnetic data signals 107 and generates the corresponding electric data signals 131 .
[0022] The converters 120 - 124 on the chip 100 and converters 126 - 130 on the chip package 102 may communicate via any of a variety of suitable communication protocols, as will be understood by those skilled in the art. Moreover, each converter 120 - 124 and converter 126 - 130 may correspond to a number of converters with one converter handling conversion of a single address, control, or data signal. For example, where the data bus 118 is N bits wide, the converter 124 corresponds to N converters and the converter 130 similarly corresponds to N converters. Alternatively, a single converter 120 - 124 and 126 - 130 could multiplex and demultiplex a number of data, address, or control signals, as will also be appreciated by those skilled in the art.
[0023] In operation, external circuitry (not shown) provides address, control and data signals to the respective leads 131 , 132 , 133 on the chip package 102 . These are transmitted to the respective chip package converters where the electric signals are converted into electromagnetic signals 107 , 105 , 104 and transmitted to the respective converters on the chip 100 . The converters on the chip may then convert the electromagnetic signals 107 , 105 , 104 to electric signals and transmit them over the address bus 114 , the control bus 116 and the data bus 118 to the address decoder 106 , the control circuit 108 and the read/write circuitry 110 respectively.
[0024] In operation during a read cycle of the memory device 99 , external circuitry (not shown) provides a read command to the converter 128 in the form of the signals 132 , and the converters 128 and 122 operate in combination to apply the read command to the control circuit 108 . In response to the read command, the circuit 108 generates a plurality of control signals to control operation of the decoder 106 , circuitry 110 , and array 112 during the read cycle. The external circuit also provides a memory address to the converter 126 as the signals 133 , and the converters 126 and 120 operate in combination to apply the address bus 118 to the address decoder 106 . In response to the memory address, the address decoder 106 provides a decoded memory address to the memory-cell array 112 which, in turn, accesses the memory cells corresponding to the address and provides the data in the accessed cells to the read/write circuitry 110 . The read/write circuitry 110 then provides this data on the data bus 118 and the converters 124 and 130 operate in combination to output the data as the signals 131 from the chip package 102 .
[0025] During a write cycle of the memory device 99 , external circuitry (not shown) provides a write command to the converter 128 in the form of the signals 132 , and the converters 128 and 122 operate in combination to apply the write command to the control circuit 108 . In response to the write command, the circuit 108 generates a plurality of control signals to control operation of the decoder 106 , circuitry 110 , and array 112 during the write cycle. The external circuit also provides data to the converter 130 as the signals 131 , and the converters 130 and 124 operate in combination to apply the data to the data bus 118 . The read/write circuitry 110 provides the data to the memory-cell array 112 which, in turn, places the data in addressed memory cells.
[0026] [0026]FIG. 6 is a block diagram of a computer system 139 which includes the memory device 99 of FIG. 5. The computer system 139 includes a processor 140 for performing various computing functions, such as executing specific software to perform specific calculations or tasks. In addition, the computer system 139 includes one or more input devices 142 , such as a keyboard or mouse, coupled with the processor 140 to allow an operator to interface with the computer system 139 . Typically, the computer system 139 also includes one or more output devices 144 coupled to the processor 140 , such output devices typically being a printer or video terminal. One or more data storage devices 146 are also typically coupled to the computer processor 140 to store data or retrieve data from external storage media (not shown). Examples of typical storage devices 146 include hard and floppy disks, tape cassettes, and compact disk read only memories (CD-ROMs). The processor 140 is typically coupled to the memory device 99 through a control bus, a data bus, and an address bus to provide for writing to and reading from the memory device.
[0027] It is to be understood that even though various embodiments and advantages of the present invention have been set forth in the foregoing description, the above disclosure is illustrative only, and changes may be made in detail, and yet remain within the broad principles of the invention. Therefore, the present invention is to be limited only by the appended claims. | A chip and a chip package can transmit information to each other by using a set of converters capable of communicating with each other through the emission and reception of electromagnetic signals. Both the chip and the chip package have at least one such converter physically disposed on them. Each converter is able to (1) convert received electromagnetic signals into electronic signals, which it then may relay to leads on the device on which it is disposed; and (2) receive electronic signals from leads on the device on which it is disposed and convert them into corresponding electromagnetic signals, which it may transmit to a corresponding converter on the other device. Not having a direct physical connection between the chip and the chip package decreases the inductive and capacitive effects commonly experienced with physical bonds. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the priority of German Patent Application Serial No.: 10 2006 060 619, filed Dec. 21, 2006 pursuant to 35 U.S.C. 119(a)-(d), the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a device for depositing and dispensing a paper payment medium and in particular a device for depositing and dispensing paper currency for a machine having a currency validation unit and a storage module.
From DE 198 29 458 A1, a device is known for the storage and dispensation of paper currencies such as bank notes and which comprises in addition to a currency stacking till, a storage drum located beneath the currency stacking till in which the bank notes are rolled around in layers separated by at least one foil strip. Incoming bank notes are sent through a conveyor unit to a verification unit and then to the currency stacking till, respectively the storage drum.
Furthermore, from the WO 00/52649 a device for the deposit and dispensation of bank notes is known. The bank notes are conveyed to a unit with three roller storages. The unit in which the roller magazines are seated can be pivoted into a position for dispensing the bank notes.
The conventional devices that are known for the storage and dispensation of bank notes for the most part are insufficiently compact in their construction. In addition, the bank note storage capacity of such machines is not suitably dimensioned for compactness and efficiency.
It would therefore be desirable and advantageous to provide an improved device for intake and dispensation of currencies to obviate prior art shortcomings and to provide a unit that is compact, easy to install and efficient in use.
SUMMARY OF THE INVENTION
The present invention resolves prior art problems since the device has a compact construction thus permitting that a sufficient amount of the incoming paper currency can be stored in the storage module and that such currency is at any time again available for dispensation in accordance with the determined dispensation schedule.
According to one aspect of the present invention, a device for depositing and dispensing paper payment medium includes a unit for verification of the value of the payment medium and the authenticity of the incoming payment medium, a payment medium storage till for stacking the accepted payment medium such as bank notes and a storage module for the intake and dispensation of the accepted bank notes, as well as a transport unit for conveying the accepted bank notes from the verification unit to the storage till and/or the storage module and wherein the storage module is constructed as a revolving magazine which includes a plurality of roller magazines, each of which is provided with its own opening for entry and exit of bank notes. Each of the roller magazines is pivotable by means of an actuator into a transfer position to an entry and exit opening of the transport system.
In the context of the present invention the terms “paper payment medium”, “bank note”, “currency”, “paper currency” or “bills” are interchangeable terms designating paper or paper like legal tender as payment means.
A further advantageous feature of the device according to the present invention is that the bank note transport unit is separated from the bank note verification unit. A transport unit of the bank note stacking unit is able to deliver the bank notes to the bank note storage modules with a storage capacity for bank notes sorted according to three different bank note face values.
The device is very compact in its construction and requires few additional transport means other than the transport system which is already part of the device. Construction of the device thus provides high storage efficiency in conjunction with simplicity and cost efficiency. In particular, each individual storage roller magazine has a high storage capacity due to the use of only one foil strip for transporting and securing the paper note.
In order to realize both, a secure intake and a secure dispensation of the bank notes, each storage magazine and supply magazine is provided with its own actuating mechanism. These actuating mechanisms are controlled by a common control unit which controls each actuating mechanism according to its individual present function and in turn ensures that the foil strip is under sufficient tension to avoid that the bills can slip from the foil.
Furthermore, the afore-described construction ensures that the bills are always available for dispensation. Also, the device includes that a hand crank is provided inside the housing by means of which the storage modules can be individually manually operated for bill dispensation. Of course, the hand crank is located in a secure location inside the housing which is accessible only to authorized personnel.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
FIG. 1 is a longitudinal section view of the device for the deposit and dispensation of paper currency according to the present invention;
FIG. 2 is perspective view of the device shown in FIG. 1 inside a housing.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Throughout all the Figures, same or corresponding elements are generally indicated by same reference numerals.
Turning now to the drawings, and in particular to FIG. 1 , there is shown a device 1 for the deposit and dispensation of paper currency which includes a paper currency examination unit 2 connected to an attachment plate 3 of a bill stacking unit 4 . The bill stacking unit 4 comprises a transport and stacking system 5 , 6 which is assigned to a revolving magazine 7 . The revolving magazine 7 includes three bill roller magazines 8 .
The bill examination unit 2 comprises its own control and transport unit for transporting the accepted bills to a bill dispensing opening 9 of the bill examination unit 2 .
The bill dispensation opening 9 is followed by the transport system 5 which consists of two endless bands 10 in parallel disposition to each other and corresponding press rollers 11 . Perpendicular to the longitudinal extension of the transport system 5 is the removable bill stacking till 12 . The bill stacking till 12 is provided with a spring-loaded stacking floor 13 . With one of its ends, the spring 14 is supported at the stacking floor 13 and with the other end supported at a rear wall 15 of bill collecting till 12 . A scissor-type lifting system 17 , which is driven by an electromotor is located at the side opposite the stacking floor 13 and corresponds to an access opening (not shown here) to the bill stacking till 12 . An accessory drive operatively engages the lifting system 17 thereby causing the lifting system 17 to deflect. A press roller 11 is disposed in a pivotable holding device which is fixed in the area central to the stacking floor 13 . An electromagnetic actuator 19 is assigned to the fixed holding device for the press roller 11 . The transport system 5 extends to an entry/exit opening 20 of the revolving magazine 7 . The revolving magazine 7 is attached in formfitting and/or friction fitting manner at the bottom side of the housing in which the bill stacking unit 4 is situated.
The revolving magazine 7 which comprises at least one face plate 22 is disposed in a housing 35 and is rotatable about a central longitudinal axis 21 . Disposed at the face plate 22 are three roller magazines 23 each of which consists of a transport band supply spool 24 and a bill collecting spool 25 . A transport band 26 which is coiled about the transport band supply spool 24 is fed to the bill collection spool 25 by means of two deflection rollers 27 that are disposed at the face plate 22 . The transport band supply spool 24 and the bill collection spool 25 each comprise its own accessory drive. Each roller magazine 23 is assigned a bill entry and exit opening 29 . Deflection rollers 27 , 28 , bearing transport band 26 are disposed in the area of opening 29 . A spring loaded pivotable drag bar 30 is disposed between deflection roller 28 and the bill collection roller 25 and supported by the bill collection spool 25 . The drag bar is 30 is mounted at the face plate 22 in a pivotable manner.
The revolving magazine 7 is rotatably disposed at the central longitudinal axis 21 . The face place 22 can be swiveled by 240° by means of a motor drive. A motor drive with a swivel gear 31 is operatively engaged with a crown gear of the face plate 22 . Each of the bill entry/exit opening 29 of each roller magazine 23 can thus be aligned with the input and output opening 20 . At the outer circumference of the face plate 22 there are three spaced apart index notches 32 each of which is correspond to a locking roller 33 with a spring-loaded notch lever 34 . A photoelectric barrier is assigned to the notch lever 34 for recognizing the position of the notch lever 34 . The photoelectric barrier (not shown here) is connected to a control unit. Each of the roller magazines 23 is provided with its own identical control unit. Data exchange among the control units is carried out by a single-strand data line. The three control units of roller magazines 23 are in correspondence with a control unit of the stacking- and transport system 5 , 6 .
The revolving magazine 7 is shown in a perspective view in FIG. 2 . The housing 35 of revolving magazine 7 shows service openings with corresponding shutters 37 , 38 . The housing 35 can be separated from the stacking system 6 by opening a lock with a key. Only after removal of the housing 35 from the stacking system 6 , it is possible to open rear shutter 38 and bottom shutter 37 . The rear shutter 38 as well as the floor shutter 37 is pivotably disposed at a side wall 39 of the housing 35 . On the inner side of rear shutter 38 is a bracket 40 to which a hand crank 41 is form-fittingly attached. The side wall 39 of housing 35 has a cover 42 for locking service opening 43 . The axle of the transport band supply spool 24 is located behind the cover 42 . A spur gear of the transport band supply spool 24 gearing is connected to the axle of the transport band supply spool 24 . At its face, the spur gear has recesses, which correspond with a pin that is fastened at the end of the hand crank 41 . The transport band supply spool 24 thus can be manually rotated with the hand crank 41 for winding the transport band up onto the spool 24 . By means of the manual operation of the transport band supply spool 24 , bills that have been rolled into and stored on the bill collection spool 25 can be dispensed through the bill input/output opening 29 located at the side of the bottom shutter 37 . After removal of the hand crank 41 from the service opening 43 , the face plate 22 can be pivoted into a next position which permits to insert the hand crank 41 again in order to actuate the transport band supply spool 24 of another roller magazine 23 . The face plate 22 can also be pivoted by means of a manual access at the side corresponding to the stacking system 6 .
The purposeful pivoting of the face plate 22 ensures that the bill intake and dispensation opening 29 of the respective roller magazine 23 corresponds to the bottom shutter 37 and that the bills which are to be dispensed can be purposefully and securely removed from the revolving magazine 23 .
Due to its compactness, device 1 for the deposit and dispensation of bank notes can for example be utilized in coin operated entertainment machines. After the entertainment machine is turned on, device 1 operates under the same electric power source as the entertainment machine.
A bank note is inserted into a deposit opening after which it first moves through a bank note examination unit 2 where it is authenticated and its face value determined. If the bank note is accepted, it is moved via a transport unit of the bank note deposit opening 9 adjoining the examination unit 2 , to transport system 5 . The transport system 5 moves the bank note to the area of the stacking floor 13 . An actuator 19 for the press roller 11 is put into operation so that the press roller 11 is moved in opposite direction of the stacking floor 13 . By means of an actuator, the scissor-like lifting system 17 is operated such that the bank note is pressed into the bank note stacking till 12 . Thereafter, the actuator of the lifting system 17 is returned to its start position.
After a deposited bank note has been verified and accepted it is then transferred to the transport system 5 and transported along a travel path to the entry/exit opening 20 . When reaching the entry/exit opening 20 , a light barrier located in the travel path and connected to the control unit of the stacking system 6 is activated and interrupts the transport of the bank note. The determined face value of the bank note which is located in the transport system 5 is then communicated to the control unit of the revolving magazine 7 . Depending on the face value of the present bank note, the respective roller magazine 23 is pivoted by means of the actuator 31 on the face plate 22 , whereby the bank note intake/output opening 29 of the respective roller magazine 23 will line up with the entry/exit opening 20 of the transport system 5 . The recognition of the line-up position is determined by means of the notch lever 34 , which locks into an index notch 32 by means of a locking roller 33 . Notch lever 34 is assigned a light barrier, which is connected to the control unit of the actuator. After the predetermined line-up position has been reached, the control unit for the roller magazine 23 is activated by the control unit of the bank note stacking unit 4 . The control unit of the roller magazine 23 thus activates the actuator of bank note collection spool 25 . The bank note is then moved by the transport system 5 into the input/output opening 29 to the point until the light barrier of the roller magazine 23 is activated. The control unit of the roller magazine 23 activates the actuators (not shown) of the transport band supply spool 24 and the bank note collection spool 25 , whereby the bank note is now rolled onto the bank note collecting spool 25 .
Upon a demand for dispensation of a bank note of a certain face value which is rolled up in the roller magazine 23 , the control unit of the bank note stacking unit 4 examines whether the bank note of the demanded face value is available from the roller magazine 23 , whose input/output opening 29 is still lined up with the entry/exit opening 20 . If the roller magazine 23 , currently lined up with the entry/exit opening 20 , does not have the bank note of the demanded face value, the actuator 31 of the control unit of the bank note stacking unit 4 becomes activated and continues to be activated until the next respective roller magazine 23 has reached the position where the bank note input/output opening 29 of the respective roller magazine 23 has lined up with the entry/exit opening 20 . When the desired locking position is reached, a light barrier is activated by the notch lever 34 thereby stopping the motor followed by the control unit of the bank note stacking unit 4 now activating the control unit of the roller magazine 23 lined up to input entry/exit 20 . The control unit of the roller magazine 23 activates the actuator of transport band supply spool 24 and bank note collecting spool 25 . When the dispensation position has been reached, that is, when the banknote input/output 29 is aligned with the entry/exit opening 20 of the transport system 5 , the control unit of each of the particular roller magazine 23 activates the actuator of each of the transport band supply spool 24 and the bank note collecting spool 25 . The bank note is then transported under rejection of the drag bar 30 to the bank note input/output 29 and then transferred into the transport system 5 . The outgoing bank note is fed to a bank note examining unit 2 and subsequently dispensed from there.
Since each incoming bank note is registered by the control unit of stacking unit 4 , the number and the face value of each bank note is known as well as the sequence of the notes, respectively each individual bank note in each roller magazine 23 . This allows bank notes of different face value to be deposited in one roller magazine 23 . When a dispensation is forced from the roller magazine 23 carrying bank notes of different face value, the bank notes which physically precede the note to be dispensed is transferred to the transport system 5 and then moved via the stacking system 6 into the stacking till 12 .
While the invention has been illustrated and described as embodied in a device for an entertainment machine, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. | A device for the intake and output of paper currencies comprises an arrangement for examining the value and authenticity of the currency, which thereafter is fed to a transport system of a currency stacking bank via a currency storage module, wherein the storage module, which is exchangeable located below the currency stacking bank is constructed as a revolving magazine and comprises a series of roller magazines, whereby the intake and output opening of each of the roller magazines is pivoted by means of an actuator into a d position of the transport system. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a sewing machine frame made from a synthetic resin in which an arm portion, a tower portion and a bed portion are provided integrally. The present invention also relates to a sewing machine having the sewing machine frame.
In the sewing machine frame, a horizontally extending arm portion supports a reciprocation mechanism for a needle carrying a needle thread, and the tower portion vertically extends from the bed portion for supporting the arm portion in a cantilevered fashion. In the bed portion, a loop taker is supported for trapping a loop of the needle thread carried on the vertically reciprocating needle in order to form a stitch.
In the sewing machine, a smooth stitching operation is required. To this effect, vibration and displacement of a needle tip due to the vertically reciprocating motion of the needle must be reduced or minimized, otherwise a loop seizing beak of the loop taker disposed in the bed portion cannot trap the needle thread loop formed by vertical reciprocation of the sewing needle. Thus, the stitching may be degraded.
In order to avoid this problem, the needle & rotary hook timing must be adequately provided. To this effect, the sewing machine frame must provide high rigidity capable of avoiding deformation or displacement thereof due to reaction force occurring when the needle penetrates a workpice fabric. Therefore, in the conventional sewing machine, a metallic frame having high rigidity is provided in an interior of a sewing machine cover, and a stitch forming mechanism including a needle vertical reciprocating mechanism and the loop taker is attached to the metallic frame.
However, such a conventional arrangement is costly, bulky and heavy. More specifically, the sewing machine frame has a rigid box shape arrangement in order to provide high rigidity. Further, the frame is made from a metal such as a cast iron or aluminum, which in turn increase weight and size. Further, high skill and elaboration is required for assembling the sewing machine because the stitch forming mechanism must be installed into the metallic frame through a small area opening thereof. This increases assembly cost.
Laid open Japanese Patent Application Kokai No.Hei-11-137880 discloses a sewing machine frame made from a synthetic resin to reduce production cost and to provide a light weight frame. As shown in FIG. 16, the frame 300 has an open end arrangement in a U-shape cross-section in which a bed portion 304 , a tower portion 303 and an arm portion 302 are provided integrally, and a reinforcing plate 301 is fixed between upper and lower portions at the open end of the bed portion 304 .
However, the disclosed sewing machine frame 300 provides a rigidity still lesser than that of the metallic frame. More specifically, as shown in FIG. 16, vertical vibration occurs in the arm portion 302 due to a load exerted along a vertical line containing the needle, the load being caused by the reciprocating motion of the needle during stitching operation. Further, a horizontal swing also occurs at an upper portion of the tower portion 303 during stitching. The horizontal swing may be generated by distortion of the tower portion 303 and the bed portion 304 due to the distortion of the arm portion 302 caused by the vertical reciprocation of the sewing needle.
Accordingly, the disclosed sewing machine frame 300 is still insufficient in terms of rigidity, to lower stitching quality in comparison with the conventional sewing machine provided with the metallic frame.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome the above-described problems and to provide a sewing machine frame having a bed portion, a tower portion and an arm portion those integrally with each other and formed of a synthetic resin, yet having high rigidity, and to provide a sewing machine having such an improved sewing machine frame.
This and other objects of the present invention will be attained by a sewing machine frame for a sewing machine including an integral frame member, and reinforcing ribs. The integral frame member is made from a synthetic resin and provides an outer surface defining an external shape and an inner surface providing an internal space. The integral frame member includes a bed portion, a tower portion upstanding from the bed portion, and an arm portion extending from the tower portion in a cantilevered fashion. The reinforcing ribs are provided at substantially entire area of the inner surface for reinforcing the integral frame member.
In another aspect of the invention, there is provided a sewing machine frame for a sewing machine, the sewing machine including a vertical reciprocation mechanism for a needle carrying a needle thread, and a loop taker trapping a loop of the needle thread carried on the reciprocating needle to form a stitch. The frame includes an integral frame member, and reinforcing ribs. The integral frame member is made from a synthetic resin and provides an outer surface defining an external shape and an inner surface providing an internal space. The integral frame includes a bed portion for supporting the loop taker in the internal space, a tower portion upstanding from the bed portion, and an arm portion extending from the tower portion in a cantilevered fashion for supporting the vertical reciprocation mechanism in the internal space. The reinforcing ribs are provided at substantially entire area of the inner surface.
In still another aspect of the invention, there is provided a sewing machine including a stitch forming mechanism and any one of the above-described sewing machine frame.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned aspects and other features of the invention are explained in the following description, taken in connection with the accompanying drawing figures wherein:
FIG. 1 is a front view showing the overall construction of a sewing machine comprising a frame according to the preferred embodiment;
FIG. 2 is a side view showing the overall construction of the sewing machine in FIG. 1;
FIG. 3 is a perspective view showing the external appearance of a main frame;
FIG. 4 is a perspective view showing the internal construction of the main frame;
FIG. 5 is a plan view showing the internal construction of the main frame;
FIG. 6 (A) is a cross-sectional view along the plane of the main frame indicated by the arrows A in FIG. 5;
FIG. 6 (B) is a cross-sectional view along the plane of the main frame indicated by the arrows B in FIG. 5;
FIG. 7 (A) is a cross-sectional view along the plane of the main frame indicated by the arrows C in FIG. 5;
FIG. 7 (B) is an enlarged view showing the lower end of the main frame;
FIG. 7 (C) is a cross-sectional view along the plane of the main frame indicated by the arrows D in FIG. 5;
FIG. 8 (A) is a cross-sectional view along the plane of the main frame indicated by the arrows E in FIG. 5;
FIG. 8 (B) is a cross-sectional view along the plane of the main frame indicated by the arrows F in FIG. 5;
FIG. 8 (C) is an enlarge view of a protrusion;
FIG. 8 (D) is a cross-sectional view along the plane of the main frame indicated by the arrows M in FIG. 5;
FIG. 9 (A) is an enlarged plan view showing the main frame from the perspective of the line G in FIG. 5;
FIG. 9 (B) is an enlarged plan view showing the main frame from the perspective of the line H in FIG. 5;
FIG. 10 is a perspective view showing the external appearance of the frame cover;
FIG. 11 is a perspective view showing the internal construction of the frame cover;
FIG. 12 is a plan view showing the internal construction of the frame cover;
FIG. 13 is a cross-sectional view along the plane of the frame cover indicated by the arrows I in FIG. 12;
FIG. 14 (A) is a cross-sectional view along the plane of the frame cover indicated by the arrows J in FIG. 12;
FIG. 14 (B) is an enlarged view showing the lower end of the frame cover;
FIG. 15 (A) is an enlarged plan view along the plane of the frame cover indicated by the arrows K in FIG. 12;
FIG. 15 (B) is an enlarged plan view along the plane of the frame cover indicated by the arrows L in FIG. 12; and
FIG. 16 is a perspective view showing a conventional sewing machine frame.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Structure of a Sewing Machine
A sewing machine frame according to a preferred embodiment of the present invention will be described while referring to the accompanying drawings. First the overall construction of a sewing machine comprising a frame according to the preferred embodiment will be described with reference to FIGS. 1 and 2. FIG. 1 is a front view, and FIG. 2 is a side view showing the overall construction of the sewing machine comprising a frame 1 according to the preferred embodiment.
As shown in FIG. 1, the frame 1 substantially comprises a bed 8 , a cantilever support 7 provided vertically on the bed B, an arm 6 , and an arm 6 cantilevered from the cantilever support 7 above the bed 8 . The bed 8 , the cantilever support 7 , and the arm 6 are integrally formed of a synthetic resin in a substantially C shape.
The frame 1 supports a stitch forming mechanism including a loop taker and a mechanism for driving a needle 16 reciprocally up and down, and constitutes a shell of the sewing machine. In other words, the frame 1 does not need any metallic frame for mounting the stitch forming mechanism. Accordingly, it is possible to manufacture a lighter frame 1 having simplified structure, compared with a conventional metal frame to mount a stitch forming mechanism, covering with a resin cover. The frame 1 may be formed of a synthetic resin material by using a well-known injection molding method.
The synthetic resin material for the frame 1 may be a noncrystalline thermoplastic resin, such as a styrene resin. More specifically, the material may be one or mixture of acrylonitrile-butadiene-styrene copolymer, polystyrene, acrylonitrile-styrene, acrylonitrile-acrylate-styrene, acrylonitrile-ethylene-styrene, chlorinated acrylonitrile-polyethylene-styrene. Of these materials, a resinous matter having acrylonitrile-butadiene-styrene copolymer as the primary component with an inorganic additive of talc or glass bead has good rigidity and a good thermal expansion coefficient. The usage of the above material may eliminate frame coating in the later step due to a good appearance of the frame.
The arm 6 supports a top mechanism 3 for reciprocally driving the needle 16 up and down, the needle 16 retaining needle thread. A motor 2 provided in the cantilever support 7 generates rotational motion. The top mechanism 3 converts this rotational motion to reciprocal motion by means of a crank mechanism to transfer the reciprocal motion to the needle 16 . The top mechanism 3 comprises a spindle 12 , a thread take-up crank 13 , a needle bar holder 14 , a needle bar 15 , and a thread take-up lever link hinge pin 17 mounted in a metal top frame 11 . The top frame 11 is directly attached to the frame 1 by several screws.
Next, the operations of the top mechanism 3 will be described. A rotational driving force generated by the motor 2 is transferred to a large pulley 35 via a motor belt 36 . The rotational driving force transferred to the large pulley 35 is further transferred to the thread take-up crank 13 via an arm shaft 31 and the spindle 12 . The arm shaft 31 is rotatably supported by two bearings 32 , 32 . The spindle 12 is linked to the arm shaft 31 via a coupler. Through the movement of a needle bar crank rod, rotational motion transferred to the thread take-up crank 13 is converted to reciprocal motion of the needle bar 15 that is supported rotatably on the needle bar holder 14 . The needle bar 15 is capable of moving vertically in the needle bar holder 14 . This reciprocal motion is transferred to the needle 16 .
The arm 6 is supported on the top end of the cantilever support 7 , while the bed 8 is connected to the bottom end of the cantilever support 7 . A drive transferring mechanism 5 is disposed in the cantilever support 7 for transferring rotational driving force generated by the motor 2 to the top mechanism 3 housed in the arm 6 and a lower mechanism 4 housed in the bed 8 . The drive transferring mechanism 5 comprises the motor 2 , the large pulley 35 , the motor belt 36 , a pulley 38 , a pulley 39 , and a timing belt. The drive transferring mechanism 5 is directly attached to the frame 1 . The motor 2 is supported by motor supporting brackets 33 that are fixed near the bottom end of the cantilever support 7 .
Next, the operations of the drive transferring mechanism 5 will be described. The rotational driving force provided by the motor 2 is transferred to the large pulley 35 via the motor belt 36 . The rotational driving force transferred to the large pulley 35 is then transferred to the arm shaft 31 rotatably supported by the two bearings 32 , 32 . As described above, this rotational motion is transferred to the top mechanism 3 via the spindle 12 , while this movement is also transferred to the lower mechanism 4 . That is, the pulley 39 is fixed at approximately the center point of the arm shaft 31 . Rotational motion transferred to the pulley 39 is further transferred to the pulley 38 disposed in the bed 8 via the timing belt 41 . A rotary hook shaft 37 is rotatably supported by a bearing 32 . Since the rotary hook shaft 37 is linked to the pulley 38 , the rotary hook shaft 37 rotates in synchronization with the rotations of the arm shaft 31 due to the rotational motion of the pulley 38 .
The cantilever support 7 is formed on one end of the bed 8 . The bed 8 supports a rotary hook 23 constituting a loop taker for catching a thread loop of the needle thread as the needle moves up and down and forming a stitch. The lower mechanism 4 is provided inside the bed 8 for rotating the rotary hook 23 in synchonization with the reciprocal motion of the needle 16 . The lower mechanism 4 comprises a rotary hook shaft 21 , a helical gear 22 , the rotary hook 23 , a helical gear 24 , and the rotary hook shaft 37 mounted on a metal lower frame 20 . The lower frame 20 is mounted directly on the frame 1 by a plurality of screws.
Next, the operations of the lower mechanism 4 will be described. The rotational motion transferred via the timing belt 41 to the pulley 38 is transferred to the helical gear 22 via the rotary hook shaft 37 rotatably supported by the bearing 32 and the rotary hook shaft 21 rotatably supported by two bearings 25 , 25 and linked to the rotary hook shaft 37 via a coupler. As shown in FIG. 2, the helical gear 22 is fixed on the rotary hook shaft 21 . A rotary hook shaft on which the rotary hook 23 is fixed is rotatably supported on the lower frame 20 for rotating beneath the top surface of the bed 8 . The helical gear 24 engaged with the helical gear 22 is fixed to the rotary hook shaft. Accordingly, when the rotary hook shaft 21 rotates, the rotary hook 23 rotates via the helical gear 22 and helical gear 24 . At the same time, A loop seizing beak of the loop taker moves in synchronization with the tip of the needle 16 , and catches the thread loop of the needle thread supported on the needle 16 as the needle 16 moves vertically.
Sewing Machine Frame
In order to execute smooth sewing operations with a sewing machine having the construction described above, it is necessary to minimize vibration caused by the vertical movement of the needle 16 . Simultaneously, displacement of the needle tip caused by deformation of the frame 1 due to the vertical movement of the needle 16 is required to be minimized. This is because large amount of the displacement and the vibration of the needle tip can prevent the loop seizing beak of the loop taker provided in the bed 8 from catching the thread loop, resulting in the formation of an inappropriate stitch. To avoid this, it is necessary to maintain at all times an appropriate needle and rotary hook timing between the loop seizing beak of the rotating rotary hook 23 and the needle 16 that is moved reciprocally up and down. Accordingly, the frame 1 must have high rigidity in order to prevent deformation (displacement) due to a reaction force generated when the needle penetrates a working piece cloth. However, since it is difficult to maintain sufficient rigidity in a frame formed of synthetic resin, the frame 1 of the present embodiment employs various constructions to achieve sufficient rigidity.
As shown in FIG. 2, the frame 1 is formed of a main frame 1 A and a frame cover 1 B along a dividing plane 52 formed in approximately the center of the periphery of the frame 1 when viewed from the end (the dotted line in FIG. 2 ). The main frame 1 A is provided with the stitch forming mechanism including the top mechanism 3 for driving the needle 16 reciprocally up and down and the lower mechanism 4 for rotating the rotary hook 23 . The frame cover 1 B is coupled to the main frame 1 A to cover the stitch forming mechanism.
The insides of the main frame 1 A and frame cover 1 B are configured to accommodate the top mechanism 3 and the lower mechanism, as shown when the main frame 1 A and frame cover 1 B are in an open state divided along the dividing plane 52 (refer to FIGS. 4 and 11 ). When assembling the sewing machine, the top mechanism 3 and the lower mechanism are first mounted in the main frame 1 A while the main frame 1 A is rendered in an open state. The main frame 1 A and frame cover 1 B are then joined together by inserting screws through couplings 90 , 190 provided in the main frame 1 A and the frame cover 1 B (see FIGS. 4 and 11 ). By simplifying the process for assembling the sewing machine in this way, it is possible to reduce the assembly costs. Since the open area of the frame is closed after assembly, the frame retains sufficient rigidity, and the arm 2 is not easily subject to torsional deformation due to reciprocal motion of the needle 16 .
Main Frame
Next, the main frame 1 A of the frame 1 will be described with reference to FIGS. 3 through 9. FIG. 3 is a perspective view showing the external appearance of the main frame 1 A. FIG. 4 is a perspective view showing the internal construction of the main frame 1 A FIG. 5 is a plan view showing the internal construction of the main frame 1 A. FIG. 6 (A) is a cross-sectional view along the plane of the main frame 1 A indicated by the arrows A in FIG. 5 . FIG. 6 (B) is a cross-sectional view along the plane of the main frame 1 A indicated by the arrows B in FIG. 5 . FIG. 7 (A) is a cross-sectional view along the plane of the main frame 1 A indicated by the arrows C in FIG. 5 . FIG. 7 (B) is an enlarged view showing the lower end of the main frame 1 A. FIG. 7 (C) is a cross-sectional view along the plane of the main frame 1 A indicated by the arrows D in FIG. 5 . FIG. 8 (A) is a cross-sectional view along the plane of the main frame 1 A indicated by the arrows E in FIG. 5 . FIG. 8 (B) is a cross-sectional view along the plane of the main frame 1 A indicated by the arrows F in FIG. 5 . FIG. 8 (C) is an enlarge view of a protrusion shown in FIG. 8 (B). FIG. 8 (D) is a cross sectional view along the plane of the main frame 1 A indicated by the arrows M. FIG. 9 (A) is an enlarged plan view showing the main frame 1 A from the perspective of the line G in FIG. 5 . FIG. 9 (B) is an enlarged plan view showing the main frame 1 A from the perspective of the line H in FIG. 5 .
As shown in FIG. 3, the main frame 1 A substantially comprises the arm 6 , the cantilever support 7 , and the bed 8 formed integrally. The semicircular space surrounded by the arm 6 , cantilever support 7 , and bed 8 is a space 9 .
In addition, the main frame 1 A comprises a back panel wall 250 constituting a back side of the sewing machine, and side wall 251 extending from a peripheral edge 250 a of the back panel wall 250 . Especially, the surface of the main frame 1 A facing the space 9 is designated as an inner surface wall 51 . The inner surface wall 51 has a rectangular opening 53 that a cloth-pressing lever for fabric (not shown) is passed through.
As shown in FIGS. 1, 4 and 5 , the main frame 1 A is provided with an arrangement for mounting stitch forming mechanism. More specifically, the interior of the arm 6 is provided with a pair of thread take-up shaft supports 140 , 140 for rotatably supporting the thread take-up lever link hinge pin (not shown); a needle bar holder mount 141 on which the needle bar holder 14 is mounted; an upper frame mount 142 on which the top frame 11 is mounted; and a pair of arm shaft supports 144 , 144 for rotatably supporting the arm shaft 31 that transfers the rotational drive force from the motor 2 to the top mechanism 3 . Motor support bracket mounts 146 are mounted in the cantilever support 7 for attaching the motor supporting brackets 33 that fixedly support the motor 2 . Further, the interior of the bed 8 is provided with a pair of lower conducting shaft supports 147 , 147 for rotatably supporting the rotary hook shaft 37 that transfer the rotational drive force from the motor 2 to the lower mechanism 4 , and a lower frame mount 148 on which the lower frame 20 is mounted.
Reinforcing Member
Referring to FIGS. 4 and 5, a reinforcing member 60 is provided around the inner surface wall 51 of the main frame 1 A facing the space 9 surrounded by the arm 6 , cantilever support 7 , and bed 8 . The reinforcing member 60 is formed integrally with the back panel wall 250 . One end of the reinforcing member 60 extends along the longitudinal direction of the arm 6 to the point adjacent to the side wall 251 at one end of the arm 6 opposing the cantilever support 7 . The other end of the reinforcing member 60 extends along the longitudinal direction of the bed 8 to the point adjacent to the side wall 251 at one end of the bed 8 opposing the bed 8 . As described above, the reinforcing member 60 comprises three parts: one part placed around the inner surface wall 51 in a semicircle shape, another part placed in a linear manner as if it crosses the arm 6 , and the other part placed in a linear manner as if it crosses the bed 8 . Accordingly, the reinforcing member 60 is placed in a continuous manner to form a U-shape as a whole. The above structure of the reinforcing member 60 reinforces projecting portions of the arm 6 and the bed 8 which extend from the cantilever support 7 .
Referring to FIG. 8 (D), the reinforcing member 60 has a tubular shape with a hollow circular cross-section. This reinforcing member 60 is formed with the back panel wall 250 integrally to project from the inner surface of the back panel wall 250 . The reinforcing member 60 is formed in a tubular shape for the following reasons. As described above, the main frame 1 A is formed according to an injection molding method. In this method, after injecting a molten resinous material in a cavity die shell, the resinous material is cooled. At this time, thicker portions of the molded product harden slower than thinner portions. Since contraction is greater at the thicker portions, shrinkage occurs in those portions. In order to prevent such shrinkage, it is necessary to maintain a uniform thickness in the molded product. For this reason, the reinforcing member 60 is formed in a hollow tubular shape. When forming the frame 1 , the tubular shape of the reinforcing member 60 is formed by injecting an inert fluid, such as argon gas or nitrogen gas, through an injection hole 61 formed at one end of the reinforcing member 60 adjacent to the side wall 251 , and subsequently cooling the reinforcing member 60 .
The above structure of the reinforcing member 60 ensures the rigidity of the inner surface wall 51 facing the space 9 surrounded by the arm 6 , the cantilever support 7 , and the bed 8 on which stress caused by the reciprocating motion of the needle 16 is concentrated. The above structure of the reinforcing member 60 also ensures the rigidity of the back panel wall 250 and the side wall 251 of the arm 6 , cantilever support 7 , and bed 8 adjacent to the inner surface wall 51 . Accordingly, a sewing machine including the main frame 1 A prevents horizontal and vertical vibrations of the main frame 1 A caused by the reciprocating motion of the needle 16 , thereby performing a smooth stitch forming action.
In addition, the reinforcing member 60 has a semicircle hollow section to achieve a light weight and provide sufficient rigidity. The reinforcing member 60 is formed integrally with the back panel wall 250 . Accordingly, process for manufacturing the main frame 1 A is simplified.
In the embodiment described above, the reinforcing member 60 has one end extending to the point adjacent to the side wall 251 placed at the tip of the arm 6 , and the other end extending to the point adjacent to the side wall 251 placed at the tip of the bed 8 . In another embodiment, the reinforcing member 60 may extend to a certain point between the arm 6 and the bed 8 It is preferable that the reinforcing member 60 is provided around at least the space 9 . In this case, the arrangement of the reinforcing member 60 may have a J-shape, C-shape, or a rectangular shape with one open side.
Auxiliary Reinforcing Member
Referring to FIGS. 4 and 5, the back panel wall 250 of the main frame 1 A has an auxiliary reinforcing member 66 formed integrally therewith. The auxiliary reinforcing member 66 is placed substantially parallel to the reinforcing member 60 outside thereof at a predetermined interval. The auxiliary reinforcing member 66 is placed in a continuous manner described as follows: The auxiliary reinforcing member 66 extends from a certain point between the cantilever support 7 and the side wall 251 at the arm 6 along the longitudinal direction of the arm 6 within the arm 6 to one end of the cantilever support 7 . The auxiliary reinforcing member 66 is then curved in a semicircle shape within the cantilever support 7 to extend to one end of the bed 8 . The auxiliary reinforcing member 66 further extends from the other end of the cantilever support 7 along the bed 8 with in the bed 8 to the point adjacent to the side wall 251 opposing to the cantilever support 7 . As describe above, the parallel arrangement of the reinforcing member 60 and the auxiliary reinforcing member 66 leads to a uniform filling to the interior of the back panel wall 250 between the reinforcing member 60 and the auxiliary reinforcing member 66 with synthetic resin, thereby preventing weld line and shrinkage appearing on the back panel wall 250 . As a result, the main frame 1 A can obtain a good appearance.
Referring to FIG. 7 ( c ), the auxiliary reinforcing member 66 has the substantially semicircle cross section similar to that of the reinforcing member 60 . The auxiliary reinforcing member 66 has a hollow tubular shape having a hollow space 6 B within the auxiliary reinforcing member 66 . The auxiliary reinforcing member 66 is formed integrally with the back panel wall 250 in a manner to project from the interior of the back panel wall 250 of the main frame 1 A. The reason why the auxiliary reinforcing member 66 has a tubular shape is the same as that of the reinforcing member 60 . Additionally, a method to form the auxiliary reinforcing member 66 is the same as that of the reinforcing member 60 .
The above arrangement of the auxiliary reinforcing member 66 ensures the rigidity of the back panel wall 250 . Therefore, a sewing machine including the above main frame 1 A can advantageously prevent horizontal and vertical vibrations of the main frame 1 A caused by the reciprocating motion of the needle 16 , thereby performing smooth stitch forming action.
In the above embodiment, the main frame 1 A is provided with the reinforcing member 60 and the auxiliary reinforcing member 66 , while the frame cover 1 B does not has any reinforcing member and auxiliary reinforcing member (See FIG. 11 ). The reason why frame cover 1 B has no reinforcing member is as follows: the main frame 1 A accommodates the stitch forming mechanism including the tope mechanism 3 for reciprocating the needle 16 and the lower mechanism 4 for rotating the rotary hook 23 . Therefore, vibrations or displacement are more easily induced to the main frame 1 A than the frame cover 1 B. However, the frame cover 1 B may be provided with a reinforcing member or an auxiliary reinforcing member, if necessary. In that case, the frame cover 1 B obtains stronger rigidity.
Inside Wall Reinforcing Rib
As shown in FIGS. 4 and 5, an inside wall reinforcing rib 70 for reinforcing the inner surface wall 51 of the main frame 1 A facing the space 9 is provided on the inside of the back panel wall 250 around the periphery of the space 9 . A lot of inside wall reinforcing ribs 70 are provided around the periphery of the space 9 from the joint of the arm 6 and the cantilever support 7 to the joint of the cantilever support 7 and the bed 8 .
The inside wall reinforcing rib 70 comprises a partitioning rib 71 spaced from the inner surface 51 and a plurality of intermediate ribs 72 intersecting with the inner surface 51 and partitioning rib 71 . The partitioning rib 71 extends from the inside of the back panel wall 250 and parallel to the inner surface wall 51 in a continuous manner. The intermediate rib 72 extends from the inside of the back panel wall 250 between the inner surface wall 51 and the partitioning rib 71 at a constant intervals perpendicularly to the back panel wall 250 . The intermediate rib 72 connects the inner surface wall 51 to the partitioning rib 71 , and connects the inner surface wall 51 and the partitioning rib 71 to the back panel wall 250 . The above arrangement of the inner surface wall 51 , the partitioning rib 71 , and the intermediate ribs 72 provides a plurality of cells (partitioning chamber) 73 in the space between the inner surface 51 and partitioning rib 71 . The intermediate ribs 72 are arranged radially from a center point located in the space 9 , because the inner surface wall 51 surrounding the space 9 has a semicircle shape. Accordingly, each intermediate rib 72 intersects the inner surface 51 and partitioning rib 71 at a perpendicular angle. Thus, the arrangement of the ribs is optimized, thereby reinforcing the inner surface wall 51 advantageously.
The above structure of the inside wall reinforcing ribs 70 provides the rigidity equal to that of the inner surface wall 51 having a considerable thickness. In other words, the above structure of the inside wall reinforcing ribs 70 ensures the rigidity over the back panel wall 250 from the area adjacent to the joint of the arm 6 and the cantilever support 7 , through the cantilever support 7 , to the area adjacent to the joint of the cantilever support 7 and the bed 8 . A sewing machine having the main frame 1 A can prevent horizontal and vertical vibrations of the main frame 1 A caused by the reciprocating motion of the needle 16 , thereby performing a smooth stitch forming action.
In the above embodiment, the inside wall reinforcing ribs 70 are provided on the back panel wall 250 from the joint of the arm 6 and the cantilever support 7 through the 7 through the 7 to the joint of the cantilever support 7 and the bed 8 . In another embodiment, the inside wall reinforcing rib 70 may be formed over the whole of the inner surface wall 51 . In the above embodiment, a lot of intermediate ribs 72 are provided. However, in another embodiment, the number of the intermediate ribs 72 may be only one or a few. Each of the intermediate ribs 72 may be coupled or crossed to each other, so that the resultant arrangement of the intermediate ribs 72 may have honeycomb or diagram shape.
As described above, the hollow reinforcing member 60 having a substantially semicircle shape is formed integrally with the back panel wall 250 around the inner surface wall 51 . In other words, both the reinforcing member 60 and the inside wall reinforcing rib 70 are formed at the substantially same positions on the inner surface wall 51 . Especially, the reinforcing member 60 is located near the back panel wall 250 inside of the inside wall reinforcing rib 70 . The inside wall reinforcing rib 70 projects from the surface of the reinforcing member 60 . The above structure is necessary to obtain considerable reinforcement, because stress induced by the reciprocating motion of the needle 16 is concentrated on the inner surface wall 51 . In addition, the space around the inner surface wall 51 has sufficient spare room because the stitch forming mechanism is not mounted. Therefore, the inside wall reinforcing rib 70 having a considerable height can be formed.
Outside Wall Reinforcing Rib
As shown in FIGS. 4 and 5, outside wall reinforcing ribs 80 are formed in a matrix shape over nearly the entire inside of the back panel wall 250 . The outside wall reinforcing rib 80 projects from the inside of the back panel wall 250 . The outside wall reinforcing rib 80 is formed of vertical ribs 81 vertically oriented when the sewing machine is placed on a working surface, and horizontal ribs 82 oriented horizontally when the sewing machine is in the same position. As shown in FIGS. 6 (A) and 6 (B), these vertical ribs 81 and horizontal ribs 82 are approximately perpendicular to the back panel wall 250 . The ends of the vertical ribs 81 and horizontal ribs 82 are joined with the side wall 251 on the side portions of the main frame 1 A. The spaces surrounded by pairs of intersecting vertical ribs 81 , 81 and horizontal ribs 82 , 82 form approximately square or rectangular shaped cells 83 . Hence, a plurality of cells 83 are formed on the back side of the back panel wall 250 .
Among the cells 83 , the outside wall reinforcing rib 80 defining a cell 83 having a wider area is formed to have a higher height from the back panel wall 250 , compared to a cell 83 having a narrower area. The above structure of the cell 83 will be explained with respect to a wider cell 83 A located on the right side of the arm conducting shaft supports 144 in the cantilever support 7 (see FIGS. 4 and 5 ), and a narrower cell 83 B located on the lower-right side of the needle bar holder mount 141 in the arm 6 (see FIGS. 4 and 5 ).
As shown in FIG. 5, the vertical length X of the wider cell 83 A is identical to the vertical length U of the narrower cell 83 B. On the other hand, the horizontal length Y of the wider cell 83 A is longer more than two times of the horizontal length V of the narrower cell 83 B. Thus, the area of the wider cell 83 A is wider than that of the narrower cell 83 B.
Referring to FIG. 6 (A), the height Z from the 250 of the outside wall reinforcing rib 80 constituting the wider cell 83 A (horizontal rib 82 ) is higher than the height W from the back panel wall 250 of the outside wall reinforcing rib 80 constituting the narrower cell 83 B (vertical rib 81 ). In the case where the outside wall reinforcing ribs 80 have different height from each other due to requirements for a design of the main frame 1 A, the wider area of the higher outside wall reinforcing rib 80 and the narrower area of the narrower outside wall reinforcing rib 80 lead to the uniform rigidity over the whole of the back panel wall 250 . Accordingly, the action of stress on the particular point on the back panel wall 250 can be avoided. Thus, the main frame 1 A ensures considerable rigidity as a whole.
The outside wall reinforcing rib 80 on the accommodating part for the stitch forming mechanism in the arm 6 or the bed 8 has a lower height from the back panel wall 250 than those of the outside wall reinforcing ribs 80 on the inside of the back panel wall 250 other than the accommodating part. In other words, as described above, the narrower cell 83 B is located on the right-lower side of the needle bar holder mount 141 for mounting the needle bar holder 14 constituting the tope mechanism 3 , thereby corresponding to the part accommodating the stitch forming mechanism. Therefore, the outside wall reinforcing rib 80 (vertical rib 81 ) has a relatively lower height W from the back panel wall 250 so as to face the stitch forming mechanism at a closer distance. On the other hand, the wider cell 83 A is not a part for accommodating the stitch forming mechanism. Accordingly, as described above, the outside wall reinforcing rib 80 (horizontal rib 82 ) has a relatively higher height 2 form the back panel wall 250 . However, the above structure may lead to insufficient rigidity over the part for accommodating the stitch forming mechanism. To overcome the above problem, the narrower area of the cell 83 , that is, the formation of the narrower cell 83 B, results in the increase of the rigidity thereof. The resultant rigidity is substantially the same as that of the wider cell 83 A. Accordingly, the concentration of stress to a certain point of the back panel wall 250 can be prevented, so that the main frame 1 A can obtain sufficient rigidity.
The above arrangement of the outside wall reinforcing rib 80 ensures the sufficient rigidity of the back panel wall 250 , thereby minimizing or restricting distortion appearing on the back panel wall 250 of the arm 6 due to the reciprocating motion of the needle 16 . The above arrangement of the outside wall reinforcing rib 80 also minimizes distortion appearing on the back panel wall 250 of the cantilever support 7 and the bed 8 due to the distortion of the arm 6 . In this embodiment, the outside wall reinforcing ribs 80 extend in vertical and horizontal directions on the back panel wall 250 to define the cells 83 . This arrangement results in the sufficient rigidity of the back panel wall 250 in the case where the outside wall reinforcing rib 80 is not allowed to have a higher height in order that the main frame 1 A accommodates the stitch forming mechanism. Accordingly, a sewing machine having the above main frame 1 A can prevent vertical and horizontal vibrations of the main frame 1 A caused by the reciprocating motion of the needle 16 , thereby performing a smooth stitch forming action.
In another embodiment, the outside wall reinforcing rib 80 may not be formed over the whole back panel wall 250 , but be formed over only a part of the back panel wall 250 which needs sufficient rigidity of the back panel wall 250 for accommodating the stitch forming mechanism. In another embodiment, the outside wall reinforcing ribs 80 may be arranged in order that the cells 83 have hexagonal or octagonal shapes.
It should be noted that the inside wall reinforcing rib 70 has a higher height from the back panel wall 250 than that of the outside wall reinforcing rib 80 . More specifically, as shown in FIG. 8 (A), at the base end of the arm 6 , the inside wall reinforcing rib 70 is formed at a height from the back panel wall 250 reaching the dividing plane 52 . In contrast, the vertical ribs 81 reach approximately halfway to the dividing plane 52 from the back panel wall 250 . As shown in FIG. 8 (B), in the center portion of the cantilever support 7 , the intermediate ribs 72 have a height from the sidewall 50 reaching the dividing plane 52 . In contrast, the horizontal ribs 82 reach less than half the height of the dividing plane 52 from the sidewall 50 . A high rigidity is necessary for the inner surface wall 51 since stress generated by the vertical movement of the needle 16 is concentrated in this area. On the other hand, these height differences are necessary to maintain space at the inside of the back panel wall 250 for accommodating the stitch forming mechanism including the top mechanism 3 and the lower mechanism 4 .
Couplings
As shown in FIGS. 4 and 5, a plurality of couplings 90 , 92 , 94 , and 96 are provided in the back panel wall 250 of the main frame 1 A for joining the main frame 1 A to the frame cover 1 B. The coupling 90 is formed near the inner surface wall 51 in the area adjacent to the joint of the bed 8 and the cantilever support 7 . More specially, the coupling 90 is placed in the vicinity of the inside wall reinforcing rib 70 and the reinforcing member 60 . The above arrangement of the coupling 90 is aimed at preventing distortion of the arm 6 and the cantilever support 7 which causes swings of the top portion of the cantilever support 7 during the reciprocating motion of the needle 16 . The coupling 92 is formed near the inner surface wall 51 at the joint area of the arm 6 and the cantilever support 7 . More particularly, the coupling 92 is placed in the vicinity of the inside wall reinforcing rib 70 and the reinforcing member 60 . The coupling 94 is formed near the inner surface wall 51 in the vicinity of the end of the inside wall reinforcing rib 70 near the arm 6 . The couplings 92 , 94 are placed on the circumference of the semicircle of the space 9 at constant intervals with respect to the coupling 90 . A plurality of couplings 96 are formed on the sides and the corners of the inside of the back panel wall 250 in order to couple the main frame 1 A and the frame cover 1 B by a uniform pressure.
Screw holes 91 , 93 , 95 , and 97 are formed inside the couplings 90 , 92 , 94 , and 96 . The main frame 1 A and frame cover 1 B can be detachably joined together by inserting screws (not shown) in the screw holes 91 , 93 , 95 , and 97 when the couplings 90 , 92 , 94 , and 96 are aligned with couplings 190 , 192 , 194 , and 196 (see FIG. 11) provided in corresponding positions on the frame cover 1 B. Accordingly, the sewing machine is easily assembled by mounting the stitch forming mechanism to the main frame 1 A, and then screwing the frame cover 1 B to the main frame 1 A, thereby enabling cost reductions. In the case of maintenance, only undoing the screws leads to remove of the frame cover 1 B from the main frame 1 A, so that all the stitch forming mechanism is exposed. Therefore, the maintenance work is facilitated. In the present embodiment, screws are used to join the main frame 1 A to the frame cover 1 B, but bolts and nuts may also be used in place of the screws.
When stress induced by the reciprocating motion of the needle 16 forces the inner surface wall 51 of the main frame 1 A and an inner surface wall 161 of the frame cover 1 B to relatively move in a vertical or horizontal directions, relative movement of the main frame 1 A and the frame cover 1 B is restricted because a plurality of couplings 190 , 192 , and 194 (see FIG. 11) are arranged around the inner surface walls 51 , 161 . Therefore, the inner surface wall 51 of the main frame 1 A remains contact with the inner surface wall 161 of the frame cover 1 B. A appropriate coupling between the main frame 1 A and the frame cover 1 B is maintained. Stress is transmitted from the main frame 1 A including the stitch forming mechanism which generates vibrations to the frame cover 1 B through the inner surface walls 51 , 161 which are contact to each other, thereby dispersing over the whole frame 1 . The stress dispersion ensures the sufficient rigidity of the frame 1 . As a result, a sewing machine including the frame 1 can prevent vertical vibrations and horizontal swings of the frame 1 induced by the reciprocating motion of the needle 16 , thereby performing a smooth stitch forming action.
In another embodiment, two or more than four couplings may be formed around the inner surface wall 51 of the main frame 1 A.
Protrusions
As shown in FIG. 4, protrusions 100 , 101 , 102 , and 103 are formed on the main frame 1 A at the dividing plane 52 . These protrusions 100 , 101 , 102 , and 103 engage with engaging units 111 , 112 , 113 , and 114 provided on the frame cover 1 B at the dividing plane 52 (see FIG. 11) when the main frame 1 A is joined with the frame cover 1 B. The protrusions 100 , 101 , 102 , and 103 are aimed at limiting the relative movement of the main frame 1 A and frame cover 1 B in the horizontal direction.
Next, the reason that the sewing machine frame of the present invention is configured in this way will be described. As mentioned earlier, a swing effect occurs in the horizontal direction in the top portion of the cantilever support 7 due to the vertical movement of the needle 16 . When this happens, the main frame 1 A and frame cover 1 B can move relative to one another in the horizontal direction, shifting their relative positions. When this positional shifting occurs, a reliable joined state cannot be maintained, resulting in insufficient rigidity, thereby promoting vibrations and displacement in the frame 1 . Moreover, the main frame 1 A and frame cover 1 B are joined by screws through considerable pressure, causing a large frictional coefficient. As a result, when the relative position of the main frame 1 A and frame cover 1 B shifts, they do not easily return to their original positions. The above construction is employed because it is necessary to prevent such shifting in the relative position of the main frame 1 A and frame cover 1 B from occurring. With this construction, it is possible to maintain sufficient rigidity in the frame 1 .
As shown in FIG. 9 (A), the protrusion 100 protrudes from the bottom of the arm 6 at the dividing plane 52 substantially perpendicular to the frame cover 1 B and near the border between the horizontal portion on which the mechanism for reciprocally driving the needle 16 is supported and the semicircular portion by which the space 9 is formed. An opening 143 is formed in the front end of the arm 6 from which the reciprocally driving mechanism protrudes downward. The protrusion 100 is positioned on one side of the opening 143 . The protrusion 100 fits in the engaging unit 111 provided on the arm 6 of the frame cover 1 B (see FIG. 11 ). This configuration prevents relative movement of the main frame 1 A and frame cover 1 B generated by vibrations and displacement at the dividing plane 52 of arm 6 .
As shown in FIG. 9 (B), the protrusions 101 and 102 protrude from the top of the bed 8 at the dividing plane 52 , that is, at both ends of an opening 149 approximately perpendicular to the frame cover 1 B. The opening 149 is aimed for exposing rotary hook 23 . The protrusions 101 , 102 are fitted into engaging units 112 , 113 provided in the bed 8 of the frame cover 1 B (see FIG. 11 ). The above arrangement can prevent relative movement of both the main frame 1 A and the frame cover 1 B caused by vibrations and displacement at the dividing plane 52 of the bed 8 in the main frame 1 A and the frame cover 1 B.
Referring to FIGS. 8 (B), 8 (C), the protrusion 103 protrudes to the frame cover 1 B being coupled at a predetermined point on the dividing plane 52 around the space 9 . The predetermined point is placed on the intermediate rib 72 constituting the inside wall reinforcing rib 70 in the vicinity of a cross point with the inner surface wall 51 around the space 9 . The protrusion 103 fits a channel-shaped engaging unit 114 (see FIG. 11) provided the periphery of the frame cover 1 B facing the space 9 . The above structure prevents vibrations and displacement at the dividing plane 52 around space 9 , thereby restricting relative movement of the coupled main frame 1 A and frame cover 1 B.
Referring to FIG. 9 (A), an engaging unit 110 for receiving the protrusion 104 (see FIG. 11) protruding from the dividing plane 52 below the arm 6 of the frame cover 1 B. The place of the engaging unit 110 is on the dividing plane 52 below the arm 6 of the main frame 1 A. The above arrangement prevents vibrations and displacement at the dividing plane 52 of the arm 6 of the coupled main frame 1 A and frame cover 1 B, thereby restricting relative movement of the main frame 1 A and frame cover 1 B.
Top Edge
As shown in FIGS. 4 and 7 (A), a top edge 120 is formed across the top of the main frame 1 A for contacting the frame cover 1 B. A raised step 121 is formed across nearly the entire top edge 120 , the bottom of raised step 121 protruding toward the frame cover 1 B. The protruding portion of the raised step 121 fits into a recessed step 126 formed in a top edge 125 of the frame cover 1 B for contacting the main frame 1 A (see FIG. 11 ). By engaging the raised step 121 with the recessed step 126 from above, this construction can limit the relative movement of the main frame 1 A in the upward direction.
Next, the reason that the sewing machine frame of the present invention is configured in this way will be described. As mentioned earlier, the portion of the main frame 1 A near the arm 6 vibrates in the vertical direction due to the vertical movement of the needle 16 . In particular, the main frame 1 A on which the top mechanism 3 is mounted for supporting the needle 16 tends to move in the upward direction. When this happens, the main frame 1 A and frame cover 1 B can move relative to one another in the vertical direction, shifting their relative positions. When this positional shifting occurs, a reliable joined state cannot be maintained, resulting in insufficient rigidity, thereby promoting vibrations and displacement in the frame 1 . Moreover, the main frame 1 A and frame cover 1 B are joined by screws through considerable pressure, causing a large frictional coefficient. As a result, when the relative position of the main frame 1 A and frame cover 1 B shifts, they do not easily return to their original positions. The above construction is employed because it is necessary to prevent such shifting in the relative position of the main frame 1 A and frame cover 1 B from occurring. With this construction, it is possible to maintain sufficient rigidity in the frame 1 .
While the raised step 121 in the present embodiment is formed across nearly the entire length of the top edge 120 of the main frame 1 A that contacts the frame cover 1 B, it is not necessary for the raised step 121 to span the entire length of the top edge 120 . In view of the reason described above for forming the raised step 121 , however, it is desirable that the raised step 121 be formed on the top edge 120 at least at portions of the main frame 1 A corresponding to the arm 6 . Similarly, the recessed step 126 (see FIG. 11) should be formed on the top edge 125 at least on portions of the frame cover 1 B that correspond to the arm 6 . With this construction, it is possible to achieve sufficient rigidity for the arm 6 .
A bottom edge 130 is formed across the bottom of the main frame 1 A for contacting the frame cover 1 B. A raised step 131 is formed across nearly the entire length of the bottom edge 130 , the top of the raised step 131 protruding toward the frame cover 1 B. As shown in FIG. 7 (B), the raised step 131 comprises an insertion part 132 for inserting into a recessed step 136 (see FIG. 11) formed on a bottom edge 135 of the frame cover 1 B for contacting the main frame 1 A; a sliding surface 133 for guiding the raised step 131 into the recessed step 136 ; and an engaging wall 134 for engaging in the recessed step 136 after the recessed step 136 has been slid to a prescribed position. By inserting the insertion part 132 in the recessed step 136 of the frame cover 1 B and engaging the sliding surface 133 with the bottom of the recessed step 136 , it is possible to limit relative movement of the main frame 1 A in the downward direction.
Next, the reason that the sewing machine frame of the present invention is configured in this way will be described. As mentioned earlier, the portion of the main frame 1 A tends to move upward due to the vertical movement of the needle 16 . When this happens, the bed 8 of the frame cover 1 B engaged with the main frame 1 A attempts to move downward relative to the main frame 1 A. As a result, the frame cover 1 B shifts vertically from the main frame 1 A, promoting the generation of vibrations and displacement in the frame 1 . Hence, it is necessary to prevent such shifting in the relative position of the main frame 1 A and frame cover 1 B from occurring. With this construction, it is possible to maintain sufficient rigidity in the frame 1 .
While the raised step 131 in the present embodiment is formed across nearly the entire length of the bottom edge 130 of the main frame 1 A that contacts the frame cover 1 B, it is not necessary for the raised step 131 to span the entire length of the bottom edge 130 . In view of the reason described above for forming the raised step 131 , however, it is desirable that the raised step 131 be formed on the bottom edge 130 at least at portions of the main frame 1 A corresponding to the bed 8 . Similarly, the recessed step 136 (see FIG. 11) should be formed on the bottom edge 135 at least on portions of the frame cover 1 B that correspond to the bed 8 . With this construction, it is possible to achieve sufficient rigidity for the bed 8 .
Here, the sliding surface 133 of the raised step 131 is retracted further internally than the back panel wall 250 of the main frame 1 A. When the recessed step 136 of the frame cover 1 B overlaps this portion, the sidewall of the main frame 1 A and frame cover 1 B become the same height. Accordingly, by engaging the main frame 1 A with the frame cover 1 B, the sidewall of the main frame 1 A and frame cover 1 B forms a continuous surface at this point, improving the appearance of the frame 1 .
While a detailed construction of the raised step 121 described above is not shown in the drawings, this construction is similar to the raised step 131 of the bottom edge 130 shown in FIG. 7 (B). However, the raised step 121 is vertically symmetrical to the raised step 131 .
Flame Cover
Next, the frame cover 1 B of the frame 1 will be described with reference to FIGS. 10 through 15. FIG. 10 is a perspective view showing the external appearance of the frame cover 1 B FIG. 11 is a perspective view showing the internal construction of the frame cover 1 B. FIG. 12 is a plan view showing the internal construction of the frame cover 1 B. FIG. 13 is a cross-sectional view along the plane of the frame cover 1 B indicated by the arrows I in FIG. 12 . FIG. 14 (A) is a cross-sectional view along the plane of the frame cover 1 B indicated by the arrows J in FIG. 12 . FIG. 14 (B) is an enlarged view showing the lower end of the frame cover 1 B. FIG. 15 (A) is an enlarged plan view along the plane of the frame cover 1 B indicated by the arrows K in FIG. 12 . FIG. 15 (B) is an enlarged plan view along the plane of the frame cover 1 B indicated by the arrows L in FIG. 12 .
As shown in FIG. 10, the frame cover 1 B Comprises the arm 6 , cantilever support 7 , and bed 8 , and is integrally formed of a synthetic resin with the arm 6 , cantilever support 7 , and bed 8 . The semicircular area surrounded by the arm 6 , cantilever support 7 , and bed 8 is the space 9 .
In addition, the frame cover 1 B comprises a front panel wall 252 constituting a front side of the sewing machine, and a side wall 253 extending from a peripheral edge 252 a of the front panel wall 252 . Especially, the surface of the frame cover 1 B facing the space 9 is designated as an inner surface wall 161 . A side portion of the arm 6 is provided with a thread cassette mount 203 in which a thread cassette including different kinds of thread.
Inside Wall Reinforcing Rib
As shown in FIGS. 11 and 12, an inside wall reinforcing rib 170 for reinforcing the inner surface wall 161 of the frame cover 1 B facing the space 9 is provided on the inside of the front panel wall 252 around the periphery of the space 9 . A lot of inside wall reinforcing ribs 170 are provided around the periphery of the space 9 from the joint of the arm 6 and the cantilever support 7 to the joint of the cantilever support 7 and the bed 8 in order to surround the inner surface wall 161 .
The inside wall reinforcing rib 170 comprises a partitioning rib 171 spaced from the inner surface 161 and a plurality of intermediate ribs 172 intersecting with the inner surface 161 and partitioning rib 171 . The partitioning rib 171 extends from the inside of the front panel wall 252 and parallel to the inner surface wall 161 in a continuous manner. The intermediate rib 172 extends from the inside of the front panel wall 252 between the inner surface wall 161 and the partitioning rib 171 at a constant intervals perpendicularly to the front panel wall 252 . The intermediate rib 172 connects the inner surface wall 161 to the partitioning rib 171 , and connects the inner surface wall 161 and the partitioning rib 171 to the front panel wall 252 The above arrangement of the inner surface wall 161 , the partitioning rib 171 , and the intermediate ribs 172 provides a plurality of cells 173 in the space between the inner surface 161 and partitioning rib 171 . The intermediate ribs 172 are arranged radially from a center point located in the space 9 , because the inner surface wall 161 surrounding the space 9 has a semicircle shape. Accordingly, each intermediate rib 172 intersects the inner surface 161 and partitioning rib 171 at a perpendicular angle. Thus, the arrangement of the ribs is optimized, thereby reinforcing the inner surface wall 161 advantageously.
The above structure of the inside wall reinforcing ribs 170 provides the rigidity equal to that of the inner surface wall 161 having a considerable thickness. In other words, the above structure of the inside wall reinforcing ribs 170 ensures the rigidity over the front panel wall 252 from the area adjacent to the joint of the arm 6 and the cantilever support 7 , through the cantilever support 7 , to the area adjacent to the joint of the cantilever support 7 and the bed 8 . A sewing machine having the frame cover 1 B can prevent horizontal vibrations and swings of the frame cover 1 B caused by the reciprocating motion of the needle 16 , thereby performing a smooth stitch forming action.
In the above embodiment, the inside wall reinforcing ribs 170 are provided on the front panel wall 252 from the joint of the arm 6 and the cantilever support 7 through the cantilever support 7 to the joint of the cantilever support 7 and the bed 8 . In another embodiment, the inside wall reinforcing rib 170 may be formed over the whole of the inner surface wall 161 . In the above embodiment, a lot of intermediate ribs 172 are provided. However, in another embodiment, the number of the intermediate ribs 172 may be only one or a few. Each of the intermediate ribs 172 may be coupled or crossed to each other, so that the resultant arrangement of the intermediate ribs 172 may have a honeycomb or diagram shape.
In order to further support the partitioning rib 171 of the inside wall reinforcing ribs 170 , a supplemental concave wall reinforcing rib 177 is provided outside of the inside wall reinforcing ribs 170 . The supplemental concave wall reinforcing rib 177 comprises an auxiliary partitioning rib 174 and a plurality of auxiliary intermediate ribs 175 . The auxiliary partitioning rib 174 is provided in a continuous manner along the partitioning rib 171 , while being spaced from the partitioning rib 171 . The auxiliary intermediate ribs 175 intersect the partitioning rib 171 and partitioning rib 174 at predetermined intervals, and form a plurality of cells or compartments 176 between the partitioning rib 171 and partitioning rib 174 . This construction attains further rigidity of the inner surface 161 of the space 9 . In another embodiment, supplemental concave wall reinforcing ribs may be provided outside of the inside wall reinforcing rib 70 of the main frame 1 A, if the main frame 1 A has sufficient spare space.
Outside Wall Reinforcing Rib
As shown in FIGS. 11 and 12, outside wall reinforcing ribs 180 are formed in a matrix shape over nearly the entire inside of the front panel wall 252 . The outside wall reinforcing rib 180 projects from the inside of the front panel wall 252 . The outside wall reinforcing rib 180 is formed of vertical ribs 181 vertically oriented when the sewing machine is placed on a working surface, and horizontal ribs 182 oriented horizontally when the sewing machine is in the same position. As shown in FIGS. 13 and 14 (A), these vertical ribs 181 and horizontal ribs 182 are approximately perpendicular to the front panel wall 252 . The ends of the vertical ribs 181 and horizontal ribs 182 are joined with the side wall 253 on the side portions of the frame cover 1 B. The upper ends of the vertical ribs 181 are not coupled to the side wall 253 . This is because the upper portion of the frame cover 1 B needs sufficient space to accommodate thread cassettes and an LED display substrate. The spaces surrounded by pairs of intersecting vertical ribs 181 , 181 and horizontal ribs 182 , 182 form approximately square or rectangular shaped cells 183 . Hence, a plurality of cells 183 are formed on the back side of the front panel wall 252 .
Among the cells 183 , the outside wall reinforcing rib 180 defining a cell 183 having a wider area is formed to have a higher height from the front panel wall 252 , compared to a cell 183 having a narrower area. The outside wall reinforcing rib 180 on the accommodating part for the stitch forming mechanism in the arm 6 or the bed 8 has a lower height from the front panel wall 252 than those of the outside wall reinforcing ribs 180 on the inside of the front panel wall 252 other than the accommodating part. The cells 183 in the vicinity of the accommodating part for the stitch forming mechanism have narrower areas than those of the cells 183 provided on the area other than the accommodating part. The reason the above arrangement has been adopted is the same as that of the main frame 1 A, so that detailed explanation will be omitted.
The above arrangement of the outside wall reinforcing rib 180 ensures the sufficient rigidity of the front panel wall 252 , thereby minimizing or restricting distortion appearing on the front panel wall 252 of the arm 6 due to the reciprocating motion of the needle 16 . The above arrangement of the outside wall reinforcing rib 180 also minimizes distortion appearing on the front panel wall 252 of the cantilever support 7 and the bed 8 due to the distortion of the arm 6 . In this embodiment, the outside wall reinforcing ribs 180 extend in vertical and horizontal directions on the front panel wall 252 to define the cells 183 . This arrangement results in the sufficient rigidity of the front panel wall 252 in the case where the outside wall reinforcing rib 180 is not allowed to have a higher height in order that the frame cover 1 B accommodates the stitch forming mechanism. Accordingly, a sewing machine having the above frame cover 1 B can prevent vertical and horizontal vibrations of the frame cover 1 B caused by the reciprocating motion of the needle 16 , thereby performing a smooth stitch forming action.
It should be noted that the inside wall reinforcing rib 170 has a higher height from the front panel wall 252 than that of the outside wall reinforcing rib 180 . More specifically, as shown in FIG. 14 (A), at the base end of the arm 6 , the inside wall reinforcing rib 170 is formed at a height from the front panel wall 252 reaching the dividing plane 52 . In contrast, the vertical ribs 181 reach approximately halfway to the dividing plane 52 from the front panel wall 252 . The reason is as follows: the inner surface wall 161 needs sufficient rigidity, because stress induced by the reciprocating motion of the needle 16 generally tends to concentrate on the inner surface wall 161 .
In another embodiment, the outside wall reinforcing rib 180 may be provided on the only part of the frame cover 1 B. Alternatively, the frame cover 1 B may have no outside wall reinforcing rib 180 . The frame cover 1 B does not need so high rigidity as that of the main frame 1 A.
Couplings
As shown in FIGS. 11 and 12, a plurality of couplings 190 , 192 , 194 , and 196 are provided in the front panel wall 252 of the main frame 1 A for joining the main frame 1 A to the frame cover 1 B. The coupling 190 , 192 , 194 , and 196 are placed at positions corresponding to the positions of the couplings 90 , 92 , 94 , and 94 of the main frame 1 A. The coupling 190 is formed near the inner, surface wall 161 in the area adjacent to the joint of the bed 8 and the cantilever support 7 . More specially, the coupling 190 is placed in the vicinity of the inside wall reinforcing rib 170 formed outside of the inner surface wall 161 . The above arrangement of the coupling 190 is aimed at preventing distortion of the arm 6 and the cantilever support 7 which causes swings of the top portion of the cantilever support 7 during the reciprocating motion of the needle 16 . The coupling 192 is formed near the inner surface wall 161 at the joint area of the arm 6 and the cantilever support 7 . More particularly, the coupling 192 is placed in the vicinity of the inside wall reinforcing rib 170 outside of the inner surface wall 161 . The coupling 194 is formed near the inner surface wall 161 in the vicinity of the end of the inside wall reinforcing rib 170 near the arm 6 . The couplings 192 , 194 are placed on the circumference of the semicircle of the space 9 at constant intervals with respect to the coupling 190 . A plurality of couplings 196 are formed on the sides and the corners of the inside of the back panel wall 250 in order to couple the main frame 1 A and the frame cover 1 B by a uniform pressure.
Screw holes 191 , 193 , 195 , and 197 are formed inside the couplings 190 , 192 , 194 , and 196 . The main frame 1 A and frame cover 1 B can be detachably joined together by inserting screws (not shown) in the screw holes 191 , 193 , 195 , and 197 when the couplings 190 , 192 , 194 , and 196 are aligned with couplings 90 , 92 , 94 , and 96 provided in corresponding positions on the main frame 1 A.
Engaging Unit
As shown in FIG. 11, engaging units 111 , 112 , 113 , and 114 are formed in the frame cover 1 B at the dividing plane 52 . These engaging units 111 , 112 , 113 , and 114 engage with protrusions 100 , 101 , 102 , and 103 provided on the main frame 1 A at the dividing plane 52 (see FIG. 4) when the main frame 1 A is joined with the frame cover 1 B and function to limit the relative movement of the main frame 1 A and frame cover 1 B in the horizontal direction.
As shown in FIG. 15 (A), the engaging unit 111 is recessed in the bottom of the arm 6 on the frame cover 1 B at the dividing plane 52 and on one side of an opening 200 through which the mechanism for reciprocally driving the needle 16 protrudes downward. The engaging unit 111 engages with the protrusion 100 (see FIG. 4) formed on the arm 6 of the main frame 1 A. This construction limits relative movement of the main frame 1 A and frame cover 1 B generated by vibrations and displacement at the dividing plane 52 of the arm 6 .
As shown in FIG. 15 (B), the engaging units 112 and 113 are recessed in the top of the bed 8 at the dividing plane 52 and on both sides of an opening 202 for exposing the rotary hook 23 . The engaging units 112 and 113 engage with the protrusions 101 and 102 formed on the bed 8 of the main frame 1 A (see FIG. 4 ). This construction restricts relative movement of the main frame 1 A and frame cover 1 B caused by vibrations and displacement at the dividing plane 52 of the bed 8 .
As shown in FIG. 11, the engaging unit 114 is formed in a continuous channel on the inner surface 161 of the space 9 . The protrusions 103 provided on the main frame 1 A (see FIG. 4) engage with this channel portion. This construction restricts relative movement of the main frame 1 A and frame cover 1 B caused by vibrations and displacement at the dividing plane 52 of the space 9 .
Protrusion
As shown in FIG. 15 (A), the protrusion 104 is formed on the bottom of the arm 6 of the frame cover 1 B at the dividing plane 52 and on the opposite side of the opening 200 on which the engaging unit 111 is formed. The protrusion 104 protrudes substantially perpendicularly to the frame cover 1 B. The protrusion 104 fits in the engaging unit 110 provided on the arm 6 of the main frame 1 A (see FIG. 4 ). This construction restricts relative movement of the main frame 1 A and frame cover 1 B caused by vibrations and displacement at the dividing plane 52 of the arm 6 .
Recessed Top Edge
As shown in FIG. 14 (A), the recessed step 126 is formed across nearly the entire top edge 125 on the frame cover 1 B that contacts the main frame 1 A for accommodating the raised step 121 formed on the top edge 120 of the main frame 1 A and engaging the raised step 121 from the top. As shown in FIG. 14 (B), the recessed step 126 comprises an engaging wall 127 protruding toward the main frame 1 A for engaging the raised step 121 of the main frame 1 A when the raised step 121 is guided to a prescribed position; a sliding surface 128 for guiding the raised step 121 ; and an accommodating portion 129 for accommodating the insertion part of the raised step 121 . By accommodating the insertion part of the raised step 121 in the accommodating portion 129 and when the sliding surface of the raised step 121 engages with the sliding surface 128 from above, it is possible to limit relative movement of the main frame 1 A in the upward direction.
The recessed step 136 is formed across nearly the entire bottom edge 135 of the frame cover 1 B that contacts the main frame 1 A for accommodating the raised step 131 formed on the bottom edge 130 of the main frame 1 A and engaging the raised step 131 from below. While a detailed construction of the recessed step 136 is not shown in the drawings, this construction is basically the same as the recessed step 126 of the top edge 125 shown in FIG. 14 (B). However, the recessed step 136 Is vertically symmetrical to the recessed step 126 . By engaging the raised step 131 with the recessed step 136 , it is possible to limit the relative movement of the main frame 1 A in the downward direction.
It is understood that the foregoing description and accompanying drawings set forth the preferred embodiments of the invention at the present time. Various modifications, additions and alternative designs will, of course, become apparent to those skilled in the art in light of the foregoing teachings without departing from the spirit and scope of the disclosed invention. Thus, it should be appreciated that the invention is not limited to the disclosed embodiments but may be practiced within the full scope of the appended claims. | a sewing machine frame for a sewing machine including an integral frame member, and reinforcing ribs. The integral frame member is made from a synthetic resin and provides an outer surface defining an external shape and an inner surface providing an internal space. The integral frame member includes a bed portion, a tower portion upstanding from the bed portion, and an arm portion extending from the tower portion in a cantilevered fashion. The reinforcing ribs are provided at substantially entire area of the inner surface for reinforcing the integral frame member. | 3 |
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR 1.71(d).
The following includes information that may be useful in understanding the present invention(s). It is not an admission that any of the information provided herein is prior art, or material, to the presently described or claimed inventions, or that any publication or document that is specifically or implicitly referenced is prior art.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of handgrips and more specifically relates to removably-secured cushioning handgrip sleeves for crochet hooks.
2. Description of the Related Art
Many individuals in modern society use crochet hooks when completing handicraft projects. As designs and patterns of projects vary, so do the sizes of crochet hooks required to complete these projects. Crochet hooks of every size play vital roles in completing these projects. Easy manipulation of these implements helps to maintain a person's efficiency and good humor when completing a project. As many of these projects take copious amounts of time to complete, the frequent use of crochet hooks may cause individuals to suffer uncomfortable or even painful results: fatigue; hand and finger cramping; and painful blisters and/or calluses. Of specific concern are individuals suffering from debilitating conditions such as arthritis, psoriasis, and the like. Such individuals often struggle to complete crochet and other handicraft projects, as holding and manipulating crochet hooks for even short lengths of time is too painful.
Various attempts have been made to solve the above-mentioned problems such as those found in U.S. Pat. Nos. 2,608,077; 1,518,961; 1,502,584; 7,874,182; 2008/0272104; and U.S. Pat. No. 1,409,580. This prior art is representative of handgrips. None of the above inventions and patents, taken either singly or in combination, is seen to describe the invention as claimed.
Ideally, a removably-secured cushioning handgrip sleeve for crochet hooks should be lightweight, resilient, and user friendly and, yet, would operate reliably and be manufactured at a modest expense. Thus, a need exists for a reliable handgrip system to provide secure resilient cushioning and gripping support for a crochet hook to facilitate its manipulation and to avoid the above-mentioned problems.
BRIEF SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known handgrip art, the present invention provides a novel handgrip sleeve for use with a crochet hook system. The general purpose of the present invention, which will be described subsequently in greater detail, is to provide secure resilient cushioning and gripping support for a crochet hook to facilitate its manipulation.
A handgrip sleeve for use with a crochet hook system is disclosed herein preferably comprising: a handgrip body having a first end, a second end, an outer surface, an inner surface, and an inner cavity. In preferred embodiments, the handgrip body comprises a prismatic configuration with a circular cross-section. This essentially cylindrical handgrip body comprises an inner cavity that extends lengthwise through the handgrip body. The inner cavity of the handgrip body acts as a void, this void being defined by the inner surface of the handgrip body. In preferred embodiments, a crochet hook is friction-fit within the inner cavity of the handgrip body allowing a user to more securely and comfortably manipulate the crochet hook over a duration of use.
Ideally, the inner cavity of the handgrip body extends throughout essentially the center of the handgrip body from the first end to the second end. The inner cavity thereby creates an entrance orifice in the first end and an exit aperture at the second end of the handgrip body that preferably engage a crochet hook so as to allow the functional end of the crochet hook to protrude from the handgrip body at a sufficient distance to allow the functional use thereof. Additionally, the handgrip body may comprise a slit extending lengthwise along the entire handgrip body, penetrating the handgrip body laterally from the outer surface to the inner surface, thereby effectively creating a channel capable of acting as both an access point and an enclosure for the crochet hook within the handgrip body. The handgrip body may additionally comprise an end cap that covers the second end of the handgrip body. Such an end cap acts as a barrier to prevent the protrusion of the crochet hook from the exit aperture, effectively retaining the shank of the crochet hook within the confines of the inner cavity.
For cushioning and gripping purposes, the handgrip body preferably comprises an elastomer such as a shape-memory polymer or the like. The shape-memory polymer is capable of being deformed according to a user's hand by the pressure exerted by a user, and therefore effectively produces a perfectly shaped handgrip body to most comfortably and securely fit a user. In preferred embodiments, the handgrip body may be sufficiently deformable to accommodate crochet hooks of various sizes within one handgrip body, making the handgrip body a versatile gripping apparatus.
Additionally, the handgrip body may comprise pre-formed finger grips in which the outer surface of the handgrip body comprises concave finger indentations separated one from another by a convex spacer mound. In preferred embodiments, the outer surface of the handgrip body comprises a non-slip coating and one or more protrusions that act as additional gripping members. As each user necessitates varying comfort and support arrangements, a plurality of handgrip bodies may be arranged in series on one crochet hook, thereby altering the overall shape and performance of the handgrip sleeve for use with a crochet hook system.
A method of using a handgrip sleeve for use with a crochet hook system is also described herein preferably comprising the steps of: inserting a crochet hook into an entrance orifice of a handgrip body; pushing the crochet hook through the handgrip body, causing it to protrude from an exit aperture; and gripping the handgrip body, and thereby manipulating the crochet hook during the performance of at least one project. The method preferably further comprises the step of adding additional handgrip bodies as desired to create a personalized handgrip sleeve for use with a crochet hook.
The present invention holds significant improvements and serves as a handgrip system. For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. The features of the invention which are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures which accompany the written portion of this specification illustrate embodiments and method(s) of use for the present invention, Handgrip Sleeve for Use with a Crochet Hook, constructed and operative according to the teachings of the present invention.
FIG. 1 shows a perspective view illustrating a handgrip sleeve for use with a crochet hook according to an embodiment of the present invention.
FIGS. 2A-2B are perspective views illustrating the handgrip sleeve for use with a crochet hook with an inner cavity and a slit according to an embodiment of the present invention of FIG. 1 .
FIGS. 3A-3C are perspective views illustrating the handgrip sleeve for use with a crochet hook with protrusions according to an embodiment of the present invention of FIGS. 1-2B .
FIGS. 4A-4C are perspective views illustrating the handgrip sleeve for use with a crochet hook according to an embodiment of the present invention of FIGS. 1-3C .
FIG. 5 is a flowchart illustrating the handgrip sleeve for use with a crochet hook according to an embodiment of the present invention of FIGS. 1-4C .
The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements.
DETAILED DESCRIPTION
As discussed above, embodiments of the present invention relate to a handgrip device and more particularly to a handgrip sleeve for use with a crochet hook as used to improve the secure cushioning and gripping support for a crochet hook to facilitate its manipulation.
Referring now to the drawings by numerals of reference there is shown in FIG. 1 , a perspective view illustrating a handgrip sleeve for use with a crochet hook 100 according to an embodiment of the present invention.
Handgrip sleeve for use with a crochet hook 100 preferably comprises: handgrip body 200 preferably having first end 215 ; second end 220 ; outer surface 205 ; inner surface 210 ; and at least one inner cavity 225 . Ideally, handgrip sleeve for use with a crochet hook 100 may be modifiable in size and shape in order to meet the needs and/or preferences of a user. Length and/or thickness of each handgrip body 200 may be variable within the present embodiment, yet alternate embodiments may consist of handgrip bod(ies) 200 of standard lengths and/or thicknesses.
Within this particular embodiment, handgrip body 200 may comprise a prismatic configuration, thereby effectively maintaining a constant overall thickness throughout the length of handgrip body 200 . Alternatively, handgrip body 200 may be tapered, as shown in FIG. 4A , thereby effectively creating a non-prismatic configuration. Additionally, in this particular embodiment, handgrip body 200 may comprise a circular cross-section. Alternatively, handgrip body 200 may comprise a non-circular configuration such as triangular, rectangular, octagonal, or the like, as shown in FIG. 4B . Regardless of overall size and shape of handgrip body 200 , handgrip body 200 may preferably be adapted to hold a shank of a crochet hook within inner cavity 225 such that crochet hook may be removably secured and comfortably gripped and manipulated by a user during at least one duration of use.
FIGS. 2A-2B are perspective views illustrating handgrip sleeve for use with a crochet hook 100 with inner cavity 225 and slit 240 according to an embodiment of the present invention of FIG. 1 .
Inner surface 210 preferably defines inner cavity 225 which may act in a capacity of a void. Ideally, inner cavity 225 extends lengthwise within handgrip body 200 from first end 215 to second end 220 . In other embodiments, inner cavity 225 may extend only partially throughout the length of handgrip body 200 , extending only from either first end 215 or second end 220 but not simultaneously intersecting both first end 215 and second end 220 . Any intersection of inner cavity 225 with first end 215 effectively creates entrance orifice 230 .
Alternately, any intersection of inner cavity 225 with second end 220 effectively creates exit aperture 235 . Entrance orifice 230 and exit aperture 235 essentially act in the capacity of entrance and exit points, respectively, for a crochet needle engaging handgrip body 200 . A crochet hook may preferably be friction-fit within the confines of inner cavity 225 , abutting inner surface 210 of handgrip body 200 , such that the crochet hook may be inserted into entrance orifice 230 ; driven through inner cavity 225 ; and expelled from exit aperture 235 of handgrip body 200 for use. While handgrip body 200 of the present embodiment comprises one inner cavity 225 , handgrip body 200 of alternate embodiments may comprise a plurality of inner cavit(ies) 225 .
In the present embodiment, handgrip body 200 may preferably comprise slit 240 . Slit 240 may preferably extend: longitudinally along handgrip body 200 from first end 215 to second end 220 ; and laterally through handgrip body 200 from outer surface 205 to inner cavity 225 . Any intersection of slit 240 and inner cavity 225 may preferably define channel 245 , which ideally acts in a capacity of both an access point and an enclosure for a crochet hook engaging handgrip body 200 . In alternate embodiments, slit 240 may extend only partially along handgrip body 200 —extending laterally either from first end 215 or from second end 220 but not simultaneously intersecting both first end 215 and second end 220 .
Within the present embodiment, slit 240 is preferably narrower than a diameter of a crochet hook, thereby essentially preventing a crochet hook from being unintentionally removed from handgrip body 200 . Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other securing and fastening arrangements such as, for example, adhesive, cords, zippers, hook-and-loop fasteners, etc., may be sufficient. Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of securing and/or sealing crevices as described herein, methods of securing and/or sealing crevices will be understood by those knowledgeable in such art.
FIGS. 3A-3C are perspective views illustrating handgrip sleeve for use with a crochet hook 100 with protrusion(s) 300 according to an embodiment of the present invention of FIGS. 1-2B .
Ideally, an interior of handgrip body 200 may preferably be sufficiently deformable to accommodate a plurality of sizes of crochet hooks. Within the present embodiment, handgrip body 200 may accommodate a single crochet hook; however, in alternate embodiments, handgrip body 200 may accommodate multiple crochet hooks to accommodate the needs and/or preferences of a user. Handgrip body 200 may comprise a resilient foam; a soft resin; and, alternately, an elastomer such as silicone rubber utilizing injection molding to create a desired shape and size. Handgrip body 200 may comprise a shape-memory polymer capable of being deformed according to the shape of a user's hands and the pressure exerted thereby upon handgrip body 200 . Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other deformable material arrangements such as, for example, rubber, polystyrene beads, etc., may be sufficient. Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of molding and/or casting as described herein, methods of molding and/or casting handgrips will be understood by those knowledgeable in such art.
Handgrip body 200 may comprise pre-formed finger grip(s) 305 along outer surface 205 . Planar outer surface 205 may preferably be interrupted by at least one concave finger indentation 310 which may be separated from any additional finger indentation(s) 310 by at least one convex spacer mound 315 . Handgrip body 200 of the present embodiment preferably comprises a plurality of finger indentation(s) 310 and spacer mound(s) 315 in a series relationship, preferably occurring in an alternating pattern. Alternately, (and in some embodiments, additionally) handgrip body 200 may comprise at least one protrusion 300 along outer surface 205 . Protrusion 300 preferably acts in a capacity of a gripping member. Handgrip body 200 of preferred embodiments comprise a plurality of protrusion(s) 300 to increase the security of a user's grasp of handgrip sleeve for use with a crochet hook 100 and his or her manipulation thereof. Protrusion(s) 300 may take the form of ridges, raised bumps, and the like. Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of gripping member construction as described herein, methods of constructing gripping members will be understood by those knowledgeable in such art.
FIGS. 4A-4C are perspective views illustrating handgrip sleeve for use with a crochet hook 100 according to an embodiment of the present invention of FIGS. 1-3C .
In order to retain a crochet hook within handgrip body 200 , handgrip body 200 may comprise end cap 400 , as shown in FIG. 4A . End cap 400 may be releasably secured to first end 215 or second end 220 of handgrip body 200 and act in a capacity of a barrier to prevent a crochet hook from protruding from entrance orifice 230 or exit aperture 235 , respectively. While end cap 400 of the present embodiment may be releasably connected to handgrip body 200 , handgrip body 200 of alternate embodiments may comprise an integral end cap 400 created by the partial extension of inner cavity 225 (as opposed to its full extension) throughout handgrip body 200 . Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of securing and fastening as described herein, methods of releasably securing structural elements one to another will be understood by those knowledgeable in such art.
Both outer surface 205 and inner surface 210 may comprise a non-slip coating. A non-slip coating along inner surface 210 may act as an additional securing means for a crochet hook within handgrip body 200 , which may essentially prevent: undesired rotation of a crochet hook within inner cavity 225 ; and undesired removal of a crochet hook from within inner cavity 225 . A non-slip coating along outer surface 205 may act as an additional steadying and securing means for a crochet hook within a user's hand during use. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other gripping material arrangements such as, for example, surface projections, magnets, fasteners, etc., may be sufficient. Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of surface coating and/or texturing as described herein, methods of coating and/or texturing surfaces will be understood by those knowledgeable in such art.
As is shown in FIG. 4C , a plurality of handgrip bod(ies) 200 may preferably be arranged in series on one crochet hook. Each configuration and placement of individual handgrip bod(ies) 200 may alter an overall shape and performance of handgrip sleeve for use with crochet hook 100 . In this way, a user may manipulate the number and placement of handgrip bod(ies) 200 on a crochet hook in order to reach a desired configuration to effectively ensure optimal security and comfort when grasping and manipulating the crochet hook during use.
Handgrip sleeve for use with a crochet hook system 100 may be sold as kit 490 comprising the following parts: at least one handgrip body 200 ; at least one end cap 400 ; and at least one set of user instructions. Handgrip sleeve for use with a crochet hook 100 may be manufactured and provided for sale in a wide variety of sizes and shapes for a wide assortment of applications. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other kit contents or arrangements such as, for example, including more or less components, customized parts, different color combinations, parts may be sold separately, etc., may be sufficient.
FIG. 5 is flowchart 550 illustrating handgrip sleeve for use with a crochet hook 100 according to an embodiment of the present invention of FIGS. 1-4C .
A method of using (at least hereby enabling method of use 500 ) a handgrip sleeve for use with a crochet hook 100 preferably comprising the steps of: step one 501 inserting a crochet hook into entrance orifice 230 of handgrip body 200 ; step two 502 pushing the crochet hook through handgrip body 200 to protrude from exit aperture 235 ; and step three 503 gripping handgrip body 200 and thereby manipulating the crochet hook during a performance of at least one project. The method of use 500 preferably further comprises the step of: step four 504 adding additional handgrip bod(ies) 200 as desired to create a personalized handgrip sleeve for use with a crochet hook 100 .
It should be noted that step four 504 is an optional step and may not be implemented in all cases. Optional steps of method 500 are illustrated using dotted lines in FIG. 5 so as to distinguish them from the other steps of method 500 .
It should be noted that the steps described in the method of use can be carried out in many different orders according to user preference. The use of “step of” should not be interpreted as “step for”, in the claims herein and is not intended to invoke the provisions of 35 U.S.C. §112, ¶6. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods of use arrangements such as, for example, different orders within above-mentioned list, elimination or addition of certain steps, including or excluding certain maintenance steps, etc., may be sufficient.
The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. | An apparatus for removably securing resilient cushioning and gripping support to a crochet hook to facilitate its manipulation. Handgrip sleeve for use with a crochet hook is a lightweight, resilient gripping sleeve having an interior cavity for the accommodation of a crochet hook. Complete with gripping members and an elastomeric composition, handgrip sleeve for use with a crochet hook provides increased comfort and decreased fatigue for a user during the completion of a handicraft project. | 3 |
BACKGROUND OF THE INVENTION
The present invention is a universal retrofit valve actuator and system. The system is particularly adapted for use in steam heat regulating systems with a remote thermostat.
In existing steam heating systems it is difficult, dangerous and in many jurisdictions, illegal to repair or replace a valve while the system is operating. In large installations, whole heating systems have to be shut down, in order to make any repair that opens the system even for only one valve. Repairs cannot be tested when the system is not working. Thus, repair or installation requires at least two sessions and the expenses attendent thereto. The expense includes the cost of experienced technicians, plumbers for each session.
In large buildings, hotels, office buildings, and factories, valve repair or setting up temperature regulators is an onerous scheduling and project management problem fraught with delay. There may also be seasonal problems during a cold winter. Valves or pipes may break when worked with. The valves are difficult or impossible to duplicate and the piping is expensive and inconvenient to repair if damaged.
Most buildings with steam heating systems of the past have mixes of different valves. In the prior art, installing temperature regulators oftentimes required surveys in order to to accommodate the different parts needed in order to retrofit the valves or valve regulating systems in a heating system.
Prior art systems have been provided to be installed to actuate valves. Such systems have even been provided with thermostatic regulating means to control temperature. The systems have required specific matches to various valve configurations, and the thermostatic controls are usually at the valve, as distinguished from an appropriate place in a room. Remote thermostatic systems with capillary tubes actuating the valve are easily damaged and sluggish in operation.
There is an almost infinite set of problems to be faced in the universe of repair or regulating existing valves in a steam heat system. There are different size valves, valve stems and handle means. The prior art had to supply an infinitude of actuating systems to actuate the different size valves and regulate the temperature.
Some prior art heat regulating systems are easily broken or misaligned and depend upon mechanical position indication. The mechanical positioning of the valve settings in existing thermostatic heat systems of the prior art renders them prone to installation error and post installation misalignment. The delicate temperature sensors are close to the heat source.
In steam heat systems, valves work best with the valves either fully open, or fully closed. Incompletely closed or open valves may cause leakage of steam and/or formation and dripping of condensate. Incompletely closed or open valves are also a cause of the proverbial banging radiator. Leaking also can be a result of this problem.
In prior art steam heat systems, the valve stems usually have combinations of internal threads at their ends and/or round or square ends no receive various types of valve handles. Old valves may be bent, twisted or misaligned. The present invention provides a system for a single valve actuator to adapt to almost all valve stem states and sizes and be installable without skilled labor, independent of whether a heat system is operating or not.
DESCRIPTION OF THE RELATED ART
Annexed hereto is Form PTO-1449 and copies of the patents and prior art cited therein.
A typical prior art retrofit valve actuating temperature regulating system is the Honeywell ML984A VERSADRIVE™ Integrated Valve Actuator, a five page specification for which, Form #95C-10513 1988 05 PCY/GLS, from Honeywell, 740 Elsmere Road, Scarborough, Ontario M1P 2V9, Canada, describes a self contained, self adjusting linear motor linkage that mounts directly onto one half inch through three inch V5011 two way, or V5011 three way valves. The control is obtained from a motor with a step down transformer and has thermostatic control ambiently regulated from 32™F to 130™F.
A typical prior art regulating valve for a steam installation, according to Instruction Sheet 102-051, Form H92-051, effective Jan. 1, 1986, consisting of four pages, are the Heat-Gard™ Thermostatic Valves from Taco, Inc. of 1160 Cranston Street, Cranston, R.I. 02920. With regard to Heat-Gard theromstatic valves, operating models and valve models 5201-2, 5201-2, 5203-2, 5204-2 and valves 5221-1, 5222-1, 5223-1, 5227-1, 5228-1, 5229-1, 5231-1, 5232-1, 5233-1, 5234-1, 5237-1, 5239-1, 5241-1, 42-1, 5243-1, 5251-1, 5252-1, 5253-1, the Taco Heat-Gard™ valve is an inline replacement steam valve with a remote temperature sensor that actuates the valve by capillary action.
U.S. Pat. No. 2,997,437 discloses a motor actuated valve system for controlling vanes or dampers in heat systems, where the motor controls are driven by an arrangement about the motor driven shaft so that they are easily accessible for making necessary electrical connections.
U.S. Pat. No 3,703,763 discloses an axial motor driven spindle of an element upon rotation of the spindle guided by a sleeve for the connection with a positioning of valve elements in valve seats.
U.S. Pat. No 4,754,949 discloses a motor actuated valve system with a speed reduction mechanism incorporating internal gears. The motor actuator for the valve has no brake mechanism as the drive means includes a worm gear with external peripheral teeth meshed.
U.S. Pat. No 4,889,315 discloses a sensor and motor actuate system for the opening and closing of valves for discharge of water.
U.S. Pat. No 5,025,826 discloses a replacement handle system for a valve stem with a pair of jaws and camming surfaces and handle to engage the valve stem.
U.S. Pat. No 5,152,316 discloses a servo system for opening and closing valves responsive to various pressure situations.
U.S. Pat. No. 5,156,373 discloses a remotely controlled motor means with remote energization of a motor to rotate a valve stem.
It is respectfully requested that this citation of art be made of record with regard to the within application.
SUMMARY OF THE INVENTION
The present invention is a universal retrofit valve actuator and system for use in the remote actuation of valves. When the actuating valves are in a heating system, the actuation ordinarily is by way of a signal from a thermostat.
In a preferred embodiment, the retrofit actuator is engaged to a valve stem in a steam heat systems, actuated by a remote thermostat.
Actuation of the valves is totally electronic and self aligning at each on and off cycle. No expensive skilled labor is required to install.
The present invention can accommodate an arbitrary wide range of valve stem diameters and total travel distances, open to close, turns per inch, number of turns open to close, bonnet nut lengths and diameters and stems in bent and twisted or crooked condition. Insofar as understood, prior art retrofits only work on perfect, or nearly perfect stems.
No survey nor shutdown is required to retrofit the valve actuators of the present invention.
Valves may be actuated remotely with or without thermostatic initialization.
The remote valve actuating system of the present invention and the thermostatic actuation is able to heat at the full open or closed positions of the valve.
According to the present invention, a valve actuator is in a system for driving a valve stem to open or close a valve. An actuator is anchorable apposed to the valve stem. The actuator drives a rotatable drive gear. The drive gear has at least one cam having an extending length. The cam has two driving surfaces. There is a lug with at least one cam having a first and second driven surface. The lug is fixed to rotate the valve stem. The drive cam is engagable with the driven cam when the actuator is anchored. The driven cam is engagable along the drive cam's extending length. The drive cam and driven cam's first surfaces engage to rotate the lug in one direction, the drive cam and driven cam's second surfaces engage to rotate the lug in reverse. The respective surfaces of the drive cam and driven cam are spaced apart from each other, and when not engaged, have ample play to allow for eccentric rotation of the valve stem.
The actuator may have a bottom portion open to the valve stem. The periphery of the bottom portion may have at least one slotted opening, including a lock notch.
The actuator may be anchorable to the valve body or a bonnet nut on the valve. A centering cap may be anchorable to the bonnet nut with the actuator anchored to the centering cap. The centering cap may be anchored to the bonnet nut by more than one centering screw. The actuator may have anchoring screws.
The drive gear may be driven by an electric motor, having a gear train, including reduction gears and a warm gear. The drive gear may be cylindrical and have peripheral teeth and an internal drive cam extending longitudinally substantially the length of the cylinder. The drive gear may have at least one ball bearing race and ball bearings in the bearing race.
The drive gear may have a base and at least one drive cam extending from the base.
The lug may have a central opening for a screw to fix the lug to the valve stem, or a partial central opening, to engage the valve stem. There may be another opening to the central opening for a set screw. The central opening may be tapered.
The actuator may be in a system, driven by a DC electric motor to drive the drive gear. The motor has an on and off state and may operate forward or backward. The system includes integrated circuitry, to energize it. The integrated circuitry can sense temperature and measure motor current. The temperature sensing can be set, to set points of selected temperature readings and actuate a change of the motor's state, when the surrounding temperature reaches the selected temperature reading. The motor current measure also has a set point above a threshold of normal operating current, to sense a surge in the load, such as encountered when a valve stem reaches its limit of travel opening or closing. At such point, the system signals the motor to change to an off state and to also reverse the polarity of current to the motor. The polarity reversal is sequenced to change with the off state or to change before the next the on state.
The system may have a housing to hold the integrated circuitry and a display window. The display window can display time information and temperature information. There are control buttons to adjust both time in the circuitry and temperature settings. The integrated circuitry is interfaced with the display window, and the control buttons with the integrated circuitry, and means to interface the control buttons with the display window.
In a system to drive a DC electric motor, the motor has an on and off state and may operate forward or backward. The system includes integrated circuitry to energize it. The integrated circuitry can sense temperature and measure motor current. The temperature sensing can be set to set points of selected temperature readings and actuate a change of the motor's state when the surrounding temperature reaches the selected temperature reading. The motor current measure also has a set point above a threshold of normal operating current to sense a surge in the load such as such as an overload. At such point the system signals the motor to change to an off state and to also reverse the polarity of current to the motor. The polarity reversal is sequenced to change with the off state or to change before the next the on state.
Although such novel feature or features believed to be characteristic of the invention are pointed out in the claims, the invention and the manner in which it may be carried out, may be further understood by reference to the description following and the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front elevation of a steam radiator with a mounted valve actuator of the present invention and a remote thermostat control box.
FIG. 2 is a detail front elevation view of FIG. 1 showing the mounted valve actuator.
FIG. 3 is a top plan view of the valve actuator as shown in FIG. 2.
FIG. 4 is a longitudinal section view of FIG. 3 at lines 4--4.
FIG. 5 is a partial section view of the centering cap adapter for the valve bonnet nut substantially taken at lines 5--5 of FIG. 2.
FIG. 6 is a partial section view of FIG. 2 at lines 6--6 with 90° screws from the body of the valve actuator engaged.
FIG. 7 another view of FIG. 5, with the screws from the centering cap adaptor, rotated to disengagement with the lock notch in the slots in the body.
FIG. 8 is a top plan view of a driving lug of the valve adaptor of the present invention.
FIG. 9 is a section view of FIG. 8 at lines 9--9 showing the internal taper of the lug.
FIG. 10 is the section view of the lug of FIG. 9 on a valve stem held by a screw in the valve stem and by a set screw.
FIG. 11 partial section through the body of the valve actuator shows the lug engaged on the annular gear of the valve actuator held by a screw with a washer.
FIG. 12 is section of FIG. 11 showing the lug in driving engagement with the cam of the annular gear of the valve actuator.
FIG. 13 is a perspective broken away section of the annular gear.
FIG. 14 is a partial section of FIG. 3 showing the annular gear with its upper ball bearings.
FIG. 15 is a front elevation in section of an alternate embodiment of an annular gear for of the present invention.
FIG. 16 is a block diagram of the thermostat control box and driver of the valve actuator system.
FIG. 17 is a schematic of the switching interface of the thermostat control box setting buttons of FIG. 16.
FIG. 18 is a schematic of the temperature sensing circuitry of FIG. 16.
FIG. 19 is a schematic of the motor drive and current sensing circuitry of FIG. 16.
FIG. 20 is a schematic including the watch dog output circuitry of FIG. 16.
FIG. 21 is a schematic of the liquid crystal display interface circuitry of FIG. 16.
Referring now to the figures in greater detail, where like reference numbers denote like parts in the various figures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a steam heat radiator 4 is shown with a conventional steam valve 5 having a stem 6, and as can be seen in FIG. 4. The valve 5 has a bonnet nut 7 shown in FIGS. 5 and 7. A valve actuator 10 is mounted on a centering cap 12, mounted on the bonnet nut 7, as can be seen in FIGS. 2, and 4-7. The centering cap 12 is centered and held to the bonnet nut 7 by screws 13.
The thermostat control box 40 in FIG. 1 is connected at the snap fitting 35 of the valve actuator 10 by a cable 41. The cable 41 is also connected to the thermostat control box 40 at another snap fitting 42. A plug-in transformer 44 is connected to the thermostat control box 40 by a power cable 43 and a power connector 45. The thermostat control box 40 has a liquid crystal display 46 and a temperature increase button 47, temperature decrease button 48, an override button 49, time view button 50, hour set button 51 and a minute set button 52.
In FIG. 2, the body 11 of the valve actuator 10 includes openings 33 with lock notches 34. The openings 33 each receive screws 13, which then may be engaged in a lock notch 34, to be held against accidental displacement. Screws 14 through the body 11 engage the centering cap 12 to hold the body 11 of the valve actuator 10 in place, fixed to the centering cap 12.
As shown in FIGS. 4 and 10, the stem 6 has a lug 15 mounted on it, held by a screw 21 through an opening 17 in the lug 15, and/or optionally held by a set screw 19 through an opening 18 in the lug 15.
In FIGS. 8-10, the lug 15 includes cams 16, the opening 17 for the screw 21, the opening 18 for the set screw 19 and a tapered opening 20 to receive the stem 6.
In FIGS. 4 and 13, an annular gear 22 is engaged in the body 11 of the actuator 10. The annular gear 22 has gear teeth 23 in train with a worm drive 30, reduction gears 29 and a motor 28.
The annular gear 22 includes an upper ball bearing race 25 and a lower ball bearing race 26. There are cams 24 internal of the annular gear 22 which are longitudinal along its length. In FIGS. 4 and 14, there are ball bearings 27 in the upper ball bearing race 25 and lower ball bearing race 26.
In FIGS. 4, 11 and 12, the cams 16 of the lug 15 are engagable with the internal cams 24 of the annular gear 22, when the motor 28 is in train with reduction gears 29 and the worm drive 30 rotates the annular gear 22.
In FIGS. 3 and 4, there is a cover 31 on the body 11 for the annular gear 22 which is held in place by screws 32.
FIG. 15 shows an alternate annular gear 22a with gear teeth 23 and a cover 60, from which extends longitudinal cams 24a, engagable with the cams 16 of the lug 15.
The block diagram of the thermostatic controls and driver of the valve actuator system in FIG. 16, includes a switching interface, shown in FIG. 17, temperature sensing circuitry, shown in FIG. 18, the motor drive and current sensing circuitry, shown in FIG. 19, a watchdog circuit, shown in FIG. 20 and the liquid crystal display control circuitry shown in FIG. 21.
The thermostat control box 40, in FIG. 16, has a micro controller chip 70, a crystal oscillator 71, connected to two pins and a second crystal oscillator 72, as shown in greater detail in FIG. 20. The switches 73 for the thermostat control box 40 set buttons 47-49, 50-52, are shown in detail in FIG. 17, interfaced with the micro controller chip 70. The liquid crystal display 46 interface with the micro controller chip 70 is shown in detail in FIG. 21. The temperature sensing circuitry 74, of FIG. 16, is shown in detail in FIG. 18. The circuitry for driving the motor 28 and current sensing circuitry are shown in detail in FIG. 19.
The software in micro controller chip 70 includes debounce circuitry to protect against multiple pressing of the set buttons 47-49, 50-52. In FIG. 20, the crystal oscillator 71 times some of the micro controller chip's 70 functions and the crystal oscillator 72 is the master drive of the micro controller chip 70. The micro controller chip 70, is for instance, a TOSHIBA™ TMP47C446VF microcontroller mask program. The crystal oscillator 71 is, for example, a STANDARD™ 32.768 Khz and crystal oscillator 72 is, for example, a PANASONIC™ EFO-V4004E54Mhz ceramic resonator with a two capacitors 75 in parallel. The capacitors 75 are, for example, a PANASONIC™ ECU-V1H150JCN 15pf, 50v ceramic capacitor 0805 smd.
There is a watchdog output for the micro controller chip 70 from a grounded micro processor supervisor 76 which is, for example, a DALLAS™ 12332-10 chip.
The temperature sensing circuitry 74, in FIG. 18, is basically a constant current source, to get a voltage from the thermistor 77 and provides one stage of gain to amplify the voltage, before it goes into an analog to digital converter in micro controller chip 70. The thermistor 77 is an interchangable 100 k ohm thermistor. The input signal is fed back from the thermistor 77 through an amplifier 78 through another amplifier 79 and into the micro controller chip 70. Between the micro controller chip 70 and the amplifier 79 is a resistor and a zener diode 82 to ground. The amplifiers 78, 79, are for example, a NATIONAL™ LM324 quad chip. The zener diode 82 is, for example, a ZETEX™ 5.1 volt sot 23.
The motor drive and current sensing circuitry 74 are shown in FIG. 19. There is an H bridge driver 80 with two sets of transistors 81, connected in such a way, that they can bring either of the outputs from the motor 28 to positive or ground. In this way, the motor 28 can be reversed, or if both of its inputs are the same polarity, turned off. The transistors 81 are, for example, PHILLIPS™ NPN bipolar switches, 40 v. 150 ma sot 23. The H bridge driver 80 is, for example, a MOTOROLA™ MMDFC05E H-Bridge driver IC.
There is a night time override feature in the software of the micro controller chip 70 which forces the system to control the daytime setpoint instead of the lower night time set point.
Operation
The Actuator
The valve actuator 10 of the present invention is a universal retrofit that enables its installation on existing stems 6 of existing valves 5 of the prior art. When a valve 5 is in a steam heating system, no special preparation need be made for installation. The valve actuator 10 need only be installed and the valve actuator 10 connected to the thermostat control box 40.
Old standing valves 5 in old steam heating systems may be bent, or even twisted. The valve actuator 10 of the present invention works well on almost any valve 5, stem 6, no matter what its condition. The valve handle (not shown) must be generally removed for the valve actuator 10 to be installed. Without a valve handle, the stem 6, as shown in FIGS. 4 and 10 usually has a tapered square end to accommodate the valve handle. The stem 6 oftentimes has an opening for a screw to engage the valve handle.
The lug 15, as shown in FIGS. 4 and 8-12, is provided with a tapered opening 20 and an opening 17 for a screw 21. The tapered opening 20 accommodates the wide variety of diameters of the stems 6 to make the lug 15 a universal retrofit. The screw 21 preferably has an allen head. As shown in FIG. 11, the screw 21 is engaged with an interposed washer 36.
As can be seen in FIGS. 4 and 10, the lug 15 can be independently held to the stem 6, with the screw 21, or held independently or in conjunction with the set screw 19. The lug 15 is thus, also adapted to attach to a stem 6 that has a threaded end or non threaded end.
The annular gear 22, as shown in FIGS. 4 and 11-14, has inner cams 24 and outer gear teeth 23. The annular gear 22 is driven by the motor 28 in train with the reduction gears 29 and the worm drive 30.
The cams 24 are widely spaced apart beyond the width of the cams 16 of the lug 15 and extend inward beyond the length of the cams 16. The cams 16 are narrower than the spacing between the cams 24 and shorter than the distance to the inner wall of the annular gear 22. Thus the cams 16 are engagable with the cams 24 when the annular gear 22 is rotated. There a is large play between the cams 16 and the cams 24 enabling full engagement during rotation, even under eccentric rotation of the lug 15 engaged on a distorted stem 6 of a valve 5. The configuration of the lug 15 and the annular gear 22 enable the universality of the retrofit of the valve actuator 10 of the present invention.
The cam 24 of the annular gear 22 has a first driving surface 55 and a second driving surface 56. The cam 16 of the lug 15 has a first driven surface 57 and a second driven surface 58. The first surfaces 55 and 57 of the cam 24 and the lug 15 are engagable to rotate the lug 15 in one direction. The second surfaces 56 and 58 of the cam 24 and the lug 15 are engagable to rotate the lug 15 in a reverse direction. The width of the cam 16 is less than the spacing between the cams 24. The spacing difference provides a play that maintains a gear engagement even during eccentric rotation.
The cams 24, 24a must extend a substantial linear distance in the annular gears 22 and 22a. The lengths of the cams 24, 24a allow a parameter for a selection of stem lengths of prior art valves 5.
The diameter of the annular gears 22 and 22a must be sufficient to permit the eccentric rotation of a bent or twisted stem 6 of a valve 5 with a lug 15 mounted. The diameter must allow for a parameter of overlap of the cam 16 of the lug 15 and the cams 24, 24a so that there is engagement therebetween and yet play to account for the eccentric movement.
The lower ball bearing race 26 and upper ball bearing race 25 with the ball bearings 27 enable the annular gear 22 to rotate easily in the body 11 of the valve actuator 10 with little need for maintenance. The ball bearings 27 may even be of a plastic such as nylon, or could be a brass or plastic sleeve bearing.
The valve actuator 10, to properly function, must be engaged in a fixed position with relation to the valve 5. As shown in FIGS. 4 through 7, a centering cap 12 is affixed to the bonnet nut 7 by screws 13. Once done, the lug 15 may be affixed on the stem 6 and the body 11 of the valve actuator 10 slid over the centering cap 12. The screws 13 are then engaged in the openings 33 in the body 11 and engagable lock notch 34 in the opening 33 as a safety catch. Once screws 14 are tightened on to the centering cap 12 the valve actuator 10 can operate the stem 6 of the valve 5.
The Thermostat
The operation of the thermostat control box 40 is controlled by the micro controller chip 70. The micro controller chip 70 is a TOSHIBA™ TMP47C446VF with burned in programmed software or a programmed TOSHIBA™ TMP47C446AF which periodically measure the temperature, comparing it to the set point and opens or closes valve 5, or multiple valves 5, if more than one is included in the system. Each valve 5 is moved no more than once every five minutes. As the motor 28 for valve 5 begins to drive in the open or closed direction, its power consumption is monitored by the micro controller chip 70 software. During a move, the motor 28 is started with a current threshold which is significantly higher than the operating current. This is done in case the valve 5 is somewhat stuck. After one half a revolution, the current threshold is lowered by the software in an effort to accurately achieve the alternative valve 5 position and prevent it from becoming jammed. The motor 28 runs indefinitely if the current threshold is not achieved, thus alerting the user that there has been a mechanical failure.
More than one actuator 10 may operate from micro controller chip 70 software in the thermostat control box 40.
The measured temperature is constantly displayed during normal operation in the liquid crystal display 46. The time of day set at the thermostat control box 40 determines whether it is in day mode or night mode. The mode determines whether the temperature is at the entered daytime set point, or the daytime set point minus thirteen, which is used to control the room temperature. It is during night mode that the control point consists of the daytime set point minus thirteen, or 55° F., whichever is greater. During the night mode, the symbol "O" should appear to the left of the displayed measured temperature in the liquid crystal display 46. During day mode or night mode override, the "O" disappears. Day mode occurs when the time is between 6:00 AM and 10:00 PM, or night time override has been set. Any other time is considered night mode, provided that night time override has not been set. The night time override button 49 sets the day mode for two to four hours. The remaining override time splayed when the override button 49 is pressed. Holding the button 49 continues to add two hours to the remaining time up to a maximum of four hours. During day mode, pressing the override button 49 produces a"----" on the display to indicate that the temperature is already controlled according to the daytime set point.
Pressing the time display view button 50 displays the time. Pressing the hour set button 51 displays the hours and then begins to advance the hours. The time increments at the rate of one per second and then increases to one and one half per second after two increments. To the right of the hours is displayed "A" or "P" to indicate AM or PM. The minute set button 52 works similarly. The maximum an minimum temperature set points, which can be set, are 85° F. to 55° F. respectively. Shortly after any of these buttons have been pressed, the measured temperature is compared with the control set point.
If necessary, the valve 5 is then moved. If the valve 5 has not been moved in the twenty four hour period preceding midnight, the valve 5 is moved through one complete open, or open-close, or close-open-close cycle, depending upon the present state of the valve 5. The valve 5 is then considered moved for a new twenty four hour period. Thus, the valve 5 will be, at most cycled, once every other day when it is inactive during normal operation. The valve 5 is cycled in this way to keep the valve 5 rotating freely during periods of inactivity.
The thermostat control box 40 is plugged in, as shown in FIG. 1, with the plug-in transformer 44 at an outlet. The thermostat control box 40 software in the micro controller chip 70 determines the position of the valve 5 by attempting to drive a valve 5 to the open position. If it is unable to turn more than a half turn, it immediately begins to close the valve 5, thus ascertaining a known position for the valve 5. Once the valve's 5 position has been determined, the liquid crystal display 46 flashes "12:00". Next, the unit may open or close the valve 5, based on the default set point of 70° F., the measured temperature and the present position of the valve 5. During such time, the display 46 stops flashing, but continues to display "12:00". When this move is complete, the display 46 continues to flash until the hour or minutes set buttons 52 are pressed.
As shown in FIG. 20 a microprocessor supervisor 76 is in circuit with the micro controller chip 70 so that the software resets the micro controller chip 70 in a watchdog output to protect the micro controller chip 70 against responding to undesired intermediate signals.
As shown in FIG. 18 the zener diode 82 protects the micro controller chip 70 from being burned out from a current overload.
As shown in FIG. 19 the H bridge driver 80 acts as an ammeter and senses the increased current as the valve 5 reaches the open or closing extremes of movement. The software of the micro controller chip 70 is programmed to cycle the valve to remain open or closed depending, on the setting of the temperature at the thermostat control box 40 actuated by the current surges, as the valve 5 is turned to its extreme open or extreme closed position.
The H bridge driver 80 is a solid state toggle for a DC motor 28 which is bidirectional. The shaft of the motor 28 revolves clockwise or counterclockwise depending on the polarity of the current. The H bridge driver 80 is the functional equivalent of exchanging leads. The DC motor 28 draws variable amounts of current, depending upon the load, During the active cycle the software of the micro controller chip 70 monitors the current as an ammeter circuit would. The software polls at approximately 100 time per second. When the stem 6 of the valve 5 reaches the end of travel in either direction the load and consequently the current rises signaling the software to begin the end of cycle processing.
The circuitry of the H bridge driver 80 includes two sets of transistors wired back to back. The microprocessor outputs to the gates of each transistor pair and controls which transistor of each pair is conducting. The signal from the microprocessor is sent first through a bipolar transistor T to change it from a 0-5 volt signal to a 0-12 volt signal. When the input to a transistor pair of the H bridge driver 80 is high (12 v), the upper transistor is off (open circuit) and the lower one is on (shorted to ground). Consequently, the output of the H bridge driver 80 corresponding to this transistor pair and is grounded an so is the motor lead connected to this output. At the same time, when the input to a transistor pair is at ground (0 v), the upper transistor is on (closed circuit) and the lower one is off (open circuit). Under this circumstance, the output which corresponds to this transistor pair is at 12 volts. If both outputs from the H bridge driver 80 are at ground or both are at 12 volts then the motor 28 will be off. If one output is high and the other low, the motor 28 will spin in one direction. If the same outputs are reversed (the high brought low and the low brought high), the motor 28 will spin in the opposite direction.
The controlling arrangement with the H bridge driver 80 enables the system of the present invention to control the valve actuator 10 to effectively open or close valves 5 an arbitrary wide range of total travel distances, open to close, turns per inch, number of turns open to close completely opening or closing the valve 5. In a steam heat system this is essential in order to have effective control.
The system of the present invention can be used to remotely actuate valves in other than a steam heat system also. The cams 24a of the annular gear 22a as shown in FIG. 15, extending from the cover 60 are engagable with the cams 16 of the lug 15.
As shown in FIG. 1, the cable 41 is connected to the thermostat control box 40 in snap fitting 35, which is a telephone wire RJ 11 or RJ 45, depending on the number of wires desired. The snap fitting 42 in the thermostat control box 40 is also an RJ 11 or RJ 45. The power connector 45 for the system plugs into the thermostat control box 0 from a cable 43 running from the plug-in transformer 44 plugged into a standard 120 VAC outlet.
An advantage of the present invention over the prior art is that the cable 41 to the valve actuator 10 snap fitting 35 is a low voltage line. Thus there is not the danger of a long 120VAC line to the thermostat control box 40 that can shock or be damaged.
The mode of actuating the valve actuator 10 could also be a remote signal to a sensor such an, infra red, ultra violet, ultra sonic or even sonic. It is important that the thermostat control box 40 be remote from the radiator 4 and/or the valve 5 since the heat from the radiator 4 or the valve 5 can distort the temperature regulating function of the system of the present invention. A remote thermostat control box 40 can be placed where can best respond to the desired temperature in the room.
The cable 43 has the same safety advantage as the cable 41. The cable 41 is a low voltage line from the plug-in transformer 44. The plug-in transformer 44 steps down the 120VAC current to the desired low voltage DC current of the system of the present invention.
The voltages can be selected to the needs of the chips and the motor 28. The usual operating voltages are 5 volt or 12 volts DC or a mix thereof in the system. These voltages enable the use of off the shelf components to allow great cost efficiency in the assembly of the system. The snap fitting 35 and snap fitting 42 are in the form of an RJ11 or RJ45 and the simple power connector 45 allows easy unskilled installation of the connection of the present invention.
The cable 43 and power connector 45 may also be in the form of a telephone handset cord with RJ11 connectors (not shown) plugged directly into a plug in transformer 44 and the thermostat control box 40. Such a configuration maximizes simplicity of installation and electrical safety. The circuitry using the RJ11 power cord is integratable with the use of RJ45 connectors for the snap fitting 35 and snap fitting 42.
The terms and expressions which are employed are used as terms of description; it is recognized, though, that various modifications are possible.
It is also understood the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might fall therebetween. | An actuator has a drive gear set to interact with a driven lug to rotate the lug and whatever the lug is fixed to. The actuator must be separately anchored to interact with the lug. The drive gear and the lug have cams that are spaced apart, so that when the lug is fixed to an object which is off its linear axis, there is play in the gear relationship to allow rotation to function. In a system with an actuator, such as a thermostat, temperature can be controlled by turning a valve on a radiator on and off. End of travel is sensed by a current surge stopping the acutation. The system is ideal to operate radiators in a steam heat system. | 5 |
FIELD OF THE INVENTION
This invention is in the field of corn breeding, specifically relating to an inbred corn line designated G06-NP2598. This invention also is in the field of hybrid maize production employing the present inbred.
BACKGROUND OF THE INVENTION
The original maize plant was indigenous to the Western Hemisphere. The plants were weedlike and only through the efforts of early breeders were cultivated crop species developed. The crop cultivated by early breeders, like the crop today, could be wind pollinated. The physical traits of maize are such that wind pollination results in self-pollination or cross-pollination between plants. Each maize plant has a separate male and female flower that contributes to pollination, the tassel and ear, respectively. Natural pollination occurs when wind transfers pollen from tassel to the silks on the corn ears. This type of pollination has contributed to the wide variation of maize varieties present in the Western Hemisphere.
The development of a planned breeding program for maize only occurred in the last century. A large part of the development of the maize product into a profitable agricultural crop was due to the work done by land grant colleges. Originally, maize was an open pollinated variety having heterogeneous genotypes. The maize farmer selected uniform ears from the yield of these genotypes and preserved them for planting the next season. The result was a field of maize plants that were segregating for a variety of traits. This type of maize selection led to, at most, incremental increases in seed yield.
Large increases in seed yield were due to the work done by land grant colleges that resulted in the development of numerous hybrid corn varieties in planned breeding programs. Hybrids were developed from inbreds which were developed by selecting corn lines and selfing these lines for several generations to develop homozygous pure inbred lines. One selected inbred line was emasculated and another selected inbred line pollinated the emasculated inbred to produce hybrid seed F1 on the emasculated inbred line. Emasculation of the inbred usually is done by detasseling the seed parent; however, emasculation can be done in a number of ways. For example an inbred could have a male sterility factor which would eliminate the need to detassel the inbred.
In the early seventies the hybrid corn industry attempted to introduce CMS (cytoplasmic male sterility) into a number of inbred lines. Unfortunately, the CMS inbreds also introduced some very poor agronomic performance traits into the hybrid seed which caused farmers concern causing the maize industry to shy away from CMS material for a couple of decades thereafter.
However, in the last 10-15 years a number of different male sterility systems for maize have been successfully deployed. The most traditionally of these male sterility and/or CMS systems for maize parallel the CMS type systems that have been routinely used in hybrid production in sunflower.
In the standard CMS system there are three different maize lines required to make the hybrid. First, there is a cytoplasmic male-sterile line usually carrying the CMS or some other form of male sterility. This line will be the seed producing parent line. Second, there must be a fertile inbred line that is the same or isogenic with the seed producing inbred parent but lacking the trait of male sterility. This is a maintainer line needed to make new inbred seed of the seed producing male sterile parent. Third there is a different inbred which is fertile, has normal cytoplasm and carries a fertility restoring gene. This line is called the restorer line in the CMS system. The CMS cytoplasm is inherited from the maternal parent (or the seed producing plant), therefore for the hybrid seed produced on such plant to be fertile the pollen used to fertilize this plant must carry the restorer gene. The positive aspect of this is that it allows hybrid seed to be produced without the need for detasseling the seed parent. However, this system does require breeding of all three types of lines: 1) male sterile—to carry the CMS: 2) the maintainer line; and, 3) the line carrying the fertility restorer gene.
In some instances, sterile hybrids are produced and the pollen necessary for the formation of grain on these hybrids is supplied by interplanting of fertile inbreds in the field with the sterile hybrids.
Whether the seed producing plant is emasculated by detasseling or by CMS or by transgenes, the seed produced by crossing two inbreds in this manner is hybrid seed. This hybrid seed is F1 hybrid seed. The grain produced by a plant grown from a F1 hybrid seed is referred to as F2 or grain. Although, all F1 seed and plants, produced by this hybrid seed production system using the same two inbreds should be substantially the same, all F2 grain produced from the F1 plant will be segregating maize material.
The hybrid seed production produces hybrid seed which is heterozygous. The heterozygosis results in hybrid plants, which are robust and vigorous plants. Inbreds on the other hand are mostly homozygous. This homozygosity renders the inbred lines less vigorous. Inbred seed can be difficult to produce since the inbreeding process in corn lines decreases the vigor. However, when two inbred lines are crossed, the hybrid plant evidences greatly increased vigor and seed yield compared to open pollinated, segregating maize plants. An important consequence of the homozygosity and the homogenity of the inbred maize lines is that all hybrid seed produced from any cross of two such elite lines will be the same hybrid seed and make the same hybrid plant. Thus the use of inbreds makes hybrid seed which can be reproduced readily.
The ultimate objective of the commercial maize seed companies is to produce high yielding, agronomically sound plants that perform well in certain regions or areas of the Corn Belt. To produce these types of hybrids, the companies must develop inbreds, which carry needed traits into the hybrid combination. Hybrids are not often uniformly adapted for the entire Corn Belt, but most often are specifically adapted for regions of the Corn Belt. Northern regions of the Corn Belt require shorter season hybrids than do southern regions of the Corn Belt. Hybrids that grow well in Colorado and Nebraska soils may not flourish in richer Illinois and Iowa soil. Thus, a variety of major agronomic traits is important in hybrid combination for the various Corn Belt regions, and has an impact on hybrid performance.
Inbred line development and hybrid testing have been emphasized in the past half-century in commercial maize production as a means to increase hybrid performance. Inbred development is usually done by pedigree selection. Pedigree selection can be selection in an F 2 population produced from a planned cross of two genotypes (often elite inbred lines), or selection of progeny of synthetic varieties, open pollinated, composite, or backcrossed populations. This type of selection is effective for highly inheritable traits, but other traits, for example, yield requires replicated test crosses at a variety of stages for accurate selection.
Maize breeders select for a variety of traits in inbreds that impact hybrid performance along with selecting for acceptable parental traits. Such traits include: yield potential in hybrid combination; dry down; maturity; grain moisture at harvest; greensnap; resistance to root lodging; resistance to stalk lodging; grain quality; disease and insect resistance; ear and plant height. Additionally, Hybrid performance will differ in different soil types such as low levels of organic matter, clay, sand, black, high pH, low pH; or in different environments such as wet environments, drought environments, and no tillage conditions. These traits appear to be governed by a complex genetic system that makes selection and breeding of an inbred line extremely difficult. Even if an inbred in hybrid combination has excellent yield (a desired characteristic), it may not be useful because it fails to have acceptable parental traits such as seed yield, seed size, pollen production, good silks, plant height, etc.
To illustrate the difficulty of breeding and developing inbred lines, the following example is given. Two inbreds compared for similarity of 29 traits differed significantly for 18 traits between the two lines. If 18 simply inherited single gene traits were polymorphic with gene frequencies of 0.5 in the parental lines, and assuming independent segregation (as would essentially be the case if each trait resided on a different chromosome arm), then the specific combination of these traits as embodied in an inbred would only be expected to become fixed at a rate of one in 262,144 possible homozygous genetic combinations. Selection of the specific inbred combination is also influenced by the specific selection environment on many of these 18 traits which makes the probability of obtaining this one inbred even more remote. In addition, most traits in the corn genome are regrettably not single dominant genes but are multi-genetic with additive gene action not dominant gene action. Thus, the general procedure of producing a non segregating F 1 generation and self pollinating to produce a F 2 generation that segregates for traits and selecting progeny with the visual traits desired does not easily lead to a useful inbred. Great care and breeder expertise must be used in selection of breeding material to continue to increase yield and the agronomics of inbreds and resultant commercial hybrids.
Certain regions of the Corn Belt have specific difficulties that other regions may not have. Thus the hybrids developed from the inbreds have to have traits that overcome or at least minimize these regional growing problems. Examples of these problems include in the eastern corn belt Gray Leaf Spot, in the north cool temperatures during seedling emergence, in the Nebraska region CLN (corn Lethal necrosis and in the west soil that has excessively high pH levels. The industry often targets inbreds that address these issues specifically forming niche products. However, the aim of most large seed producers is to provide a number of traits to each inbred so that the corresponding hybrid can useful in a broader regions of the Corn Belt. The new biotechnology techniques such as Microsatellites, RFLPs, RAPDs and the like have provided breeders with additional tools to accomplish these goals.
SUMMARY OF THE INVENTION
The present invention relates to an inbred corn line G06-NP2598. Specifically, this invention relates to plants and seeds of this line. Additionally, this relates to a method of producing from this inbred, hybrid seed corn and hybrid plants with seeds from such hybrid seed. More particularly, this invention relates to the unique combination of traits that combine in corn line G06-NP2598.
Generally then, broadly the present invention includes an inbred corn seed designated G06-NP2598. This seed produces a corn plant.
The invention also includes the tissue culture of regenerable cells of G06-NP2598 wherein the cells of the tissue culture regenerates plants capable of expressing the genotype of G06-NP2598. The tissue culture is selected from the group consisting of leaf, pollen, embryo, root, root tip, guard cell, ovule, seed, anther, silk, flower, kernel, ear, cob, husk and stalk, cell and protoplast thereof. The corn plant regenerated from G06-NP2598 or any part thereof is included in the present invention. The present invention includes regenerated corn plants that are capable of expressing G06-NP2598's genotype, phenotype or mutants or variants thereof.
The invention extends to hybrid seed produced by planting, in pollinating proximity which includes using preserved maize pollen as explained in U.S. Pat. No. 5,596,838 to Greaves, seeds of corn inbred lines G06-NP2598 and another inbred line if preserved pollen is not used; cultivating corn plants resulting from said planting; preventing pollen production by the plants of one of the inbred lines if two are employed; allowing cross pollination to occur between said inbred lines; and harvesting seeds produced on plants of the selected inbred. The hybrid seed produced by hybrid combination of plants of inbred corn seed designated G06-NP2598 and plants of another inbred line are apart of the present invention. This inventions scope covers hybrid plants and the plant parts including the grain and pollen grown from this hybrid seed.
The invention further includes a method of hybrid F1 production. A first generation (F1) hybrid corn plant produced by the process of planting seeds of corn inbred line G06-NP2598; cultivating corn plants resulting from said planting; permitting pollen from another inbred line to cross pollinate inbred line G06-NP2598; harvesting seeds produced on plants of the inbred; and growing a harvested seed are part of the method of this invention.
The present invention also encompasses a method of introducing at least one targeted trait into maize inbred line comprising the steps of: (A) crossing plant grown from the present invention seed which is the recurrent parent, representative seed of which has been deposited, with the donor plant of another maize line that comprises at least one target trait selected from the group consisting of male sterility, herbicide resistance, insect resistance, disease resistance, amylose starch, and waxy starch to produce F1 plants; (b) selecting from the F1 plants that have at least one of the targeted trait, forming a pool of progeny plants with the targeted trait; (c) crossing the pool of progeny plants with the present invention which is the recurrent parent to produce backcrossed progeny plants with the targeted trait; (d) selecting for backcrossed progeny plants that have at least one of the target trait and physiological and morphological characteristics of maize inbred line of the recurrent parent, listed in Table 1 forming a pool of selected backcrossed progeny plants; and (e) crossing the selected backcrossed progeny plants to the recurrent parent and selecting from the resulting plants for the targeted trait and physiological and morphological characteristics of maize inbred line of the recurrent parent, listed in Table 1 and reselecting from the pool of resulting plants and repeating the crossing to the recurrent parent and selecting step in succession to form a plant that comprise the desired trait and all of the physiological and morphological characteristics of maize inbred line of the recurrent parent if the present invention listed in Table 1 as determined at the 5% significance level when grown in the same environmental conditions.
This method and the following method of introducing traits can be done with less back crossing events if the trait and/or the genotype of the present invention are selected for or identified through the use of markers. SSR, microsatellites, SNP and the like decrease the amount of breeding time required to locate a line with the desired trait or traits and the characteristics of the present invention. Backcrossing in two or even three traits (for example the glyphosate, Europe corn borer, corn rootworm resistant genes) is routinely done with the use of marker assisted breeding techniques. This introduction of transgenes or mutations into a maize line is often called single gene conversion. Although, presently more than one gene particularly transgenes or mutations which are readily tracked with markers can be moved during the same “single gene conversion” process, resulting in a line with the addition of more targeted traits than just the one, but still having the characteristics of the present invention plus those characteristics added by the targeted traits.
The method of introducing a desired trait into maize inbred line comprising: (a) crossing plant grown from the present invention seed, representative seed of which has been deposited the recurrent parent, with plant of another maize line that comprises at least one target trait selected from the group consisting of nucleic acid encoding an enzyme selected from the group consisting of phytase, stearyl-ACP desaturase, fructosyltransferase, levansucrase, amylase, invertase and starch branching enzyme, the donor parent to produce F1 plants; (b) selecting for the targeted trait from the F1 plants, forming a pool of progeny plants; (c) crossing the progeny plants with the recurrent parent to produce backcrossed progeny plants; (d) selecting for backcrossed progeny plants that have at least one of the target trait and physiological and morphological characteristics of maize inbred line of the present invention a listed in Table 1 forming a pool of backcrossed progeny plants; and repeating a step of crossing the new pool with the recurrent parent and selecting for the targeted trait and the recurrent parents characteristics until the selected plant is essentially the recurrent parent with the targeted trait or targeted traits. This selection and crossing may take at least 4 backcrosses if marker assisted breeding is not employed.
The inbred line and seed of the present invention are employed to carry the agronomic package into the hybrid. Additionally, the inbred line is often carrying transgenes that are introduced in to the hybrid seed.
Likewise included is a first generation (F1) hybrid corn plant produced by the process of planting seeds of corn inbred line G06-NP2598; cultivating corn plants resulting from said planting; permitting pollen from inbred line G06-NP2598 to cross pollinate another inbred line; harvesting seeds produced on plants of the inbred; and growing a plant from such a harvested seed.
A number of different techniques exist which are designed to avoid detasseling in maize hybrid production. Some examples are switchable male sterility, lethal genes in the pollen or anther, inducible male sterility, male sterility genes with chemical restorers. There are numerous patented means of improving upon the hybrid production system. Some examples include U.S. Pat. No. 6,025,546, which relates to the use of tapetum-specific promoters and the barnase gene to produce male sterility; U.S. Pat. No. 6,627,799 relates to modifying stamen cells to provide male sterility. Therefore, one aspect of the current invention concerns the present invention comprising one or more gene(s) capable of restoring male fertility to male-sterile maize inbreds or hybrids and/or genes or traits to produce male sterility in maize inbreds or hybrids.
The inbred corn line G06-NP2598 and at least one transgenic gene adapted to give G06-NP2598 additional and/or altered phenotypic traits are within the scope of the invention. Such transgenes are usually associated with regulatory elements (promoters, enhancers, terminators and the like). Presently, transgenes provide the invention with traits such as insect resistance, herbicide resistance, disease resistance increased or deceased starch or sugars or oils, increased or decreased life cycle or other altered trait.
The present invention includes inbred corn line G06-NP2598 and at least one transgenic gene adapted to give G06-NP2598 modified starch traits. Furthermore this invention includes the inbred corn line G06-NP2598 and at least one mutant gene adapted to give modified starch, acid or oil traits, i.e. amylase, waxy, amylose extender or amylose. The present invention includes the inbred corn line G06-NP2598 and at least one transgenic gene: bacillus thuringiensis , the bar or pat gene encoding Phosphinothricin acetyl Transferase, Gdha gene, GOX, VIP, EPSP synthase gene, low phytic acid producing gene, and zein. The inbred corn line G06-NP2598 and at least one transgenic gene useful as a selectable marker or a screenable marker is covered by the present invention.
A tissue culture of the regenerable cells of hybrid plants produced with use of G06-NP2598 genetic material is covered by this invention. A tissue culture of the regenerable cells of the corn plant produced by the method described above is also included.
DEFINITIONS
In the description and examples, which follow, a number of terms are used. In order to provide a clear and consistent understanding of the specifications and claims, including the scope to be given such terms, the following definitions are provided.
Plant
This term includes the entire plant and its plant cells, plant protoplasts made from its cells, plant cell tissue cultures from which corn plants can be regenerated, plant calli, plant clumps, and plant cells that are intact in plants or parts of plants, such as embryos, pollen, flowers, kernels, ears, cobs, leaves, husks, stalks, roots, root tips, anthers, silk and the like, and this term also includes any mutated gene, transgenic DNA or (RNA) or portion thereof that have been introduced into the plant by whatever method.
TWT
The measure of the weight of grain in pounds for a one bushel volume adjusted for percent grain moisture.
% Dropped Ears (DE) or PCTDE
The number of plants per plot, which dropped their primary ear, divided by the total number of plants per plot.
% Root Lodge (RL) or PCTRL
Percentage of plants per plot leaning more that 30 degrees from vertical divided by total plants per plot.
Yield (YLD)
Actual yield of grain at harvest adjusted to 15.5% moisture. Measurements are reported in bushels per acre.
Moisture
The average percentage grain moisture of an inbred or hybrid at harvest time.
% Stalk Lodge (SL) or PCTSL Percentage of plants per plot with the stalk broken below the primary ear node divided by the total plants per plot.
GREEN SNAP (Gsnap): Count the number of plants in yield rows that snapped below the ear due to brittleness associated with high winds. For FET plots, count snapped plants out of 50 from two locations in each hybrid strip, sum, and record the percentage.
STAY-GREEN (Sgreen): This is an assessment of the ability of a grain hybrid to retain green color as maturity approaches (taken near the time of black-layer) and should not be a reflection of hybrid maturity or leaf disease. Record % of green tissue.
STAND: Shall mean the number of plants in the plot that were harvested.
Color Choices:
1.
light green
2.
medium green
3.
dark green
4.
very dark green
5.
green-yellow
6.
pale yellow
7.
yellow
8.
yelow-orange
9.
salmon
10.
pink-orange
11.
pink
12.
light red
13.
cherry red
14.
red
15.
red and white
16.
pale purple (describe)
17.
purple
18.
colorless
19.
white
20.
white capped
21.
buff
22.
tan
23.
brown
24.
bronze
25.
variegated
26.
other (describe)
Form
Input
#
ABR.
Description
Value
A1
EMRGN
Final number of plants per plot
#
A2
REGNN
Region Developed: 1.Northwest
#
2.Northcentral 3.Northeast 4.Southeast
5.Southcentral 6.Southwest 7.Other
A3
CRTYN
Cross type: 1.sc 2.dc 3.3w 4.msc 5.m3w
#
6.inbred 7.rel. line 8.other
A4
KRTPN
Kernel type: 1.sweet 2.dent 3.flint 4.flour
#
5.pop 6.ornamental 7.pipecorn 8.other
A5
EMERN
Days to Emergence EMERN
#Days
B1
ERTLP
% Root lodging: (before anthesis):
#%
B2
GRSNP
% Brittle snapping: (before anthesis):
#%
C1
TBANN
Tassel branch angle of 2nd primary lateral
degree
branch (at anthesis):
C10
HUPSN
Heat units to 50% pollen shed: (from
#HU
emergence)
C11
SLKCN
Silk color:
#/Munsell
value
C12
HU5SN
Heat units to 50% silk: (from emergence)
#HU
C13
DSAZN
Days to 50% silk in adapted zone:
#Days
C14
HU9PN
Heat units to 90% pollen shed: (from
#HU
emergence)
C15
HU19N
Heat units from 10% to 90% pollen shed:
#HU
C16
DA19N
Days from 10% to 90% pollen shed:
#Days
C2
LSPUR
Leaf sheath pubescence of second leaf
#
above the ear (at anthesis) 1-9 (1=none):
C3
ANGBN
Angle between stalk and 2nd leaf above
degree
the ear (at anthesis):
C4
CR2LN
Color of 2nd leaf above the ear (at
#/Munsell
anthesis):
value
C5
GLCRN
Glume Color:
#/Munsell
value
C6
GLCBN
Glume color bars perpendicular to their
#
veins (glume bands): 1.absent 2.present
C7
ANTCN
Anther color:
#/Munsell
value
C8
PLQUR
Pollen Shed: 1-9 (0=male sterile)
#
C9
HU1PN
Heat units to 10% pollen shed: (from
#HU
emergence)
D1
LAERN
Number of leaves above the top ear node:
#
D10
LTBRN
Number of lateral tassel branches that
#
originate from the central spike:
D11
EARPN
Number of ears per stalk:
#
D12
APBRR
Anthocyanin pigment of brace roots:
#
1.absent 2.faint 3.moderate 4.dark
D13
TILLN
Numberof tillers:
#
D14
HSKCN
Husk color 25 days after 50% silk: (fresh)
#/Munsell
value
D2
MLWVR
Leaf marginal waves: 1-9 (1=none)
#
D3
LFLCR
Leaf longitudinal creases: 1-9 (1=none)
#
D4
ERLLN
Length of ear leaf at the top ear node:
#cm
D5
ERLWN
Width of ear leaf at the top ear node at the
#cm
widest point:
D6
PLHTN
Plant height to tassel tip:
#cm
D7
ERHCN
Plant height to the top ear node:
#cm
D8
LTEIN
Length of the internode between the ear
#cm
node and the node above:
D9
LTASN
Length of the tassel from top leaf collar to
#cm
tassel tip:
E1
HSKDN
Husk color 65 days after 50% silk: (dry)
#/Munsell
value
E10
DSGMN
Days from 50% silk to 25% grain moisture
#Days
in adapted zone:
E11
SHLNN
Shank length:
#cm
E12
ERLNN
Ear length:
#cm
E13
ERDIN
Diameter of the ear at the midpoint:
#mm
E14
EWGTN
Weight of a husked ear:
#gm
E15
KRRWR
Kernel rows: 1.indistinct 2.distinct
#
E16
KRNAR
Kernel row alignment: 1.straight 2.slightly
#
curved 3.curved
E17
ETAPR
Ear taper: 1.slight 2.average 3.extreme
#
E18
KRRWN
Number of kernel rows:
#
E19
COBCN
Cob color:
#/Munsell
value
E2
HSKTR
Husk tightness 65 days after 50% silk: 1-9
#
(1=loose)
E20
COBDN
Diameter of the cob at the midpoint:
#mm
E21
YBUAN
Yield:
#kg/ha
E22
KRTEN
Endosperm type: 1.sweet 2.extra sweet
3
3.normal 4.high amylose 5.waxy 6.high
protein 7.high lysine 8.super sweet 9.high
oil 10.other
E23
KRCLN
Hard endosperm color:
#/Munsell
value
E24
ALECN
Aleurone color:
#/Munsell
value
E25
ALCPR
Aleurone color pattern: 1.homozygous
#
2.segregating
E26
KRLNN
Kernel length:
#mm
E27
KRWDN
Kernel width:
#mm
E28
KRDPN
Kernel thickness:
#mm
E29
K1KHN
100 kernel weight:
#gm
E3
HSKCR
Husk extension: 1.short (ear exposed)
#
2.medium (8 cm) 3.long (8-10 cm) 4.very
long (>10 cm)
E30
KRPRN
% round kernels on 13/64 slotted screen:
#%
E4
HEPSR
Position of ear 65 days after 50% silk:
#
1.upright 2.horizontal 3.pendent
E5
STGRP
Staygreen 65 days after anthesis: 1-9
#
(1=worst)
E6
DPOPP
% dropped ears 65 days after anthesis:
%
E7
LRTRP
% root lodging 65 days after anthesis:
%
E8
HU25N
Heat units to 25% grain moisture: (from
#HU
emergence)
E9
HUSGN
Heat units from 50% silk to 25% grain
#HU
moisture in adapted zone:
DETAILED DESCRIPTION OF THE INVENTION
G06-NP2598 is shown in comparison with a number of standard inbreds used for comparison by the US PVP office. The present inbred is in the hybrid, X72314 and has a relative maturity of 6.8.
The inbred provides uniformity and stability within the limits of environmental influence for traits as described in the Variety Description Information (Table 1) that follows.
The inbred has been self-pollinated for a sufficient number of generations to give inbred uniformity. During plant selection in each generation, the uniformity of plant type was selected to ensure homozygosity and phenotypic stability. The line has been increased in isolated farmland environments with data on uniformity and agronomic traits being observed to assure uniformity and stability. No variant traits have been observed or are expected in G06-NP2598.
The best method of producing the invention, G06-NP2598 which is substantially homozygous, is by planting the seed of G06-NP2598 which is substantially homozygous and self-pollinating or sib pollinating the resultant plant in an isolated environment, and harvesting the resultant seed.
The following is a short list of the traits in Table 1 below.
SLKCN
Silk color:
5.0 green-
yellow
CR2LN
Color of 2nd leaf above the ear (at anthesis):
4.0 very
dark green
GLCRN
Glume Color:
2.5
med/dark
green
GLCBN
Glume color bars perpendicular to their veins
1. absent
(glume bands): 1.absent 2.present
ANTCN
Anther color:
5.5 green-
yellow/
pale
yellow
APBRR
Anthocyanin pigment of brace roots: 1.absent
2. faint
2.faint 3.moderate 4.dark
COBCN
Cob color:
14 red
KRCLN
Hard endosperm color:
8. yellow-
orange
ALECN
Aleurone color:
18.
colorless
TABLE 1 G06-NP2598 VARIETY DESCRIPTION INFORMATION Trait B37 B64 B68 B73 B76 NP2739 NP2742 NP2744 NPFX8042 NP2743 H84 H89 MS71 Mo17 N192 NC268 Pa91 YGSMN 39.4 37.2 53.4 88.9 55.1 88.4 72.4 72.6 123.9 85.3 74.7 47.3 54.9 87.0 62.2 50.3 78.9 LRTLP 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 ERTLP 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 NHL_P 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 EMRGN 57.8 52.0 58.5 62.5 57.5 66.0 63.5 61.8 46.0 67.5 37.0 56.5 54.8 63.0 63.0 59.5 51.2 STD_N 57.8 52.0 58.5 62.5 57.5 66.0 63.5 61.8 46.0 67.5 37.0 56.5 54.8 63.0 63.0 59.5 51.2 GRSNP −0.1 0.0 0.0 0.0 0.0 0.0 0.0 −0.1 0.0 0.0 0.0 0.0 −0.1 0.0 0.0 0.0 0.1 HSKCR 2.0 2.5 3.0 3.0 1.5 2.0 3.0 2.0 2.5 2.0 2.0 2.0 2.0 2.0 2.0 3.0 2.0 HU5SN 776.5 1438.0 1527.0 1341.0 1332.5 1352.0 1341.0 631.0 1280.0 1341.0 1401.5 1289.0 693.5 1415.0 1329.5 1487.0 731.5 PLHTN 225.8 236.9 219.8 227.9 191.4 234.4 210.1 225.8 223.3 209.2 195.2 143.8 164.0 231.7 198.8 199.2 234.2 ERHTN 95.6 106.6 84.0 91.8 80.1 93.3 76.9 79.8 86.8 79.1 64.3 35.8 60.0 97.3 75.7 80.3 92.6 HU1PN 670.5 1364.5 1355.0 1241.0 1279.0 1338.0 1303.0 594.5 1271.0 1287.5 1242.0 1177.0 631.0 1250.0 1185.0 1422.0 671.0 HU9PN 723.5 1491.0 1447.0 1341.0 1371.5 1412.5 1369.0 643.0 1369.0 1355.0 1342.0 1327.0 693.5 1350.0 1280.5 1547.0 718.0 HUPSN 693.5 1424.5 1405.5 1315.0 1323.5 1366.0 1327.0 605.5 1312.5 1327.0 1295.5 1250.0 656.5 1301.0 1227.5 1473.5 691.5 PLQUR 7.0 6.0 7.0 7.5 6.5 8.0 5.5 4.0 7.5 6.0 6.5 6.5 9.0 4.5 6.5 5.0 7.0 EARPN 1.2 1.5 1.2 1.0 1.0 1.5 1.1 2.4 1.5 1.1 1.4 1.2 1.2 1.4 1.0 1.5 1.4 SHLNN 9.0 10.8 12.8 8.3 8.0 5.5 6.3 10.5 6.0 5.3 14.8 5.5 8.0 12.3 9.3 5.8 7.0 ALCPR 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 ALECN 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 ANTCN 14.0 3.5 5.5 6.5 14.0 11.5 12.0 11.0 6.0 6.0 13.0 5.0 5.0 5.0 6.0 8.5 5.0 COBCN 11.0 19.0 13.5 14.0 11.0 16.0 11.0 14.0 19.0 19.0 14.0 19.0 14.0 12.5 10.0 12.5 9.0 CR2LN 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 3.5 4.0 4.0 4.0 3.0 4.0 4.0 4.0 4.0 CRTYN 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 DA19N 2.5 5.5 4.5 4.0 4.0 3.0 2.5 2.0 4.5 2.5 4.0 7.0 2.5 4.0 5.0 5.0 2.0 DSAZN 32.5 60.5 64.0 56.0 56.0 56.5 56.0 26.5 53.0 56.0 59.0 54.0 29.0 59.5 55.5 62.5 30.5 DSGMN 47.0 51.0 49.0 53.0 54.5 55.5 58.5 54.0 51.5 53.0 54.0 50.0 43.0 46.5 49.0 55.0 58.0 GLCBN 1.0 2.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 2.0 1.0 1.0 1.0 1.0 1.0 GLCRN 2.0 2.5 1.5 2.0 2.0 2.5 2.5 2.0 2.5 2.0 3.0 2.0 2.0 3.0 2.0 2.0 2.0 HSKCN 2.0 2.5 2.0 2.0 2.0 2.0 2.5 2.0 2.0 2.5 3.0 3.0 2.0 2.5 2.5 2.0 3.0 HSKDN 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 HU19N 53.0 126.5 92.0 100.0 92.5 74.5 66.0 48.5 98.0 67.5 100.0 150.0 62.5 100.0 95.5 125.0 47.0 HU25N 2545.0 2522.5 2554.0 2489.5 2501.0 2522.0 2587.5 2436.0 2396.0 2488.0 2557.5 2387.0 2335.0 2433.0 2412.0 2636.5 2488.0 HUSGN 992.0 1084.5 1027.0 1148.5 1168.5 1200.0 1246.5 1174.0 1116.0 1147.0 1156.0 1098.0 948.0 1018.0 1082.5 1149.5 1025.0 KRCLN 8.0 8.0 8.0 8.0 8.0 7.5 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0 KRTEN 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 KRTPN 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 SLKCN 5.0 13.0 1.0 3.0 3.0 1.0 3.0 1.0 1.0 1.0 1.0 3.0 5.0 3.0 3.0 3.0 5.0 LTEIN 14.0 14.0 14.5 17.0 13.0 13.5 15.5 15.0 13.0 13.5 12.0 11.0 11.0 15.0 11.0 10.5 14.0 ERLWN 7.8 7.9 7.7 8.2 9.6 8.3 7.2 7.6 9.6 7.5 7.9 7.3 6.4 8.7 8.7 8.6 9.4 ERLLN 72.8 92.0 91.5 75.3 67.4 71.8 75.4 72.0 86.4 65.8 72.7 61.2 71.5 72.2 78.3 71.8 93.4 LAERN 6.6 6.3 6.9 6.0 5.7 7.2 5.1 6.4 6.0 5.5 7.6 7.2 6.0 5.1 5.7 7.8 5.8 ANGBN 20.0 27.5 40.0 20.0 25.0 32.5 15.0 15.0 22.5 22.5 27.5 45.0 30.0 27.5 17.5 30.0 35.0 LTBRN 8.8 7.9 8.1 6.6 6.2 2.5 5.2 3.6 8.2 4.4 5.1 3.3 12.0 6.9 5.7 7.7 10.4 TBANN 35.0 45.0 37.5 15.0 40.0 17.5 32.5 15.0 20.0 37.5 37.5 40.0 30.0 35.0 30.0 42.5 50.0 LTASN 37.7 46.8 38.1 40.6 37.5 38.2 40.1 44.8 47.4 33.1 31.8 32.4 36.8 49.1 38.4 28.7 46.2 ERLNN 14.5 18.1 17.4 14.6 13.5 15.9 14.4 16.0 16.4 14.5 14.2 13.8 14.2 19.0 14.6 14.6 14.9 ERDIN 36.4 36.0 38.3 44.7 40.1 38.3 40.0 36.2 44.7 40.9 41.2 34.6 34.8 36.7 37.0 35.9 40.2 EWGTN 62.4 66.3 76.4 112.8 72.8 105.9 89.9 90.6 149.7 99.2 98.6 65.8 75.6 103.1 80.6 64.5 96.6 KRRWN 12.0 13.0 15.2 17.6 13.2 13.6 13.4 13.6 16.2 14.6 14.8 11.3 15.2 11.4 15.0 12.4 15.6 KRLNN 8.5 9.0 10.0 10.8 10.8 11.0 10.3 10.0 11.8 11.5 11.5 8.8 9.0 10.5 10.0 11.3 9.5 KRWDN 8.0 7.5 7.0 7.3 9.5 8.3 8.3 6.5 7.8 7.5 8.3 8.3 7.0 8.5 7.0 8.3 7.5 KRDPN 5.5 5.0 4.8 5.0 5.5 4.3 5.3 3.5 4.5 4.3 5.3 4.5 4.5 5.0 4.0 4.3 5.5 KRPRN 97.0 81.0 61.0 40.0 84.0 35.0 74.5 89.0 35.0 22.0 57.0 46.5 50.0 51.5 55.5 43.0 75.0 COBDN 22.7 24.2 25.5 27.8 26.0 22.2 24.6 21.5 27.7 21.8 24.3 22.2 22.9 19.9 24.2 21.1 25.3 APBRR 2.0 3.0 4.0 3.5 2.5 2.0 3.0 2.0 2.0 2.5 2.0 1.5 2.0 2.0 4.0 3.5 2.0 LSPUR 1.0 7.0 7.5 5.0 3.5 2.0 2.5 3.0 7.5 3.0 2.0 2.0 4.0 2.0 8.5 2.5 1.0 MLWVR 8.0 6.0 4.5 5.0 6.5 4.0 4.5 5.0 3.5 4.5 7.0 3.5 3.0 5.0 5.5 3.5 5.0 LFLCR 3.0 3.0 4.0 3.5 4.5 4.0 3.5 4.0 2.5 2.5 2.5 4.0 3.0 5.0 4.5 4.5 2.0 HSKTR 7.0 7.5 6.5 6.5 3.0 5.0 5.5 6.0 7.0 6.0 4.5 5.5 4.0 3.0 4.5 8.0 7.0 HEPSR 1.0 1.0 1.0 2.0 1.0 3.0 1.0 1.0 1.5 2.5 1.0 3.0 3.0 1.5 2.0 1.0 1.0 KRRWR 1.0 1.5 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 ETAPR 2.0 2.0 2.0 1.5 1.0 1.0 1.0 1.0 2.0 1.0 1.0 1.0 2.0 1.5 1.0 1.0 1.0 K1KHN 29.0 29.5 24.0 25.5 30.0 28.5 31.5 33.0 28.5 25.0 29.0 23.0 20.0 31.5 24.5 29.0 28.0 TILLN 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1.5 0.0 0.0 TILLP 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 2.4 0.0 0.0 DROPP 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 2.2 0.0 3.6 0.0 0.8 0.0 0.0 0.0 KERAR 3.0 2.0 1.0 1.0 1.5 1.5 2.0 2.0 2.0 2.0 2.0 1.5 1.0 1.5 1.0 1.0 1.0
The present invention shows one of the highest yield, 99 bushel per acre, of the comparison inbreds with the exception of NPFX8042. The EMRGN which counts the plants standing at harvest is higher than most of the comparison inbreds with a 65. The present invention is not a heavy shedding inbred. Its pollen shed is only 6.0. The rating scale of 9-1 is used for most rating data. In all instances 9 is the best rating and 1 is the lowest rating. Heat Units per day were calculated: HU=[MaxTemp (86)=Min Temp (50)]/2−50. An inbred's response to environment is often more pronounced than a hybrid.
The data provided above is often a color. The Munsell code is a reference book of color, which is known and used in the industry and by persons with ordinary skill in the art of plant breeding.
Hybrid Performance of G06-NP2598
Table 2 shows the inbred G06-NP2598 in hybrid combination in X72314 which is in comparison with other hybrid combinations, which have an inbred in common with the hybrid containing G06-NP2598 or are adapted to the same region as X72314. When in this hybrid combination the present inbred G06-NP2598 carries into the hybrid significantly less yield than one inbred and more than the other and less moisture than both of the comparison inbreds. The present invention in the hybrid X72314 is showing less root lodging than the other two hybrids. The present invention has an RM of 6.8 and is a 110 day hybrid. The test weight for the hybrid combination containing the present invention is similar to one hybrid and heavier than the other hybrid.
TABLE 2
PAIRED HYBIRD COMPARISON DATA
AbbrCode
Yld
Moist
TWT
% SL
% RL
% DE
Stand
Sgreen
Gsnap
N76-D3
214.4
21.1
55.2
0.4
9.9
0.0
63.3
27.8
0.0
X72314*
209.5
18.4
55.9
0.8
0.8
0.0
62.7
17.0
14.3
NG394CB/LL
202.0
19.9
55.9
0.4
0.9
0.0
61.1
22.0
0.0
*Hybrid made with G06-NP2598.
This invention also is directed to methods for producing a corn plant by crossing a first parent corn plant with a second parent corn plant wherein the first or second parent corn plant is an inbred corn plant from the line G06-NP2598. Further, both first and second parent corn plants can come from the inbred corn line G06-NP2598 which produces a self of the inbred invention. The present invention can be employed in a variety of breeding methods which can be selected depending on the mode of reproduction, the trait, and the condition of the germplasm. Thus, any breeding methods using the inbred corn line G06-NP2598 are part of this invention: selfing, backcrosses, hybrid production, and crosses to populations, and haploid by such old and known methods of using stock six material that induces haploids and anther culturing and the like.
All plants and plant cells produced using inbred corn line G06-NP2598 are within the scope of this invention. The invention encompasses the inbred corn line used in crosses with other, different, corn inbreds to produce (F1) corn hybrid seeds and hybrid plants and the grain produced on the hybrid plant. This invention includes plant and plant cells, which upon growth and differentiation produce corn plants having the physiological and morphological characteristics of the inbred line G06-NP2598.
Additionally, this maize can, within the scope of the invention, contain: a mutant gene such as, but not limited to, the amylose, amylase, sugary 1 or shrunken 1 or waxy or AE or imazethapyr tolerant (IT or IR™) mutant gene; or transgenic genes such as but not limited to insect resistant genes such as Corn Rootworm gene, Bacillus thuringiensis (Cry genes), or herbicide resistant genes such as Pat gene or Bar gene, EPSP, or disease resistant genes such as the Mosaic virus resistant gene, etc., or trait altering genes such as flowering genes, oil modifying genes, senescence genes and the like. The methods and techniques for inserting, or producing and/or identifying a mutation or a transgene into the present invention through breeding, transformation, or mutating are well known and understood by those of ordinary skill in the art.
A number of different inventions exist which are designed to avoid detasseling in maize hybrid production. Some examples are switchable male sterility, lethal genes in the pollen or anther, inducible male sterility, male sterility genes with chemical restorers, sterility genes linked with parent. U.S. Pat. No. 6,025,546, relates to the use of tapetum-specific promoters and the barnase gene. U.S. Pat. No. 6,627,799 relates to modifying stamen cells to provide male sterility. Therefore, one aspect of the current invention concerns the present invention comprising one or more gene(s) capable of restoring male fertility to male-sterile maize inbreds or hybrids.
Various techniques for breeding and moving or altering genetic material within or into the present invention (whether it is an inbred or in hybrid combination) are also known to those skilled in the art. These techniques to list only a few are anther culturing, haploid production, (stock six is a method that has been in use for thirty years and is well known to those with skill in the art), transformation, irradiation to produce mutations, chemical or biological mutation agents and a host of other methods are within the scope of the invention. All parts of the G06-NP2598 plant including its plant cells produced using the inbred corn line is within the scope of this invention. The term transgenic plant refers to plants having genetic sequences, which are introduced into the genome of a plant by a transformation method and the progeny thereof. Transformation methods are means for integrating new genetic coding sequences into the plant's genome by the incorporation of these sequences into a plant through man's assistance, but not by breeding practices. The transgene once introduced into plant material and integrated stably can be moved into other germplasm by standard breeding practices.
Though there are a large number of known methods to transform plants, certain types of plants are more amenable to transformation than are others. Transformation of dicots is usually achievable for example, tobacco is a readily transformable plant. Monocots can present some transformation challenges, however, the basic steps of transforming plants monocots have been known in the art for about 15 years. The most common method of maize transformation is referred to as gunning or microprojectile bombardment though other methods can be used. The process employs small gold-coated particles coated with DNA which are shot into the transformable material. Detailed techniques for gunning DNA into cells, tissue, callus, embryos, and the like are well known in the prior art. One example of steps that can be involved in monocot transformation are concisely outlined in U.S. Pat. No. 5,484,956 “Fertile Transgenic Zea mays Plants Comprising Heterologous DNA Encoding Bacillus Thuringiensis Endotoxin” issued Jan. 16, 1996 and also in U.S. Pat. No. 5,489,520 “Process of Producing Fertile Zea mays Plants and Progeny Comprising a Gene Encoding Phosphinothricin Acetyl Transferase” issued Feb. 6, 1996.
Plant cells such as maize can be transformed not only by the use of a gunning device but also by a number of different techniques. Some of these techniques include maize pollen transformation (See University of Toledo 1993 U.S. Pat. No. 5,177,010); Whiskers technology (See U.S. Pat. Nos. 5,464,765 and 5,302,523); electroporation; PEG on Maize; Agrobacterium (See 1996 article on transformation of maize cells in Nature Biotechnology , Volume 14, June 1996) along with numerous other methods which may have slightly lower efficiency rates. Some of these methods require specific types of cells and other methods can be practiced on any number of cell types.
The use of pollen, cotyledons, zygotic embryos, meristems and ovum as the target issue can eliminate the need for extensive tissue culture work. Generally, cells derived from meristematic tissue are useful. The method of transformation of meristematic cells of cereal is taught in the PCT application WO96/04392. Any number of various cell lines, tissues, calli and plant parts can and have been transformed by those having knowledge in the art. Methods of preparing callus or protoplasts from various plants are well known in the art and specific methods are detailed in patents and references used by those skilled in the art. Cultures can be initiated from most of the above-identified tissue. The only true requirement of the transforming plant material is that it can form a transformed plant.
The DNA used for transformation of these plants clearly may be circular, linear, and double or single stranded. Usually, the DNA is in the form of a plasmid. The plasmid usually contains regulatory and/or targeting sequences which assists the expression of the gene in the plant. The methods of forming plasmids for transformation are known in the art. Plasmid components can include such items as: leader sequences, transit polypeptides, promoters, terminators, genes, introns, marker genes, etc. The structures of the gene orientations can be sense, antisense, partial antisense, or partial sense: multiple gene copies can be used. The transgenic gene can come from various non-plant genes (such as; bacteria, yeast, animals, and viruses) along with being from plants.
The regulatory promoters employed can be constitutive such as CaMv35S (usually for dicots) and polyubiquitin for monocots or tissue specific promoters such as CAB promoters, MR7 described in U.S. Pat. No. 5,837,848, etc. The prior art promoters, includes but is not limited to, octopine synthase, nopaline synthase, CaMv19S, mannopine synthase. These regulatory sequences can be combined with introns, terminators, enhancers, leader sequences and the like in the material used for transformation.
The isolated DNA is then transformed into the plant. After the transformation of the plant material is complete, the next step is identifying the cells or material, which has been transformed. In some cases, a screenable marker is employed such as the beta-glucuronidase gene of the uidA locus of E. coli . Then, the transformed cells expressing the colored protein are selected. In many cases, a selectable marker identifies the transformed material. The putatively transformed material is exposed to a toxic agent at varying concentrations. The cells not transformed with the selectable marker, which provides resistance to this toxic agent, die. Cells or tissues containing the resistant selectable marker generally proliferate. It has been noted that although selectable markers protect the cells from some of the toxic affects of the herbicide or antibiotic, the cells may still be slightly affected by the toxic agent by having slower growth rates. If the transformed material was cell lines then these lines are regenerated into plants. The cells' lines are treated to induce tissue differentiation. Methods of regeneration of cellular maize material are well known in the art.
A deposit of at least 2500 seeds of this invention will be maintained by Syngenta Seed Inc. Access to this deposit will be available during the pendency of this application to the Commissioner of Patents and Trademarks and persons determined by the Commissioner to be entitled thereto upon request. All restrictions on availability to the public of such material will be removed upon issuance of a granted patent of this application by depositing at least 2500 seeds of this invention at the American Type Culture Collection (ATCC), at 10801 University Boulevard, Manassas, Va. 20110. The date of deposit was Jan. 31, 2008. The ATCC number of the deposit is PTA-8907 and on Feb. 15, 2008 the seeds were tested and found to be viable. The deposit of at least 2500 seeds will be from inbred seed taken from the deposit maintained by Syngenta Seed Inc. The ATCC deposit will be maintained in that depository, which is a public depository, for a period of 30 years, or 5 years after the last request, or for the enforceable life of the patent, whichever is longer, and will be replaced if it becomes nonviable during that period.
Additional public information on patent variety protection may be available from the PVP Office, a division of the US Government.
Accordingly, the present invention has been described with some degree of particularity directed to the preferred embodiment of the present invention. It should be appreciated, though that the present invention is defined by the following claims construed in light of the prior art so that modifications or changes may be made to the preferred embodiment of the present invention without departing from the inventive concepts contained herein. | Basically, this invention provides for an inbred corn line designated G06-NP2598, methods for producing a corn plant by crossing plants of the inbred line G06-NP2598 with plants of another corn plants. The invention relates to the various parts of inbred G06-NP2598 including culturable cells. This invention also relates to methods for introducing transgenic transgenes into inbred corn line G06-NP2598 and plants produced by said methods. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of cleaning contaminated water by charging electrical energy to the water in lakes, rivers, marshes or waste water reservoirs in factory sites, and an apparatus therefor.
The term "cleaning" in this specification is defined as decrease of oxidation-reduction potential (ORP), turbidity, smell, chemical oxygen demand (COD), phosphate concentration as well as increase in amount of dissolved oxygen in the water.
2. Related Art
Nowadays water in lakes, rivers and others has been contaminated with waste from general homes, factories, golf links and other sources to cause a serious public pollution.
Hitherto, an aeration treatment has been well known for cleaning the water in lakes and others, which has been widely employed for treating sewage. The aeration treatment is effected by blowing fresh air into contaminated water and/or sucking-up contaminated water in depth layer to expose the same to atmospheric air.
With recourse to such aeration treatment, however, an economically inhibited huge installation would be required for cleaning of water in lakes or marshes, and such mechanical water cleaning would be limited to relatively small areas, and the treatment of whole water in lakes or marshes would be almost impossible. The degree of contamination is determined in terms of turbidity, offensive smell, content of dissolved oxygen, chemical oxygen demand, phosphate concentration and other factors. The mechanical water cleaning can improve the quality of water in terms of selected items only.
In contrast to such mechanical water cleaning, an electrical water treatment is found to be useful in treating a relatively small amount of water, for instance for the purpose of improving quality of drinking water such as city water, well water and the like, but conventional electrical water cleaning methods and apparatuses are practically useless in treating a lot of badly contaminated water in lakes and others. Therefore, there has been an ever increasing demand on practical water cleaning method and apparatus to be applied to contaminated water in lakes and others for improving human life environment.
SUMMARY OF THE INVENTION
An object of the invention is to provide an electrical method which is capable of cleaning a lot of contaminated water in lakes, marshes, rivers and others without causing any adverse effect to aquatic animals and plants, requiring a low electric power.
Another object of the invention is to provide an apparatus for carrying out the method, which is simple in structure, and can be constructed and maintained with reasonable cost.
The present invention is based on the finding that contaminated water in lakes and others can be cleaned with good efficiency by electrically reducing oxidation-reduction potential of the water to be treated.
According to the invention, the first object can be attained by a method for cleaning contaminated water, which comprises the steps of arranging with a distance a pair of voltage application electrodes in the water to be treated, the electrodes being made of a material of relatively high electrolysis capability; placing at least one grounding electrode in the vicinity of said voltage application electrodes in the water; and applying an alternating current voltage relatively high frequency to the voltage application electrodes, thereby reducing oxidation-reduction potential of the water.
The high frequency alternating current voltage may be produced by converting direct current voltage from a direct current voltage source into the same, and in this case, a portable battery may be used as the direct current voltage source, whereby the method according to the invention can be carried out in any place, even if at the place where no commercial electricity is available.
When a pair of grounding electrodes are arranged in the water and one of them is alternatively connected to the earth with a relatively low cycle, deposition of foreign substances on the grounding electrodes can be restrained, whereby it keeps effectiveness over extended period of time.
A water cleaning apparatus according to the invention comprises a floatable casing having a hollow body and a lid; a flat electrode set secured on side wall of the casing and comprising a pair of voltage application electrodes made of relatively high electrolysis capability material arranged laterally side by side, and a pair of flat grounding electrodes arranged oppositely to the voltage application electrodes at equi-distances from the opposing grounding electrodes; and a control box accommodated in the casing, electrically connected to the electrode set through wirings, and comprising a first and second high-frequency switching means connected to a direct current voltage source via an associated variable resistor for converting the direct current voltage to alternating current voltage of relatively high frequency and for applying the so converted alternating current voltage to the voltage application electrodes, a high-frequency switching command circuit having a flip-flop circuit to give high-frequency switching command signals to the first and second high-frequency switching means via an associated resistor, and a high-frequency oscillator to give high-frequency signals to the high-frequency switching command circuit.
The flat electrode set may be secured on each of four side walls of the floatable casing. An upper flange of the casing body has an edge area extending outwardly and downwardly, which is useful to prevent entrance of water into an inner space of the hollow body, conjointly with the lid with circumferential area having a form corresponding to that of the flange of floatable casing.
When an alternating current voltage is applied to the pair of voltage application electrodes submerged in the water to be treated such as a lake, marsh, river, factory waste reservoir or the like, value of oxidation-reduction potential of water shall be reduced to about -600 mV in a relatively short period of time. Almost all organic materials in the water are decomposed into gas, and the remainder agglomerates to cause precipitation. The voltage application electrodes are liable to be heated by application of alternating current voltage thereto to raise the temperature of the surrounding water, thereby causing a convection of water near the electrodes. In case that the water temperature is below 15° C., value of the oxidation-reduction potential shows little or no decrease. Since the temperature of the water surrounding the electrodes rises as referred to, however, however, decrease of the oxidation-reduction potential of water can be recognized, even if the water temperature is below 15° C.
An experience, wherein city water colored with a dye-stuff and having oxidation-reduction potential of 500 mV was treated as referred to above, showed that the water was discolored, when the oxidation-reduction potential decreased near the value of -600 mV.
There is almost no reliable means to verify what phenomena have caused on the water, for instance in water molecules, by applying high-frequency alternating current voltage thereto, but in any event, the results of water cleaning can be determined in terms of turbidity, offensive smell, content of dissolved oxygen, chemical oxygen demand, phosphate concentration and other factors. Particularly, the degree of water quality can be estimated in terms of the value of oxidation-reduction potential. The contaminated water can be cleaned with decrease of its oxidation-reduction potential.
When the apparatus according to the invention is put in operation, the high-frequency switching command circuit responds to high-frequency signals from the high-frequency oscillator to provide switching command signals to the first and second high-frequency switching means, thereby permitting these switching means to close and open alternately so that the direct current voltage from the direct current voltage source may be converted to the high-frequency alternating current voltage, which is applied to the pair of voltage application electrodes, alternately.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical section of a water cleaning apparatus according to the invention;
FIG. 2 is an exploded perspective view of a electrode set used for the apparatus;
FIG. 3 is a vertical section of the electrode set;
FIG. 4 is an electric circuit for the apparatus;
FIG. 5 is a wave form of high-frequency alternating current voltage to be applied to the voltage application electrodes of the apparatus; and
FIG. 6 is a wave form of direct current voltage flowing through the grounding electrodes of the apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a water cleaning apparatus according to the invention comprises a box-like casing 1 floatable on water P, flat electrode sets 2, which are secured on the outer surface of the four side walls of the casing 1, and a control box 3 accommodated in the casing 1.
The floatable casing 1 is made of a reinforced synthetic resin material, and is composed of a box-like hollow body 1a and a lid 1b for closing upper open end of the body. A circumferential flange at upper open end of the body 1a is bent outwardly and downwardly to form a circumferential overhanging edge 1c to prevent entrance of water into the inner space of body, and a circumferential edge of lid 1b is bent inwardly so as to be complementary with the overhanging edge 1c of body 1.
As seen from FIGS. 2 and 3, the electrode set 2 comprises a pair of grounding electrodes 21, 21 of stainless-steel place and arranged oppositely, a pair of flat zinc voltage application electrodes 22, 22 arranged laterally side by side at the equi-distances from each grounding electrode, and a pal, of perforated protection plates 23, 23 placed on the outside of each grounding electrode 21. All electrodes 21, 22 and protection plates 23 are assembled by connecting rods 24 made of electric insulation material and passing through apertures 21a, 22a and 23a of the electrodes 21, 22 and protection plates 23, and the grounding electrodes 21 and the voltage application electrodes 22 are separated by tubular spacers 25 made of electrical insulation material. For instance, the distance between the opposing grounding electrodes is set by about 80 mm, and that between the voltage application electrodes 22, 22 is set by about 30 mm laterally from each other. The perforated protection plate 23 was subjected to anti-rusting treatment. In this embodiment, the zinc plates were employed for the voltage application electrodes, but another plate of lithium oxide, magnesium alloy, copper, iron, stainless-steel or the like of relatively high electrolysis capability may be used.
Each electrode 21 or 22 is connected to a titanium rod 26 which passes through an aperture (not shown) formed in the side wall of the body 1a to be connected to an electric circuit (FIG. 4) accommodated in the control box 3.
FIG. 4 shows the electric circuit arranged in the control box 3. As shown, first and second high-frequency switching means 32A and 32B are connected between an exterior direct current voltage source 4 (50 V) and the voltage application electrodes 22, 22 via a variable resistor 31 for converting direct current voltage from the voltage source to alternating current voltage to be applied to the voltage application electrodes 22, 22 alternately. Each switching means 32A or 32B is composed of transistors 33A, 34A or 33B, 34B. A capacitor 35 is connected between voltage application electrodes 22. 22.
To the first and second high-frequency switching means 32A and 32B, a common high-frequency switching command circuit 36 is connected through associated resistor 37A or 37B, which circuit comprises a flip-flop circuit to give high-frequency switching command signals to the first and second high-frequency switching means 32A and 32B. A high-frequency oscillator 38 is connected to the high-frequency switching command circuit 36 for providing signals of 60 KHz thereto.
The first and second low-frequency switching means 39A and 39B are connected to the grounding electrodes 21, 21 to allow these electrodes to be grounded alternately at a relatively low cycle. A low-frequency switching command circuit 40 is connected to these low-frequency switching means 39A and 39B via associated resistors 41A, 41B. The low-frequency switching command circuit 40 is connected to the high-frequency oscillator 38, so that the high-frequency signal from the oscillator 38 shall be divided for instance by 1/2 14 for applying the so divided signal to the low-frequency switching means 39A and 39B.
Resistors 42A and 42B are connected to the low-frequency switching means 39A, 39B respectively, to connect its collector to plus side of the direct current voltage source to keep the grounding electrodes 21, 21 at positive potential, when these low-frequency switching means 39A, 39B are turned off.
In use, the box-like floatable casings 1 as many as required for the purpose are anchored at suitable places in a lake or the like, and associated switches are turned on. For example, each apparatus with four electrode sets (see FIGS. 1 and 2) has an ability for cleaning contaminated water of about 1 ton/day with consumption of 600 watts. Accordingly, the number of required apparatuses can be determined for performing the cleaning the in a lake or the like.
In operation, when associated switches are turned on, the high-frequency oscillator 38 is put in operation, directing high-frequency signals to the high-frequency switching command circuit 36 in the form of flip-flop circuit, and then the high-frequency switching command circuit 36 provides high-frequency switching command signals to the first and second high-frequency switching means 32A and 32B alternately, thus allowing these high-frequency switching means 32A and 32B to turn on and off at high frequency. The resulting high-frequency alternating current voltage is applied to voltage application electrodes 22, 22. FIG. 5 shows a wave form of the alternating current voltage appearing between voltage application electrodes 22, 22. The wave height can be controlled by adjusting the variable resistor 31. FIG. 6 shows a wave form of the direct current voltage flowing between the voltage application electrodes 22, 22 and grounding electrodes 21, 21 alternately.
After determining the direction of water circulation in a lake or the like, the floatable water cleaning apparatuses may be advantageously anchored at selected upstream places to allow water to pass therethrough. For cleaning of stagnant contaminated water for instance in ditches, the apparatuses may be moved place to place at a suitable time interval.
Experiment of water cleaning according to the present invention was made with a single electrode set (see FIG. 2) put in contaminated water.
Two portable containers were filled with badly contaminated water (40 liters), which was taken from the Tega-numa (Tega marsh) in Chiba-ken, Japan, particularly around a boat harbor thereof. The water was put in a plastic reservoir in a laboratory. Table 1 shows how the oxidation-reduction potential (ORP) of the water changed with the lapse of time, and how bad smell and visual appearance were improved.
TABLE 1______________________________________Time ORP (mV) Smell Visual appearance______________________________________untreated 330 fairly bad5 min. 220 detectable suspended organic matters can be visually observed10 min. -346 hardly precipitate of organic and detectable inorganic matters is noted15 min. -600 almost no amount of precipitate bad smell increased18 hours. -300 no smell as clear as city waterafter (thickness of precipitate:treatment about 7 mm)______________________________________
As seen from Table 1, the value of ORP decreases, as the water becomes clean-up. It means the value of ORP can be made as an index showing a degree of water cleaning.
Next, measurement results of different items on the water which was left 18 hours after 15 minute-long water cleaning operation according to the present invention are shown in following Table 2.
TABLE 2______________________________________Items Pre-treatment Post-treatment Notes______________________________________water temp. 18° C. 9° C.turbidity 25 2 measured by(degree) turbidity gauge PC-06, Kyoto Denshi Kogyosmell corrupted no smell algae-like smellelectric 340 231 Yokogawa,conductivity SC82 Typedissolved O.sub.2 9.1 11.75pH 8.786 7.6ORP 300 mV -300 mV Toko Kagaku Kenkyusho, TRX-90 TypeCOD 50 ppm 10 ppm Central Kagaku HC-407phosphate 0.9 ppm 0.05 ppm Kyoritsu Kagaku Kenkyusho, F-Type______________________________________
As may be understood from the above, the water cleaning method according to the invention permits an effective, economical treatment of lake, marsh or the like contaminated water without requiring a huge installation. The water cleaning apparatus according to the invention permits use of batteries, and therefore, it can be carried out and used everywhere in the field. The apparatus can be used for an extended period of time by alternately connecting its grounding electrodes to earth at a relatively low cycle, thereby preventing deposition of foreign substances thereon. The apparatus prevents invasion of water by the overhanging edge in the circumferential flange at upper open end of the hollow body, which open end is covered with the lid, so that it can be used in wavy places. | There are provided a method and apparatus for cleaning contaminated water, for instance in lakes, marshes, rivers and waste water reservoirs in factory site. A set of fiat electrodes is immersed in the water, which electrode set includes a pair of voltage application electrodes made of relatively high electrolysis capability material and a grounding electrode placed in the vicinity of the voltage application electrode. An alternating current voltage of relatively high frequency is applied to the pair of voltage applying electrodes to give an electric power to the water. A degree of quality of resulting water is determined as an index a measured value of oxidation-reduction potential of the water. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S. application Ser. No. 13/838,747, filed Mar. 15, 2013, and entitled, “Method and Device For Analyzing Resonance.” The entire contents of which are hereby incorporated by reference.
FIELD OF THE TECHNOLOGY
[0002] The present invention relates to a method and device for analyzing resonance in musical instruments, automotive vehicles, or other structures.
BACKGROUND
[0003] In physics, resonance is the tendency of a system to oscillate with high amplitude when excited by energy at a certain frequency. This frequency is known as the system's natural frequency of vibration or resonant frequency. A resonant object, whether mechanical, acoustic, or electrical, will probably have more than one resonant frequency (especially harmonics of the strongest resonance). It will be easy to vibrate at those frequencies, and more difficult to vibrate at other frequencies. The resonant object will “pick out” its resonant frequency from a complex excitation, such as an impulse or a wideband noise excitation. In effect, it is filtering out all frequencies other than its resonance. Mechanical resonance is the tendency of a mechanical system to absorb more energy when the frequency of its oscillations matches the system's natural frequency of vibration (its resonant frequency) than it does at other frequencies.
[0004] When playing a musical instrument, such as a violoncello (commonly referred to as the cello), the cellist will choose which string or strings to play by depressing the string or strings on a fingerboard while bowing in techniques such as standard bowing, double stops, collegno, spiccato or staccato or by plucking using pizzicato. A difficulty that arises when performing using these various playing techniques on the cello is that during play, mechanical resonance may occur in strings and/or the body of the instrument. Such mechanical resonance causes undesired sound waves hereinafter referred to as wolf tone which may be detrimental to the sound during the performance of the cellist.
[0005] In addition, resonance may be detrimental in other acoustic, mechanical or electrical devices.
SUMMARY
[0006] A first general aspect of the invention provides a device for analyzing and compensating for instability and surface tension due to resonance of vibrations of a material, said device comprising: a microprocessor; a sensor, to measure vibrations due to resonance of a surface of said material at a frequency, said sensor having an output in electrical communication with the microprocessor when vibrations are present at the measured frequency; a tensioner for adjusting surface tension of the measured surface to reduce resonance, wherein said tensioner adjusts tension when said microprocessor determines resonance as sensed by said sensor.
[0007] A second general aspect of the invention provides a device for analyzing and correcting undesired resonance comprising: a power source; a microprocessor electrically connected to the power source; a sensor having an output, wherein the sensor is electrically connected to the microprocessor, which receives the output from the sensor, wherein the microprocessor generates a result; and a frequency generator, wherein the generator is determined by the microprocessor and compensates for the unwanted resonance.
[0008] A third general aspect of the invention provides a method for analyzing and correcting vibrations comprising: providing a sensor for detecting vibrations; providing a feedback loop for gathering sensed vibrations; providing a signal generator to augment the vibration; sampling the augmented vibration with the sensor; and analyzing the augmented vibration detected by the sensor with a microprocessor to determine deviance from an ideal vibration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 shows the components of a device for sensing and analyzing both environmental factors and vibrations in accordance with the present invention;
[0010] FIG. 2 shows the position where at least one substrate layer may be attached below the bass F-hole inside the instrument and also where a mute device may be attached to the short section of the strings in accordance with the present invention.
[0011] FIG. 3 shows a cross sectional view of two substrate layers attached on the inside of the instrument below the bass F-hole in accordance with the present invention.
[0012] FIG. 4 shows a tensioner or compressive device attached to the back side of a stringed instrument in accordance with the present invention.
[0013] FIG. 5 shows a tensioner or compressive device in communication with a sensing and analyzing device, said tensioner device and said sensing device comprising one hybrid device in accordance with the present invention.
[0014] FIG. 6 shows a device for sensing and analyzing environmental factors and vibrations including a wave generating device that can communicate via a feedback loop with a microprocessor in accordance with the present invention.
[0015] FIG. 7 shows a device for sensing and analyzing environmental factors and vibrations and the various positions onto a vehicle in which at least one device is located.
[0016] FIG. 8 shows a device for analyzing and correcting unwanted vibrations in accordance with the present invention.
DETAILED DESCRIPTION
[0017] The invention diagnoses and addresses problems associated with resonance in acoustic, mechanical or electrical devices and may address deficiencies in their underlying structures. Vibrations, such as sound, travel in waves and have a certain frequency. The normal unit that a frequency is measured in is hertz, which is one cycle per second. Musical frequencies are between 20 and 20,000 hertz, which coincides with what is considered the normal range of human hearing. Waves also have intensity or level called amplitude, which is a measure of the strength of the wave. The problems with unwanted vibrations and harmonics in all objects are important, but these problems are especially important in the field of acoustics.
[0018] There exists in the field of acoustics, specifically in the field of stringed instruments, a specific phenomenon known as the wolf tone that can not be corrected by mere “tuning” in the conventional sense on a string instrument. A wolf tone is defined as a type of destructive chord with a wildly fluctuating and uncontrollable tone that deviates in desired frequency or loudness from a given note on a major scale.
[0019] The invention comprises a device 100 that is useful for both analyzing and compensating for instability and surface tension in all objects, including examples of either the class of instruments that may be plagued by the wolf tone or certain automobiles that may require automotive NVH screening.
[0020] The device 100 may be used, for example, on an instrument in the class of those instruments that may be plagued by the wolf tone, including but not limited to the: violin, guitar, cello, base, banjo, harp, harpsichord, piano, viola, mandolin and ukulele. The device 100 examines the resonance of vibrations of a material and, if required, addresses the vibrations with several different methods by adjusting either the surface tension or other another unsatisfactory condition. The problem with a wolf tone is that in some circumstances and conditions it is present, and in other conditions it is absent. The wolf tone generally occurs, for example, on the violin between the E and F pitch. The wolf tone may not occur with what seems like regularity because it may be affected by environmental factors such as temperature or humidity, as well as structural deficiencies of the body of the instrument.
[0021] When a string on an instrument is plucked or bowed, waves travel back and forth through the medium being reflected at each fixed end. Waves of certain magnitudes can survive on the medium and all others are canceled out through either dampening or interaction with other waves. These waves are called the harmonics of the vibration and will not cancel each other out as they reflect back upon themselves. The harmonics are considered standing waves because they produce patterns which do not move. On a medium such as a violin string, several harmonically related standing wave patterns are possible. It is important to understand that for any one given medium fixed at each end only certain sized waves can stand.
[0022] When examining the acoustic waves of a stringed instrument, the first pattern has the longest wavelength and is called the first harmonic or the fundamental. The second harmonic has half the wavelength and twice the frequency of the first harmonic and is called the first overtone. The third harmonic has one third the wavelength and three times the frequency when compared to the first harmonic and is called the second overtone. The instrument having a structural instability that causes the interaction of these harmonics in various unexpected and undesirable resonance combinations is also referred to as the wolf tone. The device 100 can identify and isolate the structural elements that are causing the unexpected and undesirable resonance combinations, i.e. causing a wolf tone.
[0023] The higher harmonics almost always have maximum amplitudes much less than the fundamental, or first, harmonic. It is the fundamental frequency that determines the note that humans hear and, therefore, it should be considered the most important harmonic to observe first in determining the existence of destructive chords in an instrument. It is the upper harmonic structure that determines the timber of the instrument that is analyzed by the invention. However, the timber of the instrument may be deficient in some manner and cause a distortion in the fundamental frequency.
[0024] Referring to FIG. 1 , the components of a device 100 for sensing and analyzing both environmental factors and vibrations are shown in accordance with the present invention. The device 100 measures the conditions that are present during unwanted harmonics. The device 100 may create a feedback loop to constantly monitor the conditions present over a period of sampled time when an unwanted harmonic is present. The device 100 may comprise a microprocessor 101 connected to sensors 120 that monitor any direct correlation of an environmental condition to a harmonic or resonation problem. Microprocessor 101 may be a microprocessor that is available commercially in many different forms. One such example is a simple microprocessor, such as an 8 bit circuit. Another such example includes more advanced based circuits, like those commonly associated with a desktop computer.
[0025] The initial testing may measure with a plurality of sensors 120 many parameters such as wave frequency sensor 115 , wave amplitude sensor 116 , temperature sensor 117 , moisture sensor 118 , surface tension sensor 119 or additional other desired parameters to help pinpoint the conditions at which the unwanted harmonic is caused in a particular instrument or structure. The sensors 120 may monitor and pinpoint a correlation to the unwanted harmonic divergence from the ideal tone to one or more monitorable conditions over a period of time.
[0026] The surface tension of the body of an instrument may be measured simply by pointing the surface tension sensor 119 of the device 100 at the body of an instrument 201 , emitting a frequency wave and analyzing the feedback signal. This works on the principle that when a tensioned member anchored at two points is struck, it will vibrate at a frequency related to its tensile stress. The tensile stress of the material of the body of an instrument is a commonly known phenomenon. The reflected wave could also be compared to a reflected wave of a similar type and make of instrument not known to be effected by a wolf tone. For example, during the testing for the wolf tone, the test may indicate that the wolf tone is created by either too great or too little humidity. Accordingly, the solution would be to store the resonating object under certain conditions of humidity. Further, the moisture sensor 118 may have an alarm triggered when the acceptable conditions, either high or low, are exceeded. Moisture sensor 118 may be comprised of various different sensors to allow it to measure moisture levels such as a sensor that measures the change in conductance or resistance of a material by using infrared light or a laser.
[0027] Regardless of which sensor 115 , 116 , 117 , 118 or 119 is selected to measure an unwanted harmonic, each sensor may be comprised of various individual sensors, and may be calibrated in relation to occurrence of the particular unwanted harmonic under particular measurable environmental condition, such as moisture levels, and thereby the particular unwanted harmonic may be associated with the particular environmental condition. Additionally, sensors 120 may have outputs 125 , 126 , 127 , 128 , 129 that are in communication with microprocessor 101 .
[0028] Wave frequency sensor 115 and wave amplitude sensor 116 may be used to measure directly the frequency and amplitude of the vibrations of a surface, or strings 202 of instrument 201 . Further, sensors 115 , 116 have outputs 125 , 126 in electrical communication with the microprocessor 101 when vibrations are present.
[0029] For example, the frequency measured could be that of the ideal frequency of a certain component of a resonating object, where an unwanted harmonic had previously occurred in a spectrum broader than the limit of human hearing. Once the surface conditions are known, a specific and tailored fix for correction of an unwanted harmonic can be prepared for the resonating object.
[0030] For example, a wolf tone may be caused by the coupled oscillation of the string and body of a stringed instrument. The stringed instrument has two resonances; one resonance is from the string while the other is from the body of the instrument. For a coupled oscillation process to occur, the two resonances need to be very near equal in frequency, also known as a Helmholtz oscillation. There are two types of Helmholtz oscillations involved, one by bowing the instrument 201 and the other the ocarina or bottle effect of the main body of the instrument 201 . A wolf tone may disrupt the normal bowing pattern of the instrument 201 and may excite the air resonance within, making the bridge 250 of the instrument 201 excessively yield. The yielding of the bridge 250 may prevent the strings 202 from properly resonating.
[0031] In other situations, the wave may oscillate forming a shifting of energy, which results in a warbling sound due to the beat frequency between the resonant frequencies of the body of the instrument 201 and the strings 202 , respectively. In situations where the resonances are active, it may cause the production of a “growly” tone. If one of the resonances is inaudible, the instrument 201 can accumulate energy and then release it in one burst, like a sheep blat.
[0032] Wolf tones may be affected by changes in humidity, because sound travels faster in moist air which, in turn, causes the resonant frequencies of the air go up. The wood resonances may drop as the wood gets heavier and less stiff with changes in the humidity. A wolf tone can become more entrenched the more the instrument 201 is played. Additionally, a wolf tone may vanish if the instrument 201 is left to sit for long periods of time, unused. The concept behind instrument idleness allows the wood to stiffen back up again. Leaving an instrument 201 idle is largely undesirable, as during which time it is idle it cannot be played. Further, leaving an instrument 201 idle will not fix every problem. The device 100 addresses the problem without resorting to less effective and desirable alternative—lengthy periods of instrument 201 idleness.
[0033] In certain instances, once the wolf tone is examined it may be prevented by mounting a mute element 140 on the short section of the strings 202 located below the bridge 250 of the instrument. As shown in FIG. 2 , the mute element 140 may be attached to one or all of the strings 202 . At this location, the mute element 140 may aid by damping the offending mode of resonance by forcing it to sound in that section of the string only. The mute element 140 may function by adding to the mass of the string anchor 203 in the vicinity of the offending strings 202 . The mute element 140 has the effect of raising the impedance of the bridge 250 back to an acceptable level. The mute element 140 , when attached to the instrument 201 , may help to stiffen the sound board 204 so that it may not resonate as dramatically.
[0034] Another embodiment of the invention may comprise the attachment of a substrate layer 150 to the inside of the top plate just below the bass F-hole 155 , as shown in FIG. 2 and FIG. 3 . The substrate layer 150 having a first thickness 151 and first stiffness can be removably affixed and then analyzed with the device 100 . If the conditions for the wolf tone are still determined to be present after testing with the device 100 , then a second substrate layer 153 having a second thickness 154 and a second stiffness may be substituted and retested, or additionally applied and retested.
[0035] In another embodiment, a corrective response to a location where the instrument has been determined to have a wolf tone can be squeezed laterally by a compressive device 160 , as shown in FIG. 4 . Compressive device 160 may be placed on the bottom side of instrument 201 . This compressive device 160 may act to dampen the vibration of the wood of the body by altering very slightly the shape and volume of the air cavity inside the body, thereby causing the alteration of the resonant frequencies.
[0036] In one embodiment, the manner to address this deficiency in the timber of the instrument or measured surface may be by utilizing a tensioner 160 for adjusting surface tension of the measured surface. As discussed, the tension of a surface can be determined based on emitting a wave and comparing the emitted wave to the reflected wave, while basing the comparison on the known properties of the material. The tensioner 160 may be moved or adjusted to reduce undesirable vibrations on the measured surface. The device may then check for unwanted wolf tones in a feedback loop 130 so that tensioner 160 may properly adjust tension, as shown in FIG. 5 . When the microprocessor 101 determines destructive waves or problematic chords as sensed by said sensors 120 are still present, then the tension may be further changed.
[0037] The tensioner 160 may be a length adjustable wire having at least two mounting points on the surface, wherein the tension of the wire controls the tension of the surface, thus changing the frequencies of the surface measured. For example, the surface could either be internal or external to the body of an instrument 201 , or on the front or back face of an instrument 201 . The length adjustable wire 160 could be mounted with an adhesive or screws. When operating with the surface of a guitar or cello, the surface tensioner 160 could be placed in the back exterior section of the instrument so as to not interfere with the reflected acoustics inside the body.
[0038] As shown in FIG. 5 , the tensioner or compressive device 160 may be in communication with device 100 through a feedback loop 130 . When sensors 120 of device 100 determine that there is a wolf tone, the microprocessor 101 of device 100 may communicate to cause compressive or tensioner device 160 to compress or create tension in instrument 201 . In another embodiment, device 100 is included within compressive device 160 to comprise a single hybrid device 165 . In this embodiment, a single device 165 may monitor and fix the wolf tone.
[0039] In another embodiment, the surface tension sensor 119 may also be a piezoelectric film having a plurality of layers, wherein the intensity of the electrical signal determines the tension of the surface in addition to the acoustic chord itself being measured. The method is based on the direct piezoelectric effect; vis. charge liberated following stress application. The compressive stresses imparted across the films top and bottom surfaces produce a charge to be liberated that is measured using charge amplifiers. The piezoelectric effect can also be used to create tension in a surface with a piezoelectric pusher for use as a tensioning member 160 . When an electric charge is supplied to a piezoelectric pusher 160 , it causes a change in length and thus tension in the surface of the instrument or object containing the piezoelectric pusher.
[0040] Once the tension of the surface is determined to be too low, which causes unwanted harmonics (confirmed by device 100 ), then the surface tension may be increased to compensate. In another embodiment, a tensioner 160 may be an additional surface layer having a greater rigidity that may be affixed to the original surface of the musical instrument in order to create a new surface tension. Application of this layer may cause an increase in surface tension sufficient to remove an unwanted wolf tone. One method may be chemically bonding a polymer surface layer to the surface material which is capable of migration into the weak pores of a substrate having insufficient rigidity. When the surface is coated with an epoxy, polyurethane, or cyanoacrylate, and allowed to fully cure, it causes increased surface tension. The layer may also be a section of wood or other material that is then either laminated or bonded with adhesives to the original surface. The adhesives may be permanent and cross-linked as discussed above or could be thermoplastic and bonded through heat or through chain-end migration into surface irregularities of the instrument.
[0041] Other examples are mechanical in nature, such as when surfaces are stretched, bonded, and then are returned to the original surface dimensions through molecular relaxation or internal forces. For example, a plastic can be mechanically stressed within its tensile limits when it is below its Tg and then upon heating, the plastic relaxes and attempts to return to its original dimensions. The plastics that are most effective may have high amounts of crystallinity, where the crystallinity in effect acts as internal coils that retract upon relaxation induced during heating.
[0042] In another embodiment, the tensioner 160 may comprise at least one force protruding implement configured to engage the surface of the material such that force applied at the fulcrum point tensions the surface. The force protruding element may be a rigid bar or some other implement that will multiply the force on a surface, creating tension when applied to the fulcrum point.
[0043] The wolf tone may be harmonic and, therefore, may be addressed dynamically with the introduction of a corrective wave. A wave usually does not reflect when it strikes other waves, but rather, it combines with other waves into one wave. In a constructive interference situation, the amplitudes of two waves have the same sign (both either positive or negative) and they will add together to form a wave with a larger amplitude. In a destructive interference situation, the two amplitudes have opposite signs and they will subtract to form a combined wave with lower amplitude. Constructive interference will make a sound louder while destructive interference will make a sound quieter.
[0044] In a further embodiment as shown in FIG. 6 , the device 100 may further consist of a feedback loop 135 between a wave generating device 136 and microprocessor 101 that may provide a continuous monitoring and correction of a wolf tone by providing a frequency that will cancel out the unwanted secondary harmonics. Wave generating device 136 may add an additional wave comprising the proper shape and size (frequency and amplitude) to nullify the wolf tone's effect while still being present. When two waves are added together having different frequencies, the crests and troughs will not generally add up the same way with each new wave because one is moving faster than the other. Accordingly, wave generating device 136 may mimic and cancel out the wolf tone part of the waves by interfering destructively.
[0045] The material analyzed may be a string of a musical instrument, as previously discussed, or the material may also be surfaces of other structures, including, but not limited to: buildings, bridges, or even automobile members. All surfaces have an ideal tension to perform as required with the disclosed device. For example, the frame of a car can either be too soft or too stiff thus contributing too unwanted road noise.
[0046] That is, the device 100 may be utilized in analyzing and correcting unwanted vibrations of an automotive vehicle. Although certain vibrations in a vehicle are common during operation, certain vibrations may be indicative of, as referred to in the automotive industry, “automotive noise, vibration, and harshness” (hereinafter ‘automotive NVH’). Automotive NVH is a symptomatic vibration that may be present in a various automotive systems, indicative of vehicle performance problems. As such, these respective vibrations comprise respective resonances, each of which may be analyzed in efforts to diagnose and correct automotive NVH.
[0047] The phenomenon of automotive NVH not only refers to cars, SUVs, vans, and trucks, but may also apply to motorcycles, four-wheelers, or even commercial trailer trucks. Automotive NVH may be related to various issues concerning the design, manufacture, material, or performance of vehicles. Additionally, automotive NVH may be a symptom of widely varying automotive issues, including, but not limited to such areas as: engine mounts, shock absorbers, brake systems, suspensions, tire noise, powertrain torsional systems, interior acoustics, body/frame mounting, door seals, induction and exhaust systems, belt vibration, transmission rattle, piston slap, or alternators.
[0048] Specifically herein, automotive NVH refers to interior acoustics, body/frame mounting, or even door seals. Issues with respect to interior acoustics, body/frame mounting, or door seals typically present ugly noise problems that detract from the quality of the vehicle, irritating the vehicle driver and passengers. Therefore, it is desirable to create a method and device for analyzing the resonance caused by the vibrations of the vehicle as it is affected by the impact of the wind, road, or other environmental surroundings during operation. Further, it is desirable to diagnose any atypical noises or sounds produced by the vehicle and correct any problems attributed to automotive NVH.
[0049] Many of the parts within the various systems of an automotive vehicle typically vibrate during operation, creating a resonance. However, automotive NVH is a symptomatic noise, rattle, vibration, squeak, or perceived harshness in operation that is distinctive from the ordinary and typical operational noises and vibrations. Therefore, the automotive NVH vibrations create resonances are independent from the traditional operating performance resonances which may be detected, measured, or analyzed.
[0050] As shown in FIG. 7 , the device 100 (described in reference to FIG. 1 ) may be removably attached to a surface, which is a location on an exterior or interior position of a vehicle 301 . Additionally, as previously discussed, the surface may be, but is not limited to: an portion of interior surface, a portion of the vehicle body, a portion of the frame mounts, a door seal, or any part of the vehicle that is proximally located to the exterior environment of the vehicle 301 . FIG. 7 illustrates the various surfaces onto which the device 100 may be removably attached. Further, the device 100 may be used while the vehicle is running or in motion. As shown in FIG. 7 , the device 100 may be used on various surfaces of vehicle 301 to evaluate, measure, and analyze vibrations and resonances. For example, device 100 a may be placed in proximity to the various contact points where the body of the vehicle 301 is mounted to the vehicle frame. A further example provides that device 100 b may be placed in close in proximity to a door seal of the vehicle 301 . Also, the device 100 c may be placed, for example, on a section of the body to detect, measure, and analyze road noise or vibration with other vehicle parts. Additional examples include a device 100 placed on the interior to measure and analyze interior acoustics, a device 100 placed on the undercarriage to measure and analyze road noise, or a device 100 placed on contact points of the vehicle, where two different vehicle parts touch.
[0051] The device 100 operates in the same manner as previously discussed with respect to FIG. 1 and in discussion relevant to FIG. 1 applying to the alternate embodiment, the instrument 201 . The only differing factor from the previous discussion is that the device measures and analyzes automotive NVH in a vehicle in lieu of a wolf tone in an instrument. Further, once the device 100 has diagnosed a level of automotive NVH, it may be corrected, as previously discussed, by using a substrate layer 150 or a compressive device (also referred to as a tensioner) 160 to correct the automotive NVH.
[0052] Another embodiment comprises a device 200 for analyzing and correcting undesired vibrations comprising a power source 210 , as shown in FIG. 8 . The power source 210 may be either direct current or alternating current and it may be from batteries, generator, wall outlet, battery or any other known power generating or storing device.
[0053] A microprocessor 220 may be electrically connected to the power source 210 . Also a sensor 230 having an output 235 , wherein the sensor 230 may be electrically connected to the microprocessor 220 . The sensor 230 should have a resolution that may be capable of receiving waves that would be considered undesirable, at least encompassing the normal hearing range. When the sensor 230 receives a signal within that measured range it may produce an output 235 . The output 235 from the sensor 230 may include information such as magnitude of the signal. The output 235 from the sensor 230 may be sent to the microprocessor 220 , which in turn generates a result.
[0054] A frequency generator 240 may be electrically connected to the microprocessor 220 and may create a feedback loop 250 . The frequency generator 240 may be controlled by the result of the microprocessor 220 and may compensate for the unwanted frequency. The microprocessor 220 may then resample the environment and determine if the frequency generator 240 needs to be re-calibrated to a different frequency to compensate for the undesirable environmental frequencies. The device 200 may include an amplifier 260 in electrical connection with the frequency generator 240 if the magnitude of the frequency generated is not sufficient to counteract the undesirable environmental frequency.
[0055] A method for analyzing and correcting unwanted vibrations such as a wolf tone may be made by providing a sensor for detecting vibrations. If the vibration is unwanted, then it may be addressed by the device. Moreover, analyzing and correcting can be facilitated by providing a feedback loop for gathering sensed vibrations to determine if they are changing over a period of time. Furthermore, analyzing and correcting may include providing a signal generator to augment the vibration to correct any deficiencies in the frequencies. Additionally, analyzing and correcting may include sampling the augmented vibration with the sensor to determine the deviance from the desired vibration. Still further, analyzing and correcting may also include the next step, which may be analyzing the augmented vibration detected by the sensor with a microprocessor in order to determine the deviance from an ideal vibration, then generating a correction signal to correct the deviance in the ideal vibration.
[0056] In addition, the method of analyzing and correcting may include the resampling of the vibration with the sensor to determine if further correction may be required after analyzing the resampled vibration with the microprocessor. Then with the microprocessor determining a deviance in the resampled vibration, the deviance may be measured. The deviation can be addressed by generating a subsequent vibration signal to correct the deviation. When a signal is an additive wave, it may correct points canceled out by unwanted vibration. When the signal is a destructive wave, it may be used to remove the amplitude, change the frequency, or change the energy of the unwanted signal. When the signal is a complementary wave, it does not change the signal frequency, but it may increase the amplitude.
[0057] As an additional example, the frequency measured could be that of the ideal frequency (or ideal frequency threshold) of a certain automotive member, such as an engine mount or a suspension, while the respective vehicle is in operation. Once the ideal threshold frequencies of operation are known, future measurements of non-conforming or otherwise deviating frequencies may perform a diagnostic that may aid in the source identification issues and performance guidelines in the maintenance and repair of such automotive members.
[0058] While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred 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 scope of the invention as defined in the following claims. The claims provide the scope of the coverage of the invention and should not be limited to the specific examples provided herein. | A detection, analysis, and correction of unwanted frequencies is provided. The elimination of a wolf tone may be done through either correction of surface instability or dynamic frequency correction by a signal generator. | 5 |
SUMMARY OF INVENTION
[0001] The present invention relates to sealing films and mats for multi-well plates with adhesive backing present in pattern format, which provides adhesive-free areas that are in contact with the well content where seal films and mats adhere to the plate. This is achieved by exactly matching of pattern adhesive array on the sealing materials with array of multi-well, which is commercially available in 6/12/24/48/96/384/1536 well formats. Furthermore, optimum chemical barrier sealing products in single-layered, multi-layered, or roll format products can be obtained by using fluoropolymeric film materials covered by specific adhesive in desired pattern for diverse sealing applications. Also, tamper evidence sealing films, mats, and laminates with Aluminum foil and others, which are produced by either coating or premixing of leizer effect dye with desired sealing materials, would reveal any discontinuity on sealing protection under UV or visible light. The combination of tamper evidence and pattern adhesive on a single side or both sides of the sealing material provides multi-purpose sealing products which are not commercially available at the present time.
BACKGROUND OF THE INVENTION
[0002] Multi-well plates are used extensively in variety of laboratory and pharmaceutical settings, including but not limited to:
[0003] Experimental assays
[0004] Sorbent assays
[0005] High-throughput screening (HTS)
[0006] Combinatorial chemistry
[0007] Drug discovery
[0008] Drug metabolism
[0009] Liquid chromatography with tandem mass spectrometry (LC-MS-MS)
[0010] Cell culture
[0011] Tissue culture
[0012] PCR
[0013] DNA
[0014] These plates are commercially available in the 6/12/24/48/96/384/1536 well design. The foot print dimensions of these plates remain constant with the only variation in design being the number of the wells per plate. In addition, there are variety of sealing films with adhesive backing commercially available for sealing of multi-well surface for different applications. These sealing films can be heat sealed or adhered to surface of the plate by pressure application. These current methods of sealing multi-well plates with adhesive backing sealing films which mostly consist of Aluminum foil, polyester, Polypropylene and others are available in single-layer, multi-layer or roll form. These current methods of sealing with adhesive backed films have many significant drawbacks including adhesive contact with content of the wells, contamination of needles with adhesive when penetrating through sealing films to access the contents of the wells, limited chemical resistance to many solvent based solutions in the well content including DMSO, leaching of plasticizer in the sealing films by well content, condensation in the well area during thermo-bonding of sealing film to plate. Alternatively, a seal may be achieved by placing flexible rubber mats with raised dimples on the surface of the mat in array which matches exactly the array of the wells. Each dimple is sized and shaped to fit firmly into the wells. This mat design with dimples has limited usage due to the constraint of well size and geometry related to plate design. Specifically mat design with dimples matching the plate would become extremely difficult when mat design requires more than 96 wells per plate. As a further alternative, sealing caps consisting of individual circular cylinder walled caps with piercable lid can be used which would fit into the internal bore of each plate. These caps are time consuming to apply and have limited usage with refinement of well design. It is therefore an objective of the present invention to provide sealing solutions for multi-well plate in single-layer, multi-layer, or roll format in overcoming the above disadvantages.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. A shows a 96-well plate.
[0016] FIG. B shows a sealing film configured to be used with the 96-well plate of FIG. A.
[0017] FIG. C shows a sealing film having adhesive-free areas.
DETAILED DESCRIPTION OF INVENTION
[0018] Multi-well plates are commercially available with 6/12/24/48/96/384/1536 well designs. The foot print dimension of these plates remains constant, with the only variation design being the number of wells per plate. 96 multi-well plate is the one popular standard which comes with 8×12 array of wells. The well's cross-sectional area could be circular, rectangular, or any specific geometry required. FIG. A is schematic of front view area of 96 well plate, with circular 8×12 wells located in specific arrays. Each circle is indicative of the diameter of each well arranged in specific areas with a chanferd corner for this plate which is offered by Griener Company. The purpose of this invention is to duplicate exactly the pattern described in FIG. A, or any other design by first selecting optimum films or mat materials for specific sealing applications, treat candidate materials in order to accept any specific adhesive, and then coat the film and mat materials with adhesive in pattern format which is given as an example in FIG. A. As a result of the above procedure sealing products will be available which are adhesive free on specific target areas of contact to multi-plate well surface. FIG. B is schematic of a sealing film or mat based on the defined procedure. Adhesive-free circles are exactly identical to micro-plate's wells. The rest of the areas including the periphery of the wells provide sealing surfaces between films or mats on multi-well plates. In order to facilitate the matching of adhesive-free areas of sealing films with surface areas of the wells located on the plates extra adhesive-free areas are provided on both sides of sealing products. FIG. C represents this particular design. In addition, the adhesive can be colored without losing its property for additional contrast and alignment purposes. Fluoropolymers and metallized Fluoropolymers offer unique barrier properties against most of organic solvents and chemicals available in the market including but not limited to DMSO, DME, THF, and TFE. Combination of chemical and solvent barrier properties, and low vapor permeability of Fluoropolymers make this material uniquely defined for sealing application for low and high temperature usages. Fluoropolymeric film materials with adhesive in pattern format would provide new sealing products with all the benefits of barrier properties and high temperature stability of mentioned films. Furthermore, elastomeric materials like silicone rubber, butyl rubber, and others are frequently molded in mat form for sealing applications. These elastomeric materials either in single-layer or laminated with Fluoropolymeric film materials are useful sealing solutions for repeated extraction application. Application of adhesive in pattern format to treated elastomeric materials in single or laminated with Fluoropolymers would eliminate the need of dimples in sealing. This in turn would extend the application of elastomeric materials beyond 96 format with ease of application and adhesive-free contact area to well content. There are no commercial sealing products in the market which provide tamper evidence protection. Aluminum seals with central target area exposed are being commercially used for pharmaceutical packaging by sealing rubber stoppers against glass vials by crimping Aluminum seal around their necks. This sealing method provides an open area on the top which provides access to vial content to rubber stopper. The tamper-evidence seals with plastic button protecting the injection site are commercially available through West Company and others. In order to access injection site the plastic button has to be removed manually. Leiser effect is a known phenomenon which is being applied in tamper evidence protection in security field. This effect is being used by adding specialty dye materials to original resin before processing to final film products. Alternatively the mentioned dye could be part of the chemistry which can be laid down as a coating on the surface of seal film materials. The prepared substrate materials based on Leizer effect would reveal the existence of any cuts, holes, or any discontinuity through film thickness, when viewed under UV light. The illuminated seal under UV light provides distinguishable optical contrast around any kind of discontinuity on the seal for tamper evidence application. Lamination of film materials with tamper evidence properties onto the Aluminum foil, or other materials would provide multi layered laminated products with central target area exposed provides alternative sealing products for pharmaceutical packaging. The major advantage of this tamper evidence laminate compared to flip-off technology is related to cost and elimination of manual removal of tamper evident button. This new product with tamper evident sealing film can be punctured directly through the film through central target area exposed in order to access the solution in the vial. This product is auto-clavable as well.
EXAMPLE 1
[0019] 2 mil and 5 mil treated Fluoropolymers, Polypropelyn, Polyester, Barex films, including 20 mil treated EPDM, Silicone Rubber, Butyl Rubber elastomeric materials were used as representatives of different materials for pattern adhesive coating. Water and solvent based acrylic plus UV-curable pressure sensitive adhesives are used for laying down 96/384/1536 pattern formats on the above materials. Furthermore, the above adhesives were dyed with blue, red, and other colors to provide more contrast to pattern adhesive arrays to match with the plate format. Both water and solvent based pressure sensitive adhesives in virgin and dyed state provided cured adhesives with high tack value between 450-700 gram/sq.cm on pattern format. The UV-cured adhesive did not deliver the tack required for this application plus property of adhesives were severely damaged over time. All the sealing films and mats prepared this way adhered to all commercially available multi-well plates regardless of materials, or temperature cycles required for certain applications. Also, there was not any trace of adhesive left on the surface of the plate after removing the sealing film from the plate.
EXAMPLE 2
[0020] The same materials which were covered in example 1 are subjected to heat-activated adhesive in defined pattern format. In this case, water and solvent based heat-activated adhesives in virgin and dyed formula were used for the coating of pattern format. The pattern adhesive sealing films and mats with heat-activated pattern adhesive were laminated to commercial plate with Platinum press which is heated up 300-350° F. under pressure of 20-50 psi. Both water and solvent based heat activated adhesive laminated well to variety of commercial multi-well plates available.
EXAMPLE 3
[0021] There are a variety of top coat materials available commercially. In addition, visible and UV dyes are produced in a variety of chemistry. The solubility of UV or visible dyes in any particular resin or coating is optimized based on solubility limit of dye materials within the desired matrix. Water and solvent based acrylic materials were selected for mixing with visible and UV dyes in order to provide top coat for tamper-evident property. The optimum dissolved weight percent of dyes in acrylic based materials were between 0.5%-1% grams. This formulated top coat can be applied as a continuous or pattern format on treated film materials including but not limited to Fluoropolymers, Polyester, and Polypropylene. Cured acrylic top coat was intentionally cut and punctured with fine needles. The damaged films were illuminated by UV light operating at 370-380 nanometer wave length. The damaged areas were glowing under the imposed light with clear indication of discontinuety. The same coating was applied by mixing laser dye material to base acrylic coating. The damaged area viewed by laser operating at red or green wave length revealed the existence of tampered areas. There are two options for creating seal films with tamper evidence properties: either pattern adhesive and tamper evidence coating are being coated on one side, or tamper evidence(top coat), and pattern adhesive are being applied on the opposite sides of the sealing film. In the first case, heat activated, pressure sensitive adhesive were applied in pattern format on top of the top coat which has already been explained. Upon adhering these sealing films to multi-well plate, there was no sign of degradation on tack and adhesive properties used in providing sealing films with tamper evidence combined with pattern adhesive properties. In the second case, 2 mil thick Fluoropolymers, Ployesters, Polypropylene were treated on both sides. The top acrylic coating mixed with UV dye were applied first on the outside of the films and then cured. The other side of the same films was coated with heat-activated, and some others with water based pressure sensitive adhesives in pattern format. In the second procedure, the sealing film is designed in such a way that the tamper-evidence coating is on one side and pattern adhesive is coated on the other side. This example provides a variety of design routes available to produce sealing films with multiple functionalities.
EXAMPLE 4
[0022] Aluminum foil with desired thickness was coated continuously with heat activated adhesive and then cured. This prepared composite foil then was die-cut with circular die in order to provide open central target area necessary for accessing the vial content. 2 mil Polyester films were treated on one side and continuously coated with tamper evidence acrylic material. Upon lamination of heat activated adhesive side of Aluminum foil with central target area open with the tamper evidence coating side on Polyester film, would provide tamper evidence structure alternative to flip-off technology. These laminates then can be further die cut in order to provide Aluminum shell materials combined with Polyester sealing films equipped with tamper evidence properties. Then there is no need for mechanical removal instead UV inspection of the seal integrity followed by through seal film injection would provide access to the content of the vial. | An adhesive sealing film for a multi-well plate, said sealing film comprising a polymeric film coated on one side with a pattern formed from adhesive, wherein the adhesive pattern does not cover areas of the sealing film that correspond to the wells in said multi-well plate. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of United States Patent Application Ser. No. 723,842, filed Apr. 16, 1985, entitled "Fabric-Engaging Stake" by Ramon Barzana now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to anchors particularly arranged to retain a blanket, beach towel or the like on the sand of a beach and, in particular, an anchor to which a towel, blanket or the like may be secured in a stationary position on a beach without the use of pins, straps or other such mechanical fastening elements.
The purpose of this invention is to provide means for the anchoring of a sheet of fabric material such as a blanket or beach towel, in a substantially stationary position on a beach or the like without a need for permanently attaching elements to the sheet of fabric thereby causing damage to the fabric.
The maintaining of beach blankets in a stable and stationary position while stretched upon the sand of a beach has always been a problem, particularly when the wind is blowing, this being due to the tendency of the edges and corners of a blanket or towel to roll or turn over when subjected to wind or pedestrians stepping on the edges thereof. Thereby, such blankets will frequently become distorted and, in many instances, become embedded in the sand.
With consideration to the above problems, the present invention contemplates use of an anchoring means for the blanket without need of making of holes in the beach blanket.
2. Description of the Prior Art
Prior art in this area generally falls within three main categories. One being a pin which fits within an opening in the item to be secured and is secured to the ground by means of a protruding or extending head portion of the pin. This action is much like that of an ordinary thumb tack. The second class of anchors comprise the use of a stake having a clip attached to the upper end whereby the clip fastens onto an edge or corner of the towel or blanket. The third category comprises various combinations of the first two categories; for example, a headed stake over which the blanket is placed and then held thereto by a resilient clip which stretches to fit over the covered head of the stake and then closes in around the thinner neck of the stake.
None of the prior art devices operate satisfactorily. They do not firmly grasp the blanket; or, they are clumsy to use; or, they contain loose parts which may become lost; or, the resilient components break; or, they tear or permanently disfigure the blanket. There are additional other undesirable features of such prior art anchors. Accordingly, there exists a need for blanket and/or towel anchors which overcome the problems and deficiencies of the prior art.
With the above in mind, my beach towel-engaging or, more generally, fabric-engaging stake may be viewed as an improvement over the art known in this area.
SUMMARY OF THE INVENTION
The invention constitutes a ground-level fabric-engaging stake, comprising a ground-engaging spike having a plurality of earth penetrating vanes having a fabric-engaging upper end which includes a fabric-engaging radius and one or more fabric- engaging slots. There is further provided a ring secured within an opening in the stake which allows the ring to pivot about an edge of the opening. The ring and the pivot means are proportioned with the fabric-engaging radius to lockingly engage the fabric after it has been placed over the radius, and after the ring has been rotated thereby securing the fabric to the stake. The stake is also provided, in another embodiment, with an arcuate slot about which the ring can pivot and thereafter when the ring is rotated about its edge and over the fabric-engaging radius, is pushed downward to lock the ring in position. The fabric-engaging one or more slots in combination with the fabric-engaging radius provides for even more secure attachment of the blanket. A further feature comprising a detent at one end of the arcuate slot provides for further locking of the ring. Through the usage of one of said fabric-engaging stakes at each corner of a beach blanket, stable securement of the blanket to the beach is accomplished.
It is thereby an object of the present invention to provide an anchoring means for securing a blanket in an outstretched position upon a beach in which the anchoring means are independent of the blanket, prior to its engagement with the four corners of the blanket.
Another object of the present invention is to provide a useful structural refinement in the holders of beach towels, beach blankets, and the like which may be effectively employed for the securement of such objects to the ground without damaging the blanket.
A further object of the present invention is to provide an improvement in the structural arrangement of keeper devices adapted for rapid securement and withdrawal into and from the ground.
A further object of the present invention is to provide a fabric-engagement means having the above advantages and, further, exhibiting simplicity of structure and construction, efficiency in operation, a pleasing appearance, and economy in cost.
The above and yet further objects and advantages of the present invention will become apparent from the hereinafter set forth Detailed Description of the Invention, the Drawings, and the Claims appended herewith.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a beach blanket or the like secured to a beach in accordance with the usage of the present inventive fabric-engaging stake;
FIG. 2 is a perspective view of one embodiment of the invention;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is a perspective, operational view showing an initial step in usage of the embodiment of FIG. 2;
FIG. 5 is a perspective, operational view showing a subsequent step in usage of the embodiment of FIG. 2;
FIG. 6 is a perspective, operational view showing a final step in the usage of the embodiment of FIG. 2;
FIG. 7 is a longitudinal, cross-sectional view taken along the line 7--7 of FIG. 6;
FIG. 8 is a perspective view of a second embodiment of the present inventive fabric-engaging stake, showing an initial step in the usage thereof;
FIG. 9 is a perspective, operational view illustrating a subsequent step in the usage of the embodiment of FIG. 8;
FIG. 10 is perspective view showing a final step in the usage of the embodiment of FIG. 8;
FIG. 11 is a longitudinal, cross-sectional view taken along line 11--11 of FIG. 10;
FIG. 12 is a perspective view of a third embodiment of the present invention showing an initial step in the usage thereof;
FIG. 13 is a perspective, operational view of the embodiment of FIG. 11 showing a subsequent step in the usage thereof;
FIG. 14 is a perspective, operational view of the embodiment of FIG. 12 showing a final step in the usage thereof;
FIG. 15 is a longitudinal, cross-sectional view taken along the line 15--15 of FIG. 14;
FIG. 16 is a perspective, operational view of the final step in the usage of another embodiment of the invention; and,
FIG. 17 is a longitudinal, cross-sectional view taken along the line 17--17 of FIG. 16, illustrating various details of the embodiment of FIG. 16.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, there is shown in perspective view the inventive ground-engaging stake 24 holding beach blanket 20 in place. Also shown are corners 22 of the fabric of beach blanket 20.
In FIG. 2 is shown, in perspective view, one embodiment of the instant invention. Shown therein are a plurality of earth penetrating vanes 26, two of which combine to form upper end 27 of stake 24. Upper end 27 more particularly comprises a first portion 28 and a second portion 30. The relationship of the respective vanes 26 is more particularly shown in the cross-sectional view of FIG. 3 where it is seen that four vanes 26 intersect at substantially right angles relative to each other.
Portion 30 of upper end 27 comprises the fabric-engaging portion of stake 24 and, more particularly, includes a fabric-engaging radius 34 which constitutes the radiused edge of portion 30 of upper end 27 (see FIGS. 2 and 7). The fabric-engaging radius 34 beings at a mid upper part 36 of portion 30 and terminates at a lower end part 38 thereof. Just beyond the lower end 38 of radius 34 is a recess 44.
Within first portion 28 of upper end 27 is a elongated curvilinear or an arcuate slot 42 which, as more fully described below, comprises a pivot means within and about which ring 40 may be rotated.
As may be noted, the curved segment between the beginning end 36 and the terminating end 38 of fabric-engaging radius 34 comprises a rounded corner of substantially one-quarter of a circle.
The operation of the embodiment of FIG. 2 is shown in FIGS. 4 through 6. FIG. 4 shows the initial step in securing the fabric to the stake in the usage of the inventive fabric-engaging stake. Therein, fabric corner 22 is shown pressed against the radius 34 and against recess 44. In this step the ring 40 is disposed toward the upper end 41 of slot 42. Ring 40 may be connected to stake 24 by inserting ring 40 through opening 50 which intersects with slot 42. The size of opening 50 may be slightly less than the thickness of ring 40 so that in accordance with the resilience and flexibility of stake 24 a snap fit exists between ring 40 and opening 50. In this manner ring 40 is effectively secured within slot 42. A sliding fit may exist between ring 40 and slot 42.
The next step in the use of the stake is shown in FIG. 5 wherein ring 40 is shown rotated in the direction of the shaded arrow about the base of slot 42 such that ring 40 is urged over fabric corner 22 and, in the same motion, into recess 44, such that fabric corner 22 is held within recess 44 by virtue of the engagement of ring 40 thereinto.
The next step in the usage of the embodiment of FIG. 2 is shown in FIG. 6 and, as well, in the cross-section view of FIG. 7, wherein the side of ring 40, opposite to the side held within recess 44, is rotated downward, in the direction shown by the shaded arrow in FIG. 6 to thereby place ring 40 into lock point 43 of slot 42 and to further secure the opposited end of ring 40 within recess 44. See particularly FIG. 7.
As may be noted in the views of FIGS. 6 and 7 the pressing of ring 40 into lock point 43 acts to lockingly engage the fabric 22 against the radius 34 of portion 30 of the stake. It has been found that sufficient pressure is thereby applied to the fabric at the recess 44 to hold fabric corner 22 in place. In order to accomplish such locking, the distance between recess 44 and locking point 43 should approximately equal the internal diameter of ring 40. The thickness of fabric 20 then serves to effectuate a force fit of ring 40 between lock point 43 and recess 44 which is allowed by the inherent slight amount of resiliency of ring 40.
Through the views of FIGS. 2 through 7, it may be appreciated that said slot 42 having a ring pivoting base 45 defines a multiplicity of possible pivot points, each disposed at a different distance from any particular point of said fabric-engaging radius 34. Therein, said ring and said slot are proportioned with said fabric-engaging radius to lockingly engage the fabric after said fabric has been caused to overlie said radius (FIG. 4), after said ring has been rotated around said radius (FIG. 5), and after said ring has been pressed into lock point 43 (FIGS. 6 and 7).
Shown in FIG. 8 is a second embodiment of the present invention wherein it may be seen that recess 44 has been eliminated, while an elongated fabric-engaging vertical opening 248 having an axis substantially co-directional with the longitudinal axis of the stake has been provided. As may be appreciated from the operational views of FIGS. 9, 10 and 11, said opening 248 has been proportioned to accept areas of fabric corner 22 not otherwise secured between ring 40 and fabric-engaging radius 234. In the longitudinal cross-sectional view in FIG. 11, the end portion 222 of fabric corner 22 is shown pressed within longitudinal vertical opening 248.
The embodiment of FIG. 8 otherwise differs from the embodiment of FIG. 2 in that linear slot 250 in conjunction with the rounded opening 241 at the end thereof serves to connect the ring to the stake and to allow rotating of the ring. Slot 250 is, more particularly, an elongated, resilient slot capable of press-fittingly accepting ring 40 (similar to opening 50) and, thereby, permitting said ring to be slid or urged to the rounded open end 241 of linear slot 250 and, thereby, into a pivot axis which is mechanically isolated from the press-fit, sliding, linear path of slot 250 (which is similar to the relationship of opening 50 and curved slot 42). Thereby, ring 40, once "popped" into end 241 of linear slot 250 will be rotationally locked thereinto, such that the only further movement of ring 40 will be about the pivot axis defined by end 241.
The practical consequence of the above, with reference to the embodiment of FIG. 8, is shown in the operational views of FIGS. 9, 10 and 11. More particularly, in FIG. 9, the end portion 222 of fabric corner 22 is shown pressed into vertical notch 248. Additionally, the rest of fabric corner 22 is placed over fabric-engaging radius 234.
In FIGS. 10 and 11 ring 40 is shown rotated, in the direction of the shaded arrow, over fabric corner 22 and over radius 234 such that the combination of forces created by (a) the friction engagement of the walls of vertical notch 248 with end 222 of fabric corner and (b) the line of force created by rounded end 241 comprising a lock point (similar to lock point 43), which holds ring 40 within stake 228 and the pressure fit engagement of ring 40 at the terminating end 238 of radius 234, will secure fabric corner 22 against dislodgement from the stake and, thereby, will secure the fabric corner.
In FIGS. 12 through 14 is shown a third embodiment of the inventive fabric-engaging stake. The embodiment of FIG. 12 differs from the embodiment of FIG. 2 in its elimination of recess 44 and, in addition, in its usage of a linear slot 350 similar to that of the second embodiment and, as well, in its usage of a combination pivotal and lock point 341 in the upper end of slot 350 which dimensionally and functionally act similar to slot 250 and pivotal and lock point 241.
With reference to FIG. 13, the first step of the usage of the embodiment of FIG. 12 is the placement of fabric corner 22 over the radius 334 of the embodiment of FIG. 12. Thereafter, ring 40 is rotated about pivot point 341 and is frictionally secured against fabric 22 at or beginning end 336 of fabric-engaging radius 334. The rotation of ring 40 is shown by the shaded arrow in the view of FIG. 14. The simple frictional force existing between the beginning end 336 of the fabric-engaging radius and ring 40 has been found sufficient to hold most fabrics.
FIGS. 16 and 17 illustrate another embodiment of the present invention. From these figures it may be seen that a vertical fabric-engaging slot 448 and a fabric-engaging notch or recess 444 are used in addition to the fabric-engaging radius 434. And, that a curvilinear or arcuate slot 442 having a pivoting base portion 445 for rotating the ring 40 is provided. There is further provided an opening 450 for allowing connection of ring 40 to the stake 424. There is even further provided another recess 443 at the lower end of curvilinear or arcuate slot 442.
Fabric-engaging radius 434 includes a beginning point 436 and ending point 438 and comprises a rounded corner of substantially one-quarter of a circle. Fabric-engaging radius 434 is thus constructed and serves the same purpose, in the same manner, as rounded corners 34, 234 and 334 of the above embodiments. Also, recess 444 is constructed and serves the same purpose, in the same manner, as recess 44 of the embodiment of FIGS. 1 through 7.
Vertical opening 448 is constructed and positioned as in the embodiment of FIGS. 8 through 11. Accordingly, vertical opening 448 serves the same purpose and, in the same manner, as opening 248.
Opening 450 as noted in FIGS. 16 and 17 is located along a horizontal axis of portion 428 of stake 424 and, thereby, intersects with the lower end of curvilinear slot 442. Opening 450 serves the same purpose and, in the same manner, as openings 50, 250, and 350, notwithstanding the different locations. Opening 450 thereby comprises an elongated resilient slot capable of press-fittingly accepting ring 40 and thus permits ring 40 to be slid or urged into curvilinear slot 442 and effectively secured therewithin. Ring 40 is slidingly and pivotingly engaged within curvilinear slot 442 which also functions as a pivoting means for the rotation of ring 40. Ring 40, once "popped" into slot 442, cannot, therefore, be removed from slot 442 without the application of forces equal and opposite to those used during installation.
Slot 442 comprises a curvilinear or arcuate opening whereby the distance between its pivoting base 445 and recess 444 decreases as slot 442 progresses from the location of opening 450 toward its upper end 441. Conversely, this distance increases as curvilinear slot 442 progresses downward from end 441 toward opening 450. The distance between pivoting base 445 of slot 442 and recess 444 at the location just above opening 450 is substantially equal and perhaps slightly greater than the internal diameter of ring 40. In this manner, when fabric corner 22 is fitted within recess 444, the thickness of fabric 20 causes a force fit between ring 40 and the distance between base 445 and recess 444 at this location and, therefore, the fabric is compressed and securely held within recess 444.
The lower end of the pivoting base surface 445 of curvilinear slot 442 is slightly relieved in a direction toward recess 444 so as to increase the across-the-width size of slot 442 at this location. Also, the distance between the pivoting base surface 445 and recess 444 is slightly less than that at the location just above opening 450. This results in a slight detent in base surface 445 at this location which forms a lock point 443 for ring 40. When one side of ring 40 is lodged within recess 448 together with fabric corner 22 and the opposite side is rotated downward from location 441 in the direction shown by the shaded arrow in FIG. 16, the holding force on the fabric within recess 444 increases and reaches a maximum at the location just above the detent. Continued downward rotation causes the ring 40 to pass into the detent at this location which comprises lock point 443. This causes a slight but negligible decrease in the compressive force on the fabric at recess 444 but, more importantly, causes ring 40 to be resiliently "locked" in place at lock point 443. The decrease in force in negligible because the ring 40 and distance between lock point 443 and recess 444 are proportioned to provide a relatively substantial positive compressive force on the fabric due to the still greater distance between the combined thickness of fabric 20 plus the distance between lock point 443 and recess 444 than the internal diameter of ring 40. The presence of the detent provides a lock point 443 which prevents ring 40, once it is in place, from riding up in slot 442 and, thereby, prevents unintentional loosening of fabric corner 22.
The operational usage of the embodiment of FIGS. 16 and 17 is a combination of the individual operational usages described above for each of the embodiments incorporating the features of the embodiment of FIGS. 16 and 17. Accordingly, it is not necessary to further describe the operational fitting of fabric corner 22 to stake 424 and whereby the fabric is frictionally held onto the stake 424 by the recess 444, the radius 434 and vertical slot 448. Moreover, the ring 40 is more positively held in place in slot 442 because of the lock point configuration of end 443 of slot 442.
While the invention has been described, disclosed, illustrated and shown in certain terms or certain embodiments or modifications which is has assumed in practice, the scope of the invention is not intended to be nor should it be deemed to be limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | A stake for anchoring a beach blanket, towel or other like fabric is disclosed. An elongated body is provided with tapered vanes. A planar upper end is provided with an arcuate slot within which is located a rotatable ring. A vertical slot, a curved edge and a recess provide for engaging the fabric when the fabric is applied thereto and the ring is rotated into the recess. The arcuate slot allows for downward sliding of the ring into a locking location which may be provided with a detent. | 8 |
[0001] This is a Continuation-In-Part application of U.S. patent application Ser. No. 11/951,566, filed on Dec. 6, 2007, currently pending.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] A conventional automatic clothes hanger comprises a main body having a platform extending outwardly for a motor and a control circuit to be secured and connected thereon. The platform is provided with a support frame and accessories. The support frame is provided with a micro switch and a sensor at the two respective ends to detect the weather and to control the clothes hanger to extend or to collapse.
[0004] 2. Description of the Prior Art
[0005] Another conventional automatic clothes hanger comprises a basic frame, a swivel frame, an adjusting frame and a fixture, and is incorporated with a sensor to extend or to collapse the clothes hanger. The swivel frame is linked to activate simultaneously to assist the clothes hanger to extend or to collapse.
[0006] The above-mentioned clothes hangers comprise a sensor to detect the weather, however, they are not provided with proper definitions about the weather so that they can not work as expected.
SUMMARY OF THE INVENTION
[0007] The present invention provides a collapsible clothes hanger structure to react when the real-time weather has changed, which comprises:
a frame comprising a pair of supporting legs and a rail, the rail being secured between the supporting legs, a tent being provided on the frame, the tent covering a portion of the rail; a transmission unit comprising a transmission gear meshing with a transmission belt, the transmission gear and the transmission belt being disposed in the rail; a hanging unit disposed in the rail; a motor connected to and driving the transmission unit in the rail to control the hanging unit to slide along the rail; and a control unit coupled with a light sensor, a water drop sensor, and a timer, the control unit collecting signals from any of the light sensor, the water drop sensor, and the timer to control the motor and the hanging unit.
[0013] Preferably, the rail comprises contact points at respective ends to control activation of the motor when in touch with the hanging unit, the contact points being electrically connected to the control unit.
[0014] Preferably, the light sensor is a photosensitive resistance whose back surface faces the light source and an opaque board is connected on the back surface.
[0015] Preferably, the control unit further comprises a manual control key to control the motor.
[0016] Preferably, the timer is electrically connected with a time display panel.
[0017] Preferably, the control unit comprises a remote controller.
[0018] Preferably, the motor and the control unit are electrically connected to a battery.
[0019] Preferably, the battery is electrically connected to a solar energy board.
[0020] Preferably, the solar energy board comprises a receiving unit to collect signals from the light sensor, the water drop sensor, and the timer, the signals then being transmitted to the control unit to activate the motor accordingly.
[0021] Preferably, the hanging unit comprises an active hanger and a number of driven hangers, the active hanger being secured to the transmission belt, the driven hangers having holes for the transmission belt to insert and to extend there through, the active hanger and the driven hangers having slots for pulling straps to insert and to extend there through, a block being provided at a center portion of each the slot, each of the pulling straps having a securing end and a terminal end, the securing end and the terminal end being larger in size than each the slot.
[0022] Preferably, the hanging unit includes a hole for a cloth hanger to be hooked therein and the clothes hanger includes two arms extending from a hook and a transverse rod is connected between the two arms. The arms include bosses and two support links. A clip is mounted to each of the arms and includes a notch which is located corresponding to the bosses, a clip end and a press end. Besides, the transverse rod and the support links each include an anti-slip portion.
[0023] Preferably, the hanging unit comprises an active hanger and a number of driven hangers, each of the active hanger and the driven hangers comprising a shaft, the shaft having a center portion meshing with a connecting section and two exposed ends, a pair of rollers being provided on the two exposed ends of the shaft, the rollers having recesses meshing with a pair of rail straps in the rail, the active hanger and the driven hangers having slots for pulling straps to insert and to extend there through.
[0024] Preferably, the two support links each have a first transverse rod and a second transverse rod. The first transverse rod is located remote from the tent and includes three fixing holes on each end thereof. The second transverse rod has two engaging members on two ends respectively.
[0025] Preferably, two positioning ropes are connected between the first and second transverse rods. The positioning ropes are flexible and include two ends, one of the two ends is fixed to the fixing hole by S-type tie and the other end extends through a sleeve and a collar is mounted to the sleeve. A cap is inserted into the collar and the collar is engaged with the engaging member.
[0026] It is the primary object of the present invention to provide a collapsible clothes hanger structure, which may be adjusted to control the clothes hanger automatically or manually.
[0027] It is another object of the present invention to provide a collapsible clothes hanger structure, which is activated when the light has changed.
[0028] It is still another object of the present invention to provide collapsible clothes hanger structure, which is activated when rain drop is detected.
[0029] It is still another object of the present invention to provide a collapsible clothes hanger structure, which is activated by the timer.
[0030] It is a further object of the present invention to provide a collapsible clothes hanger structure, which is activated manually.
[0031] It is a still further object of the present invention to provide a collapsible clothes hanger structure, which can be controlled remotely.
[0032] It is a still further object of the present invention to provide a collapsible clothes hanger structure, which provides a solar energy board that enables to transfer light into energy to save electric power, corresponding to the concept of environmental protection.
[0033] It is a still further object of the present invention to provide a collapsible clothes hanger structure, which provides a hanging unit that does not require any fastener, which is easy to install and to work precisely.
[0034] It is a still further object of the present invention to provide a collapsible clothes hanger structure, which provides a tent to protect the clothes from getting wet by rain or humid.
[0035] It is a still further object of the present invention to provide a collapsible clothes hanger structure, which provides a locating rope between the supporting legs and the tent so as to secure clothes on the hangers.
[0036] It is a still further object of the present invention to provide a collapsible clothes hanger structure, wherein the clothes are securely connected to the hangers by the cooperation of the hangers and the clips, and the clothes are not blown away by strong wind.
[0037] It is a still further object of the present invention to provide a collapsible clothes hanger structure, wherein the positioning ropes are conveniently and quickly fixed to the first and second transverse rods and are not blown away by strong wind.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a perspective view of the preset invention;
[0039] FIG. 2 is a side view of the present invention, partially sectioned;
[0040] FIG. 3 is a partial enlarged view of the present invention;
[0041] FIG. 4 is a perspective view of a control unit of the present invention;
[0042] FIG. 5 is a partially enlarged view of the present invention showing a water drop sensor, a control unit and a solar energy board;
[0043] FIG. 6 is an exposed view of a hanging unit of the present invention;
[0044] FIG. 7 is a cross-sectional view showing that the hanging unit is secured in a rail;
[0045] FIG. 8 is a diagram of an operation of the present invention;
[0046] FIG. 9 is a side view of the present invention in a collapsed status;
[0047] FIG. 10 is an enlarged view showing the hanging unit in a collapsed status;
[0048] FIG. 11 is a perspective view showing a solar energy board facing another direction;
[0049] FIG. 12 is an enlarged view to show the first transverse rod;
[0050] FIG. 13 is an enlarged view to show the second transverse rod;
[0051] FIG. 14 shows that the positioning ropes are fixed to the fixing holes;
[0052] FIG. 15 shows the connection between the positioning rope, the sleeve, the collar and the cap;
[0053] FIG. 16 shows that the collar is engaged with the engaging member, and
[0054] FIG. 17 shows that the connection between the hanger and the clip.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0055] As shown in FIGS. 1 through 5 , a preferred embodiment of the present invention comprises a frame 1 , a transmission unit 2 , a hanging unit 3 , a motor 4 , a control unit 5 , a battery 6 and a solar energy board 7 .
[0056] The frame 1 comprises a pair of supporting legs 11 and a rail 12 . The rail 12 is secured between the supporting legs 11 . A tent 13 is provided on the frame 1 and covers a portion of the rail 12 to protect clothes from being wet by rain or dew. In addition, the two supporting legs 11 respectively have a first transverse rod 14 and a second transverse rod 15 . The first transverse rod 14 is located close to the tent 13 and the second transverse rod 15 is located remote from the tent 13 . Referring to FIGS. 12 to 16 , there are three fixing holes 141 in each of two ends of the first transverse rod 14 , and two engaging members 151 are respectively connected to two ends of the second transverse rod 15 . Two positioning ropes 16 are connected between the first and second transverse rods 14 , 15 , and each positioning rope 16 is a flexible rope and includes two ends. One of the two ends is fixed to the fixing hole 141 by S-type tie and the other end extends through a sleeve 17 and a toothed ring 171 is located in the sleeve 17 so as to secure the positioning rope 16 . A collar 18 is securely mounted to the sleeve 17 . A cap 19 is inserted into the collar 18 so as to hide the sleeve 17 . The collar 18 is eventually forced to be engaged within the engaging member 151 to fix the positioning rope 16 .
[0057] The transmission unit 2 comprises a transmission gear 21 meshing with a transmission belt 22 . Both the transmission gear 21 and the transmission belt 22 are disposed in the rail 12 of the frame 1 . By changing the direction of the transmission gear 21 , the transmission belt 22 changes its moving direction.
[0058] The hanging unit 3 , as shown in FIGS. 3 and 6 , comprises an active hanger 3 A and a number of driven hangers 3 B which are mounted in the rail 12 in sequence. The active hanger 3 A located at the outmost end is secured to the transmission belt 22 , while the driven hangers 3 B are secured by extending the transmission belt 22 through a hole 31 B of each driven hanger 3 B. The active hanger 3 A and the driven hangers 3 B have hanging holes 31 A and 32 B for a clothes hanger 8 to hang thereon. The active hanger 3 A and the driven hangers 3 B further have slots 32 A and 33 B for pulling straps 31 to extend through. Blocks 321 A and 331 B are provided at the center portions of the slots 32 A and 33 B. Every two adjacent hangers (including the active hanger 3 A and the driven hangers 3 B) are connected by an independent pulling strap 31 which comprises a securing end 311 and a terminal end 312 . Both the securing end 311 and the terminal end 312 are larger in size than the slots 32 A ad 33 B. The securing end 311 is secured to the block 321 A, and the terminal end 312 is able to engage with the block 331 B or disengage from the block 331 B.
[0059] The motor 4 is connected to the transmission gear 21 of the transmission unit 2 and outputs a power to link the hanging unit 3 to slide along with the transmission belt 22 through the transmission gear 21 , as shown in FIG. 1 .
[0060] The control unit 5 , as shown in FIGS. 1 , 4 and 5 , comprises a power switch 51 , an automatic control key 52 , a manual control key 53 , a light sensor 54 , a water drop sensor 55 , and a timer 56 which is electrically connected with a time display panel 561 . Any of the light sensor 54 , the water drop sensor 55 , and the timer 56 can trigger the motor 4 to activate the transmission belt 22 through the transmission gear 21 to slide the hanging unit 3 to stay within the tent 13 or to extend outwardly. The automatic control key 52 controls the light sensor 54 , the water drop sensor 55 , and the timer 56 . The light sensor 54 , the water drop sensor 55 , and the timer 56 may be activated by pressing the manual control key 53 as well to activate the transmission belt 22 to control the hanging unit 3 through activation of the motor 4 .
[0061] The control unit 5 further comprises a malfunction light A, a charging light B, and a battery weak signal light C, as shown in FIG. 1 . When the malfunction light A fleshes, indicating an abnormal operation, the power will be shot down itself. When the charging light B is flashing, it implies the solar energy board is charging. When the battery weak signal light is flashing, it implies either the is solar energy board has not been charging for a period of time or the battery is not working and it requires to be replaced with another one. The control unit 5 further comprises a lighting system (not shown in the drawings) which is activated automatically for 10 minutes.
[0062] The motor 4 and the control unit 5 are electrically connected to the battery 6 , and the battery 6 is electrically connected to the solar energy board 7 which transforms the light into electric power to be saved in the battery 6 .
[0063] The rail 12 is provided with a pair of contact points 121 at respective ends thereof. The contact points 121 are electrically connected to the control unit 5 . The contact points 121 are designed for the hanging unit 3 to contact so as to control the motor 4 .
[0064] When the light sensor 54 detects the light is weak, it will transmit a signal to the control unit 5 . When the water drop sensor 55 detects water drops, it will transmit a signal to the control unit 5 .
[0065] The control unit 5 is cooperated with the timer 56 and electrically connected with the time display panel 561 which can be input digits to show the hour and minute for convenience of calculating time.
[0066] FIGS. 3 and 5 show the positions where the water drop sensor 55 , the light sensor 54 and the solar energy board 7 are located. When water drops on the water drop sensor 55 , a positive wire 551 and a negative wire 552 will be conducted, and the positive wire 551 and the negative wire 552 are respectively fixed to screws D on the water drop sensor 55 . The screws D are used as output ends so as to deliver signals to the control unit 5 to collapse the hanging unit 3 . The light sensor 54 is a photosensitive resistance whose back surface faces the light source (sun and moon) and an opaque board E is connected on the back surface. The arrangement can precisely judge and send signals to the control unit 5 when it is in evenings, cloudy days or dense fogs.
[0067] As shown in FIGS. 6 and 7 , each of the active hanger 3 A and the driven hangers 3 B comprises a pair of shafts 32 . Each shaft 32 has a central portion meshing with a connecting section 33 and two ends exposed outwardly. The exposed ends of the shaft 32 are provided with rollers 34 . Each roller 34 has a recess 35 . The rail 12 comprises a pair of rail straps 122 therein for engagement of the recesses 35 of the rollers 34 so as to assist the rolling of the active hanger 3 A and the driven hangers 3 B along the rail 12 . The active hanger 3 A is secured to the transmission belt 22 and is linked to move along with the transmission belt 22 .
[0068] The active hanger 3 A and the driven hangers 3 B do not need any fasteners, such as screws, nuts, C-shaped clips, to be mounted with the rollers 34 to slide along the rail 12 . The recesses 35 of the rollers 34 are disposed on the rail straps 122 of the rail 12 , allowing the rollers 34 to roll along without detaching from the shafts 32 .
[0069] Referring to FIG. 17 , the clothes hanger 8 is hanged to the holes 31 A, 32 B and includes two arms 82 extending from a hook 81 , and a transverse rod 83 is connected between the two arms 82 . The arms 82 include bosses 821 and two support links 84 . The transverse rod 83 and the support links 84 have anti-slip portions 831 , 841 , and the transverse rod 83 has two protrusions 832 . The support links 84 can be used to position ties and socks, and the protrusions 832 are used to position female underwear. The anti-slip portions 831 , 841 increase the friction between the clothes and the clothes hanger 8 to prevent the clothes from dropping from the clothes hanger 8 . A clip 9 is connected to the arm 82 and has a notch 91 , a clip end 92 and a press end 93 . The clip end 92 has a tooth 921 which is used to secure the clothes. It is noted that the clip 9 secures the clothes on the arms 92 . The clip 9 is first moved to a desired position and the boss 821 is engaged with the notch 91 so as to fix the clip 9 . The user then presses the press end 93 to allow the clip end 92 to lift. In the meanwhile, the clothes are then clipped between the clip end 92 and the arm 82 . When releasing the press end 93 , the clip end 92 securely clips the clothes.
[0070] To expand the hanging unit 3 of the present invention, as shown in FIGS. 2 , 3 , and 6 , when the transmission belt 22 moves outward from the tent 13 , the active hanger 3 A will be pulled by the transmission belt 22 , and the adjacent driven hanger 3 B will also be pulled till the pulling strap 31 reaches to its limits. The securing end 311 and the terminal end 312 of the pulling strap 31 engage with the block 321 A in the slot 32 A and the block 331 B in the slot 33 B and are stopped thereat. The subsequent driven hangers 3 B are also pulled by the same way.
[0071] To collapse the hanging unit 3 of the present invention, as shown in FIGS. 9 and 10 , the transmission belt 22 moves towards the tent 13 , which links the active hanger 3 A to move in the same direction as well till the terminal end 312 disengages from the block 331 B of the adjacent driven hanger 3 B and forces the driven hanger 3 B to move along. One by one all of the driven hangers 3 B will be brought to move in the same direction until they are collapsed in the tent 13 .
[0072] The present invention is designed to operate either in automatic or in manual mode, as shown in FIG. 8 . The control unit 5 comprises the automatic control key 52 and the manual control key 53 . The manual control key 53 has receiving and sending directions to activate the motor 4 to do the job. The motor 4 will be stopped when the manual control key 53 is released. This allows the user to control and adjust the distance. The automatic control key 52 is activated by the light sensor 54 , the water drop sensor 55 and the timer 56 to activate the motor 4 .
[0073] The present invention further comprises the battery 6 and the solar energy board 7 , as shown in FIGS. 5 and 8 , to provide electric power to the control unit 5 and the motor 4 . The solar energy board 7 comprises a receiving unit 71 to collect signals from the light sensor 54 , the water drop sensor 55 and the timer 56 and then transfer to the control unit 5 which in turn activates the motor 4 accordingly.
[0074] To operate the present invention, as shown in FIG. 9 , the user presses the power switch 51 of the control unit 5 , adjusts the timer 56 through the time display panel 561 to set the time, and then presses either the manual control key 53 or the automatic control key 52 to activate the motor 4 which in turn activates the transmission gear 21 and the transmission belt 22 to push the active hanger 3 A and the driven hangers 3 B outwardly. When the active hanger 3 A reaches to one contact point 121 of the rail 12 , the motor 4 will be stopped. To collapse the present invention, when the most inward driven hanger 3 B is in contact with the other contact point 121 of the rail 12 , the motor 4 will be stopped, as shown in FIG. 2 .
[0075] The direction of the solar energy board 7 may be changed to direct the sun shine, as shown in FIG. 11 .
[0076] The operation of the present invention can be categorized as follows:
[0000] 1. timer mode: the time can be preset to extend or to collapse the hangers;
2. manual mode: the manual control key is pressed to extend or to collapse the hangers;
3. automatic mode: the automatic control key is pressed to activate the light sensor, the water drop sensor and the timer to control the hangers.
[0077] The present invention may further comprise a remote controller which can activate the control unit ( 5 ) remotely.
[0078] The control unit 5 , the motor 4 , the light sensor 54 , the water drop sensor 55 and the timer 56 are operated by either wire (cable, network) or wireless (wireless network, Bluetooth, frequency modulation) transmission. | A collapsible clothes hanger structure includes a frame including a pair of supporting legs and a rail. A rail is secured between the supporting legs. A tent is provided on the frame and the tent covers a portion of the rail. A transmission unit includes a transmission gear meshing with a transmission belt. The transmission gear and the transmission belt are disposed in the rail. Multiple hanging units are movably disposed in the rail in sequence. A motor is connected to and drives the transmission unit in the rail to control the hanging units to slide along the rail. A control unit is coupled with a light sensor, a water drop sensor, and a timer. The control unit collects signals from any of the light sensor, the water drop sensor, and the timer to control the motor and the hanging unit. By the structure, the collapsible clothes hanger is automatically expanded or retracted according to light and rain or the pre-set time. | 3 |
This is a continuation of application Ser. No. 06/579,394 filed Feb. 13, 1984, now abandoned.
BACKGROUND AND SUMMARY
The invention relates to pressure compensated hydraulic valves, wherein a fixed differential pressure is maintained, to maintain a uniform flow rate.
In a hydraulic valve having a reciprocal spool for communicating hydraulic fluid to work ports, it is known to create a fixed differential pressure across the spool by controlling the pressure before the flow has passed through the spool. For example in Wilke U.S. Pat. No. 3,881,512, the hydraulic fluid is preconditioned before it flows across control spool 13 by an initial pressure compensating valve mechanism 15 which divides flow from inlet 18 to either feeder 20 or bypass 19 to keep the flow through work port 22 constant for any given position of spool 13 regardless of fluxuations in pump or load pressure.
In the present invention, a fixed differential pressure is created by controlling pressure after hydraulic flow has passed through the spool.
The present invention evolved from cost reduction efforts to minimize the number and complexity of parts, particularly those requiring machining. This is accomplished in part by marrying certain open flow circuit structure with pressure compensated circuit structure. In an open flow circuit, the flow rate changes in response to load pressure. Unitary open flow hydraulic valves are known having check valves in the same housing as the control spool, typically in the area of a bridge passage between work ports through the spool.
The present invention provides a unitary pressure compensated hydraulic valve, eliminating a separate discreet pressure compensating module. The pressure compensating means of the invention is in the same housing as the control spool. Furthermore, the invention enables known check valve structure and location from open flow circuitry to be applied and used in pressure compensating and shuttle circuits. This facilitates economy of manufacture by enabling use of existing manufacturing steps and assembly line sequences for as much of the valve as possible. The use of check valve structure for pressure compensating and shuttle circuits is further desirable because it typically involves a less expensive stamping operation, as opposed to machining or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional side view of a valve constructed in accordance with the invention.
FIG. 2 is a sectional top view of the valve of FIG. 1.
DETAILED DESCRIPTION
Referring to FIG. 1, valve 2 includes a housing 4 having a reciprocal control spool 6 moveable left-right for communicating hydraulic fluid to work ports 8 and 10. Spool 6 is shown in the neutral position, and bridge passage 12 is vented to reservoir passage or tank 14 through bridge vent passage 16 in the control spool as shown at dashed line vent passages 16a, 16b and 16c.
When spool 6 is moved leftwardly by the operator, bridge vent passage 16 is blocked, and bridge passage 12 is placed in communication with work port 8 through control spool passage 20, such that the work port pressure is sensed in bridge passage 12 by hydraulic fluid flow through the spool bore. This applied work port pressure pressurizes a pilot system for load sensing and pressure compensation.
Bridge passage 12 is in communication with a sensing shuttle passage 22, FIG. 2. If the valve is a single section or monoblock valve, the hydraulic flow in passage 22 continues past shuttle check valve 24 and into crossing passage 26 and through-shuttle passage 28. If the valve is a multi-section valve, then a plurality of identical valve sections are aligned side by side, for example as shown cut away at 30 and 32. If the work port pressure of central section 31 in sensing shuttle passage 22 is greater than the work port pressure in through-shuttle passage 34 of the previous section 30, then shuttle check valve 24 moves downwardly to close passage 34 and the higher pressure from passage 22 is communicated through crossing passage 26 to through shuttle passage 28. If the work port pressure in sensing shuttle passage 22 of present valve section 31 is less than the work port pressure in the through-shuttle passage 34 of the previous section 30, then shuttle check valve 24 moves upwardly to close passge 22 and enable the higher pressure in passage 34 to be communicated to through-shuttle passage 28. Likewise, shuttle check valve 36 of the next section 32 operates to apply the higher pressure of through-shuttle passage 28 of the present section 31 and sensing shuttle passage 38 of the next section 32 to the through-shuttle passage 40 of next section 32. In this manner, the highest work port pressure of all the valve sections is communicated to a sense line 52 connected to the input 44 of hydraulic pump 46 and to a communication passage 48 which extends through all of the valve sections, as shown through respective passages 50, 52 and 54.
Transfer passage 52 communicates through cross passage 56 with a pressure compensating check valve 58, such as a spring biased poppet. The bottom side 60 of check valve 58 is thus applied with the pressure from passage 52, which is the highest work port pressure of the valve sections. The top side 62 of valve 58 is of the same area as the bottom side and thus the same pressure is applied in passage 64 above valve 58. Passage 64 around the top of valve 58 is a feeder passage which also has a section around spool 6, FIG. 1. The pressure in feeder passage 64 is thus the highest work port pressure of the multiple valve sections.
The above noted description explains pressurization of the system in response to initial movement of spool 6. This pressurization occurs before metering notch or passage 66 in the spool comes into communication with feeder passsage 64.
Further leftward movement of spool 6 brings metering passage 66 into communication with feeder passage 64. Supply passage 68 then communicates with feeder passage 64 through metering passage 66. Metering passage 70 and supply passage 72, effective during rightward movement of spool 6, are comparable. Supply passages 68 and 72 are suppled from pump 46 which outputs hydraulic flow pressure on output 74 which is a predetermined amount greater than the flow pressure input to the pump at 44. Since the pressure at 44, FIGS. 1 and 2, is the highest work port pressure of the valve sections, the pressure in supply passages 68 and 72 is the noted predetermined amount greater than the highest work port pressure. As above noted, the initial pressurization of the system causes the pressure in feeder passage 64 to be the same as the highest work port pressure. There is thus a fixed differential pressure across metering passage 66 from supply passage 68 to feeder passage 64.
Hydraulic fluid can flow from supply passage 68 through metering passage 66 to feeder passage 64. Feeder passage 64, FIG. 2, communicates with the left side of bridge passage 12 through cross passage 76 and an orifice 78 opened by downward movement of pressure compensating check valve 58. The flow rate in feeder passage 64 is such as to provide sufficient fluid to afford the same amount of pressure on the top side 62 as on the bottom side 60 of valve 58. Valve 58 can move up and down to control the size of orifice 78, such that should the load increase, causing work port pressure to increase, the shuttle system responds to impose the increased load pressure on the bottom of the check valves 58 in all of the valve sections so that the poppets 58 can operate as load holding check valves. This increased pressure is also sensed at port 44 of the pump to effect an increase in the output pressure of the pump and thereby increase the pressure in the inlet passage 68 (or 72) sufficiently to maintain the pressure differential across the metering notches 66. In as much as this same increased load pressure is manifested at the bottoms of the poppets 58 in the stack of valve sections, the desired pressure differential will be maintained across the metering notches in any of the spools in adjacent sections that have been actuated to operating positions.
Load 80 is raised via outlet and inlet work ports 8 and 10 and their respective connection lines 82 and 84. Further leftward movement of spool 6 by the operator further raises load 80 by increasing the area of metering passage 66 which is exposed to feeder passage 64. Flow rate is equal to the product of the area and the square root of the differential pressure. Since the differential pressure across metering passage 66 is constant, flow rate is a direct linear function of the area of metering passage 66 which is in communication with feeder passage 64. This area is increased during further leftward movement of spool 6, thus supplying more fluid and raising load 80. Standard pressure relief valves 86 and 88 are provided for the work ports and reservoir passage. A standard spring centering mechanism 90 is provided on the end of spool 6 for locating the latter's neutral position.
From the foregoing description it will be appreciated that one of the outstanding features of the invention resides in the fact that the valve mechanism can act as a flow divider due to the maintenance of the same pressure differential across the metering notches of all the spools that have been shifted to operating positions. This is achieved regardless of pump output, even if the demands of the various systems exceed pump output capacity.
It is recognized that various modifications are possible within the scope of the appended claims. | A pressure compensated hydraulic valve (2) is provided with a housing (4) having a reciprocal spool (6) for communicating hydraulic fluid to work ports (8,10). Pressure compensating means (58) is provided in the same housing with the valve and senses work port pressure by hydraulic fluid flow through the spool from the work port and creates a substantially fixed differential pressure across the spool by controlling the pressure after the flow has passed through the spool. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to a gripping and rotating tong device for handling drill rods, drill bits and other corresponding, at least partially rod-like pieces, the tong device comprising a housing which is fastened to movable transfer means and has an axial hole and a radial aperture for the taking of the piece to be handled from outside the housing to inside the housing; in the housing, gripping means which grip the piece entering the housing; and parts for rotating the gripping means selectively in either direction. The invention also relates to the use of the gripping and rotating tong device for handling drill rods, rock bolts, drill bits and other corresponding, at least partially rod-like pieces.
It is previously known to handle drill rods, rock bolts and drill bits by means of mechanical devices. In a conventional construction, the drill rods or corresponding pieces are placed in either a circular magazine or a chain magazine, from where a rod-retrieving device outside the magazine is capable, by means of tongs, of transferring one rod at a time to the rod chuck or other point of use, and, in a corresponding manner, removing the rod from it. Thereafter the item transferred into place, for example a drill rod, is connected as an extension to a previous drill rod by means of a screw joint, which requires that the drill rod be rotated. This rotation can be effected, for example, by using the rotation motor of the drilling machine, totally separate rotation devices connected to the rod chuck, or rotation devices connected to the rod-retrieving device. Such constructions are disclosed, for example, in U.S. Pat. Nos. 3 506 075 and 2 972 388, in Finnish Patent Application 843 734, and in Finnish Patent 65 471. In the last-mentioned Finnish patent, the rotation device includes rolls acting against the rod, some of the rolls being driven by hydraulic motors in order to rotate the rod. Patent 65 471 also includes a device, separate from the handling devices, for transferring and holding the drill bits. This drill bit replacer is made up of a basket-like part which grips the drill bit and is fastened to a pivot arm by means of which the drill bit is transferred to the rod. The drill bit is fastened by rotating the rod and not the drill bit.
There are also devices in which the gripping means and the rod-rotating mechanism are combined. German Patent DE-3 521 923 describes a device for making and detaching pipe joints, the device having inside a housing two gripping jaws which can be pressed against the pipe or the rod. The aperture into which the pipe has been introduced in order to be pressed or rotated is closed with a separate closing piece. The closing piece has no mechanism; instead, the pipe is rotated by rotating the piece to which the gripping jaws are fastened. The said two gripping jaws are made up of pieces capable of pivoting about a hinge pin towards the pipe. Patent GB-2 100 639 discloses a construction and its closing piece, otherwise corresponding to the above-mentioned German patent, except that the jaws for gripping the rod are driven by transmission of two rings placed one above the other and rotating in relation to each other, whereas in the German patent there are means one inside the other for this purpose. Furthermore, U.S. Pat. No. 4 060 014 discloses a corresponding construction with its closing piece, the purpose of the construction being to enable the workpiece to be rotated in both directions at any time without the gripping jaws opening from around the workpiece. This patent discloses use of only one ring gear but a large number of other cogged means. Norwegian Patent Application 860 054 discloses a similar construction, but without a closing piece. This construction also has a housing part, into the center of which a pipe can be introduced from the side through an aperture in it. This housing, and thereby the pipe, is rotated by ring gear transmission. The pipe, for its part, is locked in relation to the housing by means of three gripping jaws, one of which is pivotable and the other two are fixed in the holder of the locking pieces. The locking pieces with their gripping jaws are driven by means of two cams and a corresponding lever curve by means of which the gripping jaws are caused to pivot and press the pipe.
All of these constructions which have been described have a large number of disadvantages. In the first-mentioned devices, which have separate rotation devices and in which the drill rods are transferred by separate gripping arms from the magazine to the point of work, the disadvantages include the fact that the devices are extremely complicated and include several actuators. Consequently, such mechanisms are very expensive and since, owing to the large number of units, they also require a great deal of space, their installation in machine tools which have little space available around the drilling device itself may be impossible.
In this sense, the gripping and rotating devices which have been described are more advantageous, since they can be installed in a clearly smaller space than the systems provided with separate transfer and rotating devices. In the cases of Patents DE-3 521 923, GB-2 100 639, and U.S. Pat. No. 4 060 014, the disadvantage is, however, the space required by the closing piece of the aperture upon its opening, which space must be taken into consideration in planning the paths of movement of the tong and the rest of the system. In addition, in these constructions the drive mechanism will be complicated, since the closing function and the rotating function have to be controlled separately. In particular, the device of Patent GB-2 100 639 has the disadvantage that one ring gear has to be braked continually in order for the device to function. This prevents rotation over long periods. The construction of Norwegian Patent Application 860 054 has a disadvantage in its complexity, which increases the price and decreases the operational reliability of the device. In addition, owing to the structure, the outer diameter of this device is rather great as compared with the diameter of the rod or pipe to be handled; this complicates the installation of the device in many machines. The same also applies to the devices of Patents GB-2 100 639 and U.S. Pat. No. -4 060 014.
The fact that the known devices are so large that they cannot always be installed have important consequences also for occupational safety, especially in connection with rock-drilling machines. In such cases the machine operator has to carry out the replacement of the drill rod or the drill bit at least partially by hand, which is clearly dangerous. In addition, such manual replacing slows down the work, since the machine has to be stopped for the duration of the replacing, and the machine operator himself must move to the drilling device to carry out the replacing and then again return to continue the drilling.
SUMMARY OF THE INVENTION
With the help of the device according to the invention, a substantial improvement is achieved regarding the disadvantages described above.
It can be deemed that the most important advantage of the invention is that the device is so small in relation to the drill rod itself or any other corresponding piece to be handled that the gripping and rotating tong device, together with its transfer means, can be installed inside the chain magazine or circular magazine for the drill rods, rock bolts or drill bits. In this case, the mechanism, ready for operation, takes precisely as much space as does the magazine involved, since no external transfer or rotation devices are required. In addition, the gripping and rotating tong device is so simple in construction that its price is insignificant compared with the prices of the other components of the drilling equipment or the prices of the previously known transfer and rotation devices, and that the operational reliability of the device is very good. The operational reliability and the economy of price are further increased by the fact that the construction is not sensitive to errors in dimensioning any more than to impurities from the environment. This provides a very great advantage specifically in rock drilling and mining activity. Since, owing to the economical price and small size of the device, it is possible to install it wherever replacing work is required, an advantage is gained also in the form of improved occupational safety and savings in working hours. It is a further advantage of the construction that the device can be retro-installed in machines which are already in operation and can be transferred from one machine to another.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described below in detail with reference to the accompanying drawings.
In the Drawings:
FIG. 1 is a side elevational view, partly in longitudinal section, of a first embodiment of a gripping and rotating tong device in accordance with principles of the present invention, shown operating on a rod;
FIG. 2 is a horizontal transverse sectional view taken on line 2--2 of FIG. 1;
FIGS. 3, 4 and 5 are diagrammatic top plan views, generally comparable to FIG. 2, depicting different steps in operation of the gripping and rotating device of FIGS. 1 and 2;
FIGS. 6 is a fragmentary vertical sectional view of the gripping and rotating tong device in FIGS. 1-5, with an associated transfer device, installed in a chain magazine;
FIG. 7 is a reduced scale diagrammatic top plan view of the assembled apparatus of FIG. 6;
FIGS. 8, 9 and 10 are fragmentary top plan views, generally comparable to portions of FIGS. 2-5, showing alternatives for locking of the gripping and rotating tong device to the rod to be handled; and
FIG. 11 is a fragmentary longitudinal sectional view, generally comparable to the rightmost portion of FIG. 1, showing another embodiment of the gripping and rotating tong device.
DETAILED DESCRIPTION
FIGS. 2 and 1 respectively depict one embodiment of the gripping and rotating tong device according to the invention as a cross-sectional plan view and as a partially cross-sectional side elevation, the housing being sectioned along the center line. The gripping tong 10 is made up of a housing part 11 and two concentric ring gears 1 and 2, both of which are supported concentrically in bearings in the housing 11. In each ring gear 1 and 2, the cogging and the bearings are also concentric. In other words, the bearings and the cogging of the ring gear 1 and the bearings and the cogging of the ring gear 2 are all mutually concentric. In this embodiment, each cogged gear 1, 2, outer periphery is made up, in part, of a smaller-diameter cylindrical portion 5, 6, the outer surface of which constitutes a slide bearing in relation to the housing 1. External gear cogging has been machined into the larger-diameter cylindrical portions 7, 8, respectively of the ring gears 1 and 2. These ring gears 2 and 1 are installed inside the housing 11 in such a manner that the cogged portions 7 and 8 rest against each other on their end surfaces 12 and 13, respectively which are perpendicular to their rotation-symmetry axes. In the housing 11 there are cylindrical mating slide surfaces corresponding to both slide surfaces 5 and 6 in order to form slide bearings, as well as mating slide surfaces corresponding to the smaller-diameter end surfaces 14 and 15, facing away from each other, of the ring gears. The ring gears 1 and 2 are thus located inside the housing 11 in such a manner that they can rotate about their joint rotation-symmetry axis either together or separately, the surfaces 12 and 13 of the ring gears sliding in relation to each other but not being substantially capable of moving away from each other in the direction of the rotation-symmetry axis or in the peripheral direction so as to become eccentric in relation to each other. Both of these ring gears 1 and 2 are driven by a gear 3, the axis of which is parallel to the rotation-symmetry axis of the ring gears and the cogging of which has been adapted to their cogging. The housing 11 may be made up of halves which may be interconnected by any method deemed suitable.
In the center of the ring gears there is a hole in which the drill rod or other corresponding cylindrical piece or similar part of a piece to be handled fits, and from this axial hole there is a radial aperture outwards in such a manner that a notch 16 is formed in the ring gear 2, and respectively a notch 17 in the ring gear 1, for introducing the rod 20 to be handled from outside the cogged peripheries to their center, while maintaining the axial direction of the rod approximately parallel to the axis of the ring gears. In the housing 11 there is a corresponding aperture 18 for introducing the rod 20 to be handled from outside the housing 11 through its wall and further to the center of the ring gears.
Furthermore, the cogging of the ring gear 1 has been eliminated in an area in alignment with the gear 3, in other words in this case on the side opposite to the notch 17, over such a portion of the periphery that, when the notch 17 is in alignment with the aperture 18 of the housing, the gear 3 is exactly in the middle of this uncogged portion 19, in which case the gear 3 cannot touch the teeth of the ring gear 1. One advantageous length for the uncogged portion 19 is such that the central angle α corresponding to the length of the arc of the portion 19 is double, compared with the angle k of the rotation which effects the locking of the ring gears 1 and 2. In other words, α=2×k. Typically α is the same as the opening angle β of the notch 17, in which case β=2×k. On the periphery portion 19 defined by this angle α, the radius R of the ring gear 1 is thus at most the radius of the root of the cogging of the gear 1 portion of the ring gear.
The basic form of the gripping and rotating tong device described above works as follows. In FIG. 3, the ring gears 1 and 2 are in such a position that their notches 17 and 16 are in alignment and at the same time in alignment with the aperture 18 of the housing. In this case the rod-like piece 20 can be taken from outside the housing to the center of the ring gears and away from there in directions S1, when the tong device 10 is pressed, for example, onto a drill rod in the magazine. The inner surface of the notch 17 of the ring gear 1, over a distance corresponding to the diameter of the drill rod as calculated from the bottom of the notch, has been typically shaped so or coated or provided with such a mechanism that, when the tong device 10 is pushed onto the drill rod 20, so much pressure is produced between them that the friction force between the rod 20 and the ring gear 1 is greater than the friction force between the ring gears 1 and 2 when they are rotated in relation to each other. Thereafter, when the rotating of the gear 3 is started, the ring gear 2, which has cogging over its entire periphery, begins to rotate in a corresponding manner in direction S2. At this stage the ring gear 1 remains in place because of the above-mentioned difference in friction, since its cogged periphery has an uncogged portion 19 in alignment with the gear 3. The fact that the ring gear 1 remains in place, with respect to the housing, is, however, not necessary for the functioning of the device, but usually it is advantageous.
The ring gear 1 has in its end surface 13, which is against the ring gear 2, a circularly arcuate groove 21, the annular length of which (in a circumvential direction) also corresponds to the central angle α. The ring gear 2, for its part, has in the end surface 12, which comes against the ring gear 1, a protruding pin 22 which precisely fits to move in the groove 21. Now, when the cogged periphery 2 has turned over an angle of α/2, in other words over the rotation angle k, whereupon the notch 16 of the ring gear 2 has turned to such a position that typically its trailing edge has just closed the leading edge of the notch 17 of the ring gear 1, the pin 22 has moved in the groove 21 as far as its end. This situation is depicted FIG. 4. At this time, the rod 20 is locked in the center of the ring gears 1 and 2 so that it cannot rotate or escape from the tong. When the rotation of the gear 3 is discontinued at this stage, it is now possible by means of the tong 10 to transfer the rod 20 to a point of use.
When the rod 20 has, in the manner described above, been taken out of the magazine and transferred to a point of use by means of the tong 10 and at the same time been placed at the desired point and in the desired position, the next step can be the rotation of the rod 20, for example, in order to produce a screw joint. This rotation of the rod 20 is effected by continuing the rotation of the ring gears 1 and 2 by the gear 3 further in direction S2. This is possible, since in this position the ring gears 1 and 2 together form a ring with an uninterrupted cogged periphery, which is formed as follows: the uninterrupted portion of the cogged periphery of the ring gear 1 closes the notch 16 of the ring gear 2 and the uninterrupted portion of the cogged periphery of the ring gear 2 closes the notch 17 of the ring gear 1, and likewise the uninterrupted portion of the cogged periphery of the ring gear 2 closes the uncogged portion 19 of the ring gear 1, and since the axial length of the gear 3 is the same as the combined total axial length of the ring gears 1 and 2. At this time, the gear 3 rotates the whole assembly formed by the ring gears 1 and 2 at every moment of time, at least in one of the ring gears. This situation is shown in FIG. 5. When the ring gears 1 and 2 are in this position in relation to each other, they can be rotated in direction S2 over an unlimited number of rotations.
When the screw joint, or some other rotation has been completed, the ring gears 1 and 2 are returned to the position corresponding to FIG. 4, by rotating the gear 3. This return can be effected either by continuing to rotate the ring gears in direction S2 until the relationship shown in FIG. 4 has been reached, in which case the inner surfaces of the notches of the ring gears must slide in relation to the rod 20, or by rotating the ring gears 1 and 2 in the reverse direction, S3. In most cases, the fact that the rod 20 is in this case rotated less than one full rotation in the reverse direction, whereupon, for example, the screw joint opens respectively, has no importance in many practical applications, since, for example, in normal rock drilling the starting of the drill automatically removes any slack from the screws, thus finally tightening the screw joint.
Now that the ring gears 1 and 2 have been returned to the relative dispositions shown in FIG. 4, the tong is opened as follows to release the rod 20. To ensure the opening, there is provided in the ring gear 1 a pin 23, which is parallel to the longitudinal axis of the ring gear 1 and protrudes from the end surface 15 of the ring gear 1. This protruding part has an end surface shaped like a cone 24. In alignment with this pin 23, there is in the housing 11 a corresponding depression 25 in which the cone fits when the ring gear 1 is in the relative disposition shown in FIG. 3, in other words when the notch 17 is in alignment with the aperture 18. The pin 23 is provided with springs in a manner known per se. not depicted here, so as to press the pin 23 into the depression 25. When the cone 24 is in the depression 25, the other, flat end 27 of the pin 23 is disposed in the plane of the end surface 13 of the ring gear 1. In the corresponding end surface 12 of the ring gear 2 there is a depression 26 in which the end 27 of the pin 23 fits when the pin 23 has been moved against the spring force to such an extent that its conical part 24 is withdrawn completely inside the end surface 15 of the ring gear 1. The pin 23 and the depression 26 are situated, when the notches 16 and 17 of the ring gears are in mutual alignment, on the same circumferential line in relation to the axis of rotation of the ring gears and at a circumferential distance from each other, which corresponds to the angle α/2 (k). In this case, when the ring gears are in the position indicated in FIG. 4, the cone 24 is located in the depression 25 and the depression 26 is located exactly in alignment with the pin 23. When the ring gears are rotated from the disposition shown in FIG. 4, in the direction S2, since the pin 22 at the end of the groove 21 keeps the ring gears locked to each other when rotated in this direction, the turning of the ring gear 1 forces the wedge formed by the cone 24 and the corresponding depression 25 to push the pin 23 against its spring force, whereupon the other end 27 of the pin pushes into the depression 26. The end 27 of the pin is located in the depression 26 during the rotation. When the gears are disposed in the positions shown in FIG. 4, and the purpose is to open the tong device, the gear 3 is rotated in the reverse direction, whereupon the ring gear 2 rotates in direction S3. At this time the ring gear 1 remains in place, since in this position the uncogged portion 19 of the periphery of the ring gear is in alignment with the gear 3 and since in this position the spring presses the cone 24 of the pin 23 into the depression 25. Thus, the ring gear 2 turns in direction S3 until its notch 16 is in alignment with the aperture 18, whereupon both ring gears 1 and 2 are in the position corresponding to FIG. 3. At this time, the tong 10 can be withdrawn from the rod 20 and be returned to its resting position.
The operation of the tong device is completely symmetrical; in other words, it can be used for gripping a rod and rotating it in a similar manner in either direction. In order to achieve this, the groove 21 is symmetrical in relation to the diameter of the notches 16 and 17. The second springed pin 33 with its conical end 34, depression 35 and its other end 37 and depression 36 is also symmetrically located to rotate the ring gears and thereby the rod 20 in a direction reverse in relation to the above.
FIGS. 6 and 7 show how the gripping and rotating tong devices fastened to the transfer means 4 form a gripping and rotating unit 4 to be installed, for example, inside a chain magazine. In this case the gripping and rotating unit 4 is made up of two gripping and rotating tong devices 10, a motor 9 rotating the tong devices by transmission of gears 3, transfer cylinders 37 moving the tong devices between the magazine and the point of use, and a cylinder 38 which moves the tong devices axially. These said components form the gripping and rotating unit 4, which can be installed in connection with the mechanism desired. To illustrate the operation of the unit 4, FIGS. 6 and 7 also depict the placement of the unit inside the magazine; this magazine is made up of chain sprockets 40 and a chain 49 which runs on them, the rods 20 being located in spaces in the chain. The chain magazine is rotated by the drive device 39. This chain magazine with its drive device may be of any suitable type known per se, and therefore its operation is not described in greater detail. The gripping and rotating unit 4 and the chain magazine are in this case installed by means of bearing fastening parts 41 to the side of the feeding boom 42 of a rock-drilling machine. Also fastened to the feeding boom is the striking and rotating device 48 and detent 47 of the drill. The unit 4 with its tongs 10 takes a drill rod 20 from the chain magazine, transfers it onto the feeding boom as a continuation of the previous extension rod 50, rotates the rod 20 in such a manner that a screw joint is produced between the previous rod 50 held in place by the detent 47 and the introduced rod 20, whereafter the unit 4 returns its tong device 10 to the initial position inside the chain magazine. In the unit 4 the cylinders 37 effect the movement transverse to the rod, and the cylinder 38 effects the axial movement of the rod, by means of which the rod 20 is brought to the end of the rod 50, at the correct point longitudinally, and is transferred further to produce a screw joint.
That construction detail by means of which the previously mentioned sufficient friction is produced between the rod 20 and the ring gear 1 is implemented according to the point of use in each given case, the manner of implementation being affected among other things by whether the rods to be handled always have the same diameter or whether this dimension varies and how much, whether the rod is circular or perhaps polygonal in cross section, and furthermore, how rough a handling the rod can withstand, in other words how precisely the pressure must be calibrated. FIGS. 8, 9 and 10 show some alternatives. In fig. 8, an angular rod is being handled, and it has been possible to shape the notch 17 at the walls 55 surrounding its center so as to correspond to the cross section of the rod. In this case the locking and rotation of the rod is very simple and reliable.
In FIG. 9, the inside of the notch 17, over the distance 55 corresponding to the diameter of the rod is coated with, for example, rubber 51, which by means of its elasticity and the pressure keeps the rod 20 in place.
FIG. 10 illustrates the principle of a cam alternative, in which a cam 52 has been embedded into the ring gear 2, into its end surface 12, and connected to the ring gear 2 by means of a shaft 53. At a suitable distance in the gear ring 1 there is located a pin 54, which protrudes from the end surface 13 of the ring gear 1 in such a manner that it is tangent to the outer side of the cam 52. When the ring gear 2 now turns over angle k in relation to the ring gear 1, the outer surface of the cam 52 slides against the pin 54 and produces by its inner surface a pressure against the rod 20. On the opposite side there are, of course, symmetrically in relation to the center line of the notches 16 and 17, the corresponding components for rotation in the reverse direction. A few methods possible for producing the pressure are described above, but in practical implementation this sufficient friction can be produced by any one of the methods described or by any other method known per se. When necessary, the ring gears of the tong device can be provided with replaceable or adjustable inner parts in the necessary area 55. In other words, gripping parts suitable for the rod in a given case are installed in the notches 16 and 17 or, if the question is of a cam alternative, it is also possible only to adjust the cam in question in accordance with the rod used. It is also possible to use a hydraulic, remote-controlled or self-controlled gripping-part construction.
Also some other structure of the gripping and rotating tong device itself may in its details differ from the embodiment described above. It can, for example, be thought that the mutual locking of the ring gears 1 and 2, for which now a groove 21, a pin 22 and parts 23-27 and 33-37 are used, is implemented so that the ring gears 1 and 2 can as such move freely in relation to each other but means for the mutual locking and releasing of these ring gears have been arranged in connection with the gear 3. In this case the gears 3 have been divided into two parts, one being responsible for the rotation of the ring gear 1 and the other for the rotation of the ring gear 2, and the mutual locking of these parts of the gear 3 has been arranged so that it corresponds to the mutual locking, described above, of the ring gears 1 and 2. Locking techniques and locking means of other types can also be used to achieve a function corresponding to the mutual locking of the ring gears 1 and 2 described above, and these locking means can be placed in any part of the mechanism. In general it is, however, most advantageous to install them directly in the ring gears 1 and 2.
The bearings of the ring gears 1 and 2 are preferably effected as slide bearings, because, for example, in producing a screw joint the rotary speeds and the number of rotations remain relatively low. It is, however, possible to use also other types of bearings according to the requirements of the point of use.
In the embodiment described, the cogging of the ring gears is external cogging on the periphery of the rings, but in situations and conditions of use in which, for example, the teeth should entirely be protected from external influences, the use of internal teeth on the periphery could be considered. In this case the structure may be, for example, similar to that depicted in FIG. 11, in which the ring gears 1 and 2 with their drive gears 3 have been installed inside the housing 11. The construction will be more complicated, but outwards all that will be visible of the ring gears is their smooth outer periphery.
One deviating embodiment of the invention is one in which the uncogged portion 19 of the periphery of the ring gear 1 extends over the entire peripheral length of this ring, i.e. the ring gear 1 is in fact an uncogged locking ring. In this embodiment the ring gears 1 and 2 can be made to rotate without interruption, for example, by installing two gears on the periphery of the ring gear 2, the distance between these gears being greater than the length of the peripheral portion of the notch 16. In this case, when the rings 1 and 2 are rotating, one of the said two gears is at every moment in contact with the periphery of the ring gear 2. These gears must, of course, rotate at the same speed in relation to each other. One possibility to effect uninterrupted rotation is to use screw transmission, in which case the cylindrical gear 3 is replaced, for example, with a spiral the length of which is greater than the length of the peripheral portion of the notch 16. Such a spiral is in the extreme situation in contact with the teeth of the ring gear 2 on both sides of the notch 16. Otherwise the mutual limiting and locking of the rings 1 and 2 can be implemented as in the other embodiments.
When the method of FIGS. 9 and 10 to press the rod 20 tightly to the center of the ring gear 1, or some other corresponding construction also producing tight pressing is used, the rods can be used in diverse ways, since in this case the rod cannot slip even in the vertical position from the center of the tong. In this case, the tong can be used not only for transferring drill rods, drill pipes and drill bits on the horizontal level but also for transferring them or, for example, rock bolts into some other position. According to the piece to be handled, the gripping and rotating tong unit 4 may include one, two or more gripping and rotating tong devices 10. It can also be thought that, for example, in the alternative of FIGS. 6 and 7, the unit 4, by means of two gripping and rotating tong devices 10, carries out the installing and removing of extension rods, and the tong-device 10 on the side of the object to be drilled alone carries out the replacing of the drill bit when necessary, in which case the unit 4 is transferred out from one end of the chain magazine which is against the rods, one tong device 10 is disconnected, and the other tong device takes a drill bit from another magazine, not shown, which is concentric with the chain magazine 40, 49, and installs the bit in its place in otherwise the same manner as the drill rods.
It can be pointed out as a further feature of the construction, that the gripping and rotating unit 4, as such or connected to a magazine of the desired type, can be retro-installed in drilling machines. When necessary, the unit can even be transferred from one machine to another and, if at this time the type of the rod 20 changes, this dimensional change can be taken into account by using replaceable inner parts in the ring gears 1 and 2. | A gripping and rotating tong device for handling drill rods, drill bits and other corresponding, at least partially rod-like pieces. The tong device comprises a housing fastened to a movable transfer device, the housing having an axial hole and a radial aperture for taking the piece to be handled from outside the housing to inside it, and in the housing it has grippers which grip the workpiece introduced into the housing, and parts for rotating the grippers. The grippers include at least two locking ring gears which rest in bearings rotatably in relation to the housing, at least one of them having cogging on the outer periphery and each having a notch extending to the center, along which notch the workpiece can pass to the center of the ring gears and away from them. The rotating of the ring gears is effected by at least one gear, the workpiece centered with the ring gears rotating together with them. The centering and/or releasing of the workpiece is effected by a limited turning of one ring gear in relation to the other ring gear, produced by the starting, ending or changing of direction of the rotation. | 4 |
RELATED APPLICATION
[0001] This application claims the benefit of provisional application Serial No. 60/352,117 filed Jan. 24, 2002 entitled ANTI-EXPLOSIVE FERTILIZER COATINGS, the teachings of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is broadly concerned with a coating and methods of applying the coating to agricultural grade fertilizer particles. The coating inhibits the adsorption and absorption of hydrocarbons into the pores of the fertilizer particles thereby reducing the efficacy of the fertilizer as an oxidizing source in the production of incendiary devices. More particularly, the invention is concerned with coatings containing at least one polymer and methods of applying the coating to fertilizer products. The invention has particular utility in the deterrence or prevention of agricultural grade fertilizers and industrial grade ammonium nitrate being used to create weapons of terror.
[0004] 2. Description of the Prior Art
[0005] Some common agricultural grade fertilizers generally comprise compounds which serve as excellent oxidizing agents, ammonium nitrate being one such compound. Generally, the fertilizer particles contain pores into which a number of other chemical agents can infiltrate, including hydrocarbon materials. The combined ammonium nitrate/fuel infiltrated particle is commonly referred to as ANFO (ammonium nitrate fuel oil). The article “Blasting Products” of the ANFO Manual distributed by El Dorado Chemical Company (St. Louis, Mo.), a copy of which is submitted herewith, is hereby incorporated by reference. When supplied with an ignition source, the hydrocarbon material acts as a fuel that is oxidized by the fertilizer particles. The resulting chemical reaction can release considerable amounts of energy, especially when the reactants are present in substantial quantities. To be most effective as an explosive, the ANFO will comprise about 5.7% by weight fuel oil. It is understood that when alternative sources of hydrocarbon fuel are used the fuel:ammonium nitrate ratio may need to be altered to achieve a stoichiometrically balanced mixture.
[0006] Both hydrocarbon fuels and fertilizers are readily available and relatively inexpensive products thereby making them excellent raw materials for producing renegade incendiary devices. The Oklahoma City bombing incident is one tragic example of how such materials may be used to perpetrate large-scale, terrorist atrocities.
[0007] During the manufacturing process, fertilizer particles are coated with an anti-dusting agent in order to reduce the amount of fertilizer dust produced during handling of the particles.
[0008] A commonly used anti-dusting agent is Galoryl (Lobeco Products Inc., Lobeco, S.C.) which is hydrocarbon based and is sprayed on during the manufacturing process. Being hydrocarbon based, this coating does not inhibit the infiltration of other hydrocarbon materials that may be used in constructing an incendiary device. Additionally, the anti-dusting agent does not form a protective barrier film encapsulating the entire fertilizer particle thereby leaving numerous pores exposed.
[0009] In order to prevent the misuse of ammonium nitrate in improvised explosives, it is necessary physically separate the fuel from the ammonium nitrate and also prevent the penetration of the liquid fuel into the fertilizer particles. If the fuel does not enter the interior of a sufficient number of particles in an optimal amount, the utility of ammonium nitrate particles as an oxidizer is substantially reduced or completely eliminated. There is a real need in the art for a fertilizer particle coating which forms a barrier that inhibits hydrocarbon infiltration of the fertilizer pores, and which will not alter the effectiveness of the fertilizer for its intended agricultural applications.
SUMMARY OF THE INVENTION
[0010] The present invention overcomes the problems outlined above and provides a coating for use with agricultural grade fertilizers and industrial grade ammonium nitrate. The coating should comprise a solution including at least one material which exhibits one or more of the following properties: substantially water soluble, substantially hydrocarbon insoluble, and capable of forming a film.
[0011] As used herein the term “substantially water soluble” means that the material may be contacted with water or a water-containing solvent mixture for a period of time up to approximately 24 hours and be transformed into a solution that contains at least 1% w/w of the material. The solution should be relatively stable meaning that the solute will not precipitate out of solution for at least about 3-4 hours. Various procedures may need to be employed to achieve this dissolution, such as heating and agitation. As used herein, the term “substantially hydrocarbon insoluble” means that the material will not dissolve in hydrocarbons to an extent greater than about 10% w/w upon exposure for a period of time up to approximately 48 hours at temperature and conditions of use.
[0012] With respect to simple conventional coating techniques, the pH of the solution may also play a role due to its effect on ammonia volatilization. Other coating techniques may reduce or eliminate the effect that pH has on ammonia volatilization. In preferred embodiments using the coating techniques which would have an effect on ammonia volatilization, the coating should have a pH of about 7.0 or less, preferably about 6.5 or less and more preferably about 5.5 or less. Those of ordinary skill in the art of coating will be able to use and develop coating methods which eliminate or reduce the volatilization of ammonia regardless of the pH of the coating. For example, spray drying or using a fluidized bed allow use of coatings with pH's above 7.0.
[0013] There is a wide range of materials which may be suitable for use in accordance with the present invention. Such materials include various natural and synthetic gums, starches and starch derivatives, polyethers, polysaccharides, polycarboxylates, poly-sulfonates, a wide range of monomers, polymers and copolymers, and combinations thereof. Among those materials for use with the invention are compositions that contain various mineral salts in addition to or instead of polymeric materials. Useful materials also include those that are known in the art of product formulation as flame and/or fire retardants. These include but are not limited to various boron-containing compositions such as borates, various metal salts including polymeric metal salts, oxides, carbides, nitrides, borides, silicates including polysilicates, silicides, aluminum-containing compositions, sulfates, phosphates, polyphosphates, chlorides, bromides, polymolybdates, molybdate salts, halogenated (particularly brominated) water-dispersible compounds with molecular weights above about 200 AMU. Ammonium phosphates are particularly preferred fire or flame retardant materials. As used herein, ammonium phosphate refers to any ammonium salt of any phosphate, including but not limited to any one chemical or combination of chemicals from the following list: ammonium phosphate, NH 4 H 2 PO 4 ; diammonium phosphate, (NH 4 ) 2 HPO 4 ; ammonium polyphosphate, (NH 4 ) salt of
[0014] ammonium pyrophosphate, (NH 4 ) 2 H 2 P 2 O 7 ; ammonium metaphosphate, NH 4 PO 3 ; and ammonium orthophosphate. It is understood that such flame and/or fire retardant materials can be used alone in some instances, that is to say as the coating itself, or in combination with other materials suitable for use in the present invention. For example, ammonium phosphate may be used in combination with a polymer, and especially with those polymers disclosed herein.
[0015] It has even been found that ordinary water when applied to the fertilizer particles reduces the level of fuel oil infiltration by decreasing the total number of pores through dissolving and “re-drying” a portion of the fertilizer particle.
[0016] In one preferred embodiment, the coating material comprises a polymer, and more preferably a carboxylate polymer, especially one or more of those set forth in U.S. patent applications Ser. No. 09/562,579 and Ser. No. 09/799,210 which are hereby incorporated by reference as though fully set forth herein. Even more preferably the carboxylate polymer comprises a polymer of acrylic acid or it comprises at least two different moieties individually and respectively taken from the group consisting of A, B, and C moieties, recurring B moieties, and C moieties wherein moiety A is of the general formula
[0017] moiety B is of the general formula
[0018] or
[0019] and moiety C is of the general formula
[0020] wherein R 1 , R 2 and R 7 are individually and respectively selected from the group consisting of H, OH, C 1 -C 30 straight, branched chain and cyclic alkyl or aryl groups, C 1 -C 30 straight, branched chain and cyclic alkyl or aryl C 1 -C 30 , based ester groups (formate (C 0 ), acetate (C 1 ), propionate (C 2 ), butyrate (C 3 ), etc. up to C 30 ), R′CO 2 groups, and OR′ groups, wherein R′ is selected from the group consisting of C 1 -C 30 straight, branched chain and cyclic alkyl or aryl groups; R 3 and R 4 are individually and respectively selected from the group consisting of H, C 1 -C 30 straight, branched chain and cyclic alkyl or aryl groups; R 5 , R 6 , R 10 and R 11 are individually and respectively selected from the group consisting of H, the alkali metals, NH 4 and the C 1 -C 4 alkyl ammonium groups, Y is selected from the group consisting of Fe, Mn, Mg, Zn, Cu, Ni, V, Cr, Si, B, Co, Mo, and Ca; R 8 and R 9 are individually and respectively selected from the group consisting of nothing (i.e., the groups are non-existent), CH 2 , C 2 H 4 , and C 3 H 6 , at least one of said R 1 , R 2 , R 3 and R 4 is OH where said polymeric subunits are made up of A and B moieties, at least one of said R 1 , R 2 and R 7 is OH where said polymeric subunits are made up of A and C moieties, and at least one of said R 1 , R 2 , R 3 , R 4 and R 7 is OH where said polymeric subunits are made up of A, B and C moieties.
[0021] In the case of the polymer coatings comprising A and B moieties, R 1 -R 4 are respectively and individually selected from the group consisting of H, OH and C 1 -C 4 straight and branched chain alkyl groups, R 5 and R 6 are individually and respectively selected from the group consisting of the alkali metals.
[0022] One preferred polymer useful with the present invention comprises recurring polymeric subunits formed of A and B moieties, wherein R 5 and R 6 are individually and respectively selected from the group consisting of H, Na. K, and NH 4 and specifically wherein R 1 , R 3 and R 4 are each H, R 2 is OH, and R 5 and R 6 are individually and respectively selected from the group consisting of H, Na, K, and NH 4 depending upon the specific application desired for the polymer. These preferred polymers have the generalized formula
[0023] wherein R 5 and R 6 are individually and respectively selected from the group consisting of H, the alkali metals, NH 4 and C 1 -C 4 alkyl ammonium groups (and most preferably, H, Na, K and NH 4 depending upon the application), and n ranges from about 1-10000 and more preferably from about 1-5000.
[0024] As can be appreciated, polymers useful in accordance with the present invention can have different sequences of recurring polymeric subunits as defined above. For example, a polymer comprising B and C subunits may include all three forms of B subunit and all three forms of C subunit. In the case of the polymer made up of B and C moieties, R 5 , R 6 , R 10 , and R 11 are individually and respectively selected from the group consisting of H, the alkali metals, NH 4 , and the C 1 -C 4 alkyl ammonium groups. This particular polymer is sometimes referred to as a butanedioic methylenesuccinic acid copolymer and can include various salts and derivatives thereof.
[0025] Another preferred polymer useful with the present invention is composed of recurring polymeric subunits formed of B and C moieties and have the generalized formula
[0026] Preferred forms of this polymer have R 5 , R 6 , R 10 , and R 11 individually and respectively selected from the group consisting of H, the alkali metals, NH 4 , and the C 1 -C 4 alkyl ammonium groups. Other preferred forms of this polymer are capable of having a wide range of repeat unit concentrations in the polymer. For example, polymers having varying ratios of B:C (e.g., 10:90, 60:40, 50:50 and even 0:100) are contemplated and embraced by the present invention. Such polymers would be produced by varying monomer amounts in the reaction mixture from which the final product is eventually produced and the B and C type repeating units may be arranged in the polymer backbone in random order or in an alternating pattern.
[0027] As noted above, it is possible to use polymers of the present invention in combination with other materials, such as fire and/or flame retardant materials. For example, one such combination would comprise a mixture of a polymer comprising B and C type repeating units and ammonium phosphate. When such a polymer comprising B and C type repeating units is used in combination with ammonium phosphate, the ammonium phosphate may comprise a substantial portion of the mixture. However, extremely high levels of ammonium phosphate do not impart appreciably better flame retardant properties in comparison to lower levels. Therefore, for purposes of the present invention, it is preferable that the mixture comprise between about 90-99% by weight polymer and 1-10% by weight ammonium phosphate, more preferably between about 93-97% by weight polymer and 3-7% by weight ammonium phosphate, and most preferably between about 94-96% by weight polymer and 4-6% by weight ammonium phosphate. Most preferably, ammonium phosphate comprises approximately 5% of the total weight of the polymer/ammonium phosphate mixture.
[0028] The polymers useful in accordance with the present invention may have a wide variety of molecular weights, ranging for example from 500-5,000,000, more preferably from about 1,500-20,000, depending chiefly upon the desired end use.
[0029] In many applications, and especially for agricultural uses, polymers used with the invention may be mixed with or complexed with a metal or non-metal ion, and especially ions selected from the group consisting of Fe, Mn, Mg, Zn, Cu, Ni, Co, Mo, V, Cr, Si, B, and Ca. Boron is especially preferred because it may reduce the explosivity or energy released during combustion of ANFO as demonstrated by its use in various fire retardant materials.
[0030] The coating may comprise an additional material dissolved or dispersed in the same solution as the first polymer described above. Such additional materials should be selected based on their ability to increase the hydrocarbon resistance of the coating. Examples of suitable materials include natural and synthetic gums, starches and starch derivatives, polyethers, polysaccharides, polycarboxylates, poly-sulfonates, and a wide range of polymers and copolymers. Polyvinyl alcohol (PVA) is one of the preferred materials in this respect. PVA is a material highly resistant to hydrocarbon diffusion to the point where protective gloves and fuel hoses are products made from PVA. PVA is available in a variety of grades with different hydrolysis levels and molecular weights. Higher molecular weights generally give rise to higher viscosity polymer solutions. Therefore lower molecular weights in the range of about 10,000 to 30,000 are preferred due to their ability to form thin films which coat the particle surface easily. High hydrolysis level PVA is also preferred because of its increased resistance to hydrocarbon diffusion compared to that of PVA with a lower degree of hydrolysis.
[0031] Solid PVA is not rapidly water soluble at room temperature and below, therefore it is preferable that PVA be used in companion with another material of the type previously described. The weight ratio of PVA to the other polymer should be between about 1:100 to 100:1, and more preferably between about 1:10 to 10:1 and most preferably about 1:3.
[0032] It is also within the scope of the present invention to provide a fertilizer coating comprising only PVA. As previously discussed, some agricultural applications will require fertilizer coatings which are more water soluble, in addition PVA is expected to be more expensive than other materials described above, therefore preferred embodiments of the invention contain PVA used in combination with other materials.
[0033] Coatings according to the invention should have a solids content of between about 5-70% by weight and more preferably between about 20-60% with the balance comprising water. The solids content largely depends upon the compatibility of the coating viscosity with the method of application to the fertilizer particles. It is most preferable that the fertilizer coating have a solids content of between about 10-30% by weight.
[0034] The coating is applied as a film to a fertilizer particle to form a coated fertilizer particle. Preferably the fertilizer particle used will be porous and will have a bulk density of about 40 to 60, more preferably about 40 to 50 and most preferably about 44 lbs/ft 3 . 1However, less porous fertilizer particles with higher bulk densities are also suitable for use in accordance with this invention. Preferred fertilizer particles for use with the current invention are monoammonium phosphate (MAP), diammonium phosphate (DAP), any one of a number of well known N-P-K fertilizer products, and/or fertilizers containing nitrogen materials such as ammonia (anhydrous or aqueous), ammonium nitrate, ammonium sulfate, urea, ammonium phosphates, sodium nitrate, calcium nitrate, potassium nitrate, nitrate of soda, urea formaldehyde, metal (e.g. zinc, iron) ammonium phosphates; phosphorous materials such as calcium phosphates (normal phosphate and super phosphate), ammonium phosphate, ammoniated super phosphate, phosphoric acid, superphosphoric acid, basic slag, rock phosphate, colloidal phosphate, bone phosphate; potassium materials such as potassium chloride, potassium sulfate, potassium nitrate, potassium phosphate, potassium hydroxide, potassium carbonate; calcium materials, Such as calcium sulfate, calcium carbonate, calcium nitrate; magnesium materials, such as magnesium carbonate, magnesium oxide, magnesium sulfate, magnesium hydroxide; sulfur materials such as ammonium sulfate, sulfates of other fertilizers discussed herein, ammonium thiosulfate, elemental sulfur (either alone or included with or coated on other fertilizers); micronutrients such as Zn, Mn, Cu, Fe, and other micronutrients discussed herein; oxides, sulfates, chlorides, and chelates of such micronutrients (e.g., zinc oxide, zinc sulfate and zinc chloride); such chelates sequestered onto other carriers such as EDTA; boron materials such as boric acid, sodium borate or calcium borate; and molybdenum materials such as sodium molybdate. Of course, due to its explosive tendencies, ammonium nitrate is the most preferred fertilizer for purposes of the invention.
[0035] The coating is typically applied to the fertilizer particles at a level of from about 0.00014% by weight, and more preferably from about 0.01-1.0% by weight, and most preferably 0.250.5% by weight based upon the weight of the fertilizer taken as 100%. Additionally, when a coating material comprising carbon is employed, the quantity of carbon comprises about 0.2% by weight or less of the total weight of the coated particle. The film or coating should limit hydrocarbon infiltration of the fertilizer particle pores in comparison to an uncoated fertilizer particle, and preferably should reduce hydrocarbon infiltration by at least 10% in comparison to an uncoated fertilizer particle. Even more preferably, the film should reduce hydrocarbon infiltration by at least 50% and most preferably by at least 80%. Such hydrocarbon materials include fuel oil, diesel fuel, grease, wax, and other materials containing a preponderance of hydrocarbons. By preventing or inhibiting the infiltration of hydrocarbon materials into the fertilizer particle, the fertilizer particles have reduced explosivity tendencies, thereby reducing their usefulness as incendiary devices.
[0036] Another method of reducing the explosivity of agricultural grade fertilizer particles and industrial grade ammonium nitrate embraced by this invention is to selectively supply a quantity of water to the fertilizer particles. In so doing, a portion of the fertilizer particles dissolves thereby reducing the number of pores available for hydrocarbon infiltration. Finally, it is necessary to dry the fertilizer particles in order to avoid imparting to the quantity of particles undesirable characteristics such as Clumping and caking.
[0037] Thus far, the description above has focused on the coatings and coated fertilizer particles on an individual particle level. When dealing with large quantities of coated fertilizer particles, especially coated ammonium nitrate particles, it is important to note that complete coating coverage of each individual particle is not always essential. It is possible for the coatings of the invention to reduce or completely eliminate the explosivity of the quantity of particles as a whole so long as a plurality of the particles are at least partially coated. It is even possible to mix quantities of coated and uncoated particles together and still produce a fertilizer mixture that has reduced explosivity characteristics. For even when fuel oil is added to this mixture of particles, the coated particles will absorb little or no fuel and some of the uncoated particles will become super-saturated with fuel oil. Both types of particles reduce the explosivity of the entire quantity of fertilizer particles. It may seem surprising that a super-saturated particle will reduce explosivity of the entire batch, however, if too much oil is added, the ability of the ammonium nitrate to oxidize the fuel oil is reduced. As noted in the El Dorado Chemical article referenced and incorporated above, there is an optimal percentage of fuel oil (about 5.7%) which maximizes the theoretical energy released in the detonation of ANFO. Adding more or less fuel oil tends to decrease the amount of energy released upon detonation. Therefore, such super-saturated fertilizer particles act to reduce the explosivity of the entire quantity of fertilizer particles.
[0038] Advantageously, coatings of the current invention also inhibit the formation of fertilizer dust normally associated with fertilizer handling. Therefore, coatings according to the invention are suitable for use as anti-dusting agents, and may be employed in place of current hydrocarbon based anti-dusting agents.
[0039] Generally, methods of forming coated fertilizer particles in accordance with the invention comprise the steps of providing a fertilizer particle and coating the particle with a film comprising at least one material selected from the group consisting of natural and synthetic gums, starches and starch derivatives, monomers and polymers and copolymers selected from the group consisting of polyethers, polysaccharides, polycarboxylates, polysulfonates, and mixtures thereof. Polymer and copolymer coatings are preferred. The coating may be applied to the fertilizer particle in any manner commonly known or used in the art, such as spraying. The precise coating procedure employed will be based an a number of factors including but not limited to the viscosity of the coating, particle surface morphology, particle size, density, and application equipment available. Regardless of the coating method used, it is preferred that the coating be applied in such a manner as to form an evenly distributed film which will provide an effective barrier against hydrocarbon infiltration of the fertilizer particle. Generally preferred embodiments of the fertilizer coating comprise a solution including at least one of a substantially water soluble material, a material substantially insoluble in hydrocarbon materials, a material capable of forming a film including a quantity of polyvinyl alcohol dissolved or dispersed therein, and combinations thereof.
[0040] Preferred embodiments of the coated fertilizer particle of the invention comprise a fertilizer particle coated with a film comprising at least one material. It is more preferable for the material to be substantially water soluble, or substantially insoluble in hydrocarbon materials or still more preferably substantially water soluble and substantially insoluble in hydrocarbon materials.
[0041] Preferred methods of forming the coated fertilizer particle of the invention comprise the steps of providing a fertilizer particle and coating the particle with a film comprising at least one material. Again, it is preferable for the material to be substantially water soluble, or substantially insoluble in hydrocarbon materials or still more preferably substantially water soluble and substantially insoluble in hydrocarbon materials.
[0042] The coating of the invention may also be used in combination with a fertilizer particle. It is generally preferable for the coating to comprise at least one material. It is preferable that the material be substantially water soluble, substantially insoluble in hydrocarbon materials, or capable of forming a film, or a combination thereof.
[0043] Ammonium nitrate is the most preferred fertilizer particle for use with the invention because, when combined with a fuel source such as hydrocarbon materials, it acts as a powerful oxidizer. When brought into contact with an ignition source, the ammonium nitrate has the potential to violently react with the fuel source releasing considerable amounts of energy.
[0044] The most preferred polymer coating of the invention comprises a quantity of PVA dissolved or dispersed in a solution comprising a BC type polymer as described above in a weight ratio of about 1:3 (PVA:BC). The most preferred coating will comprise about 10-30% polymer solids and will be water soluble, insoluble in hydrocarbon materials, capable of forming a film and will have a pH of about 7.0 or less. Most preferably the polymer coating will be applied to an ammonium nitrate fertilizer particle in Such as manner so as to form an evenly distributed film providing an effective barrier to hydrocarbon infiltration of the fertilizer particle pores.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0045] The following examples describe preferred compositions and methods in accordance with the invention. It is to be understood that these examples are illustrations only and nothing therein should be deemed as a limitation upon the overall scope of the invention.
EXAMPLE 1
[0046] In this example, agricultural grade ammonium nitrate particles were coated with various polymeric materials, as set forth in Table 1, and then exposed to diesel fuel. The amount of diesel fuel retained by the coated particles compared to the original amount of diesel fuel added was then determined.
[0047] The ammonium nitrate particles were coated with the respective polymers according to one of the following two procedures. The most typical procedure was to weigh out an amount of the polymer solution to be coated onto a petri dish having a diameter of about 90 mm. All polymer solutions used in this experiment contained 50% by weight polymer. An appropriate amount of ammonium nitrate particles were weighed out and rolled onto the petri dish. The dish was then covered and the particles were vigorously swirled across the coating materials for several minutes. An alternative coating procedure was to weigh out an appropriate amount of ammonium nitrate particles and place them into a plastic bag equipped with a closure. The appropriate amount of polymer to be coated onto the ammonium nitrate particles was weighed and added to the bag. The bag contents were agitated vigorously for several minutes.
[0048] The coated granules were then placed into 20 mL glass vials and then saturated with diesel fuel. The diesel fuel is poured on top of the particles and then mixed with them by shaking the vial for approximately 10 minutes. The mixture was then allowed to stand for another 5 minutes to provide the fuel with the opportunity to soak into the particle and achieve intimate contact with the ammonium nitrate particles. The particles were then removed from the vials and placed on a filter with vacuum flow assist. The particles were then thoroughly washed with about 50 mL of tetrahydrofuran (THF). The filter liquid was discarded. The particles were collected from the filter and dried in a vacuum oven for about 10 minutes at about 25 in. Hg at a temperature of about 50° C. before being weighed. The difference between the coated particle weight and the washed and dried particle weight is the amount of fuel the particle retained. The results of these experiments are set forth in Table 1.
TABLE 1 Ammonium Sample Treatment type (% total particle Treatment (g 50% nitrate particle Diesel fuel Washed & dried w/w % original % wt. fuel retained/ # weight attributed to coating) polymer soln.) weight (g) (g) weight (g) fuel retained wt. washed particle 0 None 0.000 9.050 1.021 9.118 7 0.7 1 BC acid (1%) 0.205 10.073 1.014 10.020 ND ND 2 BC NH4 salt, pH 3.5 (1%) 0.208 9.984 1.040 9.971 ND ND 3 BC NH4 salt, pH 7 (1%) 0.208 9.986 1.020 10.020 ND ND 4 BC Na salt, pH 4 (0.5%) 0.100 10.057 1.083 10.079 ND ND 5 None 0.000 11.658 1.169 11.794 8 0.8 6 AB Na salt, pH 7 (1%) 0.220 10.266 1.154 10.646 23 2.5 7 C acid (1%) 0.215 10.289 1.142 10.289 ND ND 8 AB Na salt pH 7 (1%) 0.210 10.146 1.256 10.508 20 2.5 9 BC NH4 salt pH 3.5 (0.5%) 0.108 10.315 1.115 10.318 ND ND 10 B acid (0.5%) 0.102 10.021 1.144 10.037 ND ND 11 BC NH4 salt, pH 3.5 (0.25%) 0.057 10.190 1.168 10.279 5 0.6 12 BC NH4 salt, pH 3.5 (0.125%) 0.057 20.206 9 912 20.359 6 0.6 13 B acid (0.25%) 0.056 10.415 1.221 10.418 ND ND 14 C acid (0.25%) 0.059 10.227 1.178 10.251 ND ND 15 BC acid (0.25%) 0.062 10.652 1.173 10.632 ND ND 16 BC acid (0.125%) 0.060 19.584 2.657 19.608 ND ND 17 Polyacrylic acid (0.25%) 0.067 10.044 1.051 9.905 ND ND
[0049] As used in Table 1 and subsequently:
[0050] AB indicates a 1:1 mole:mole copolymer of maleic acid and vinyl acetate prepared as disclosed in U.S. patent application Ser. No. 09/562,579;
[0051] BC indicates a 1:1 mole:mole copolymer of maleic acid and itaconic acid prepared as disclosed in U.S. patent application Ser. No. 09/562,519;
[0052] B indicates a homopolymer of maleic acid obtained from Rohm and Haas Chemicals (Philadelphia, Pa.);
[0053] C indicates a homopolymer of itaconic acid prepared according to a method similar to that of BC;
[0054] Polyacrylic acid obtained from Aldrich Chemical Company (Milwaukee, Wis.); and
[0055] ND indicates that the measurement was not detectable or below what could be measured.
[0056] Next a series of experiments were performed using the same test procedure above, however the diesel infiltration time was extended to 24 hours. The results are listed in Table 2.
TABLE 2 Ammonium Sample Treatment type (% total particle Treatment (g 50% nitrate particle Diesel fuel Washed & dried w/w % original % wt. fuel retained/ # weight attributed to coating polymer soln.) weight (g) (g) weight (g) fuel retained wt. washed particle 18 None 0.000 10.451 1.130 10.623 15.22 1.62 19 BC acid (0.25%) 0.053 10.134 1.059 10.299 13.08 1.34 20 B acid (0.25%) 0.053 10.137 1.176 10.235 6.08 0.70 21 C acid (0.25%) 0.062 10.061 1.165 10.160 5.84 0.67 22 Acrylic acid (0.25%) 0.067 10.233 1.075 10.364 9.07 0.94 23 AB (0.25%) 0.100 (g 25% soln.) 10.313 1.121 10.385 4.19 0.45 24 BC acid (0.25%) 0.107 (g 25% soln.) 10.131 1.091 10.210 4.79 0.51
[0057] The above data demonstrates that even incomplete and imperfect practice of the invention disclosed herein is highly beneficial. It was further determined that polycarboxylate-containing materials are useful barrier coatings and help decrease diesel fuel infiltration into ammonium nitrate particles under the experimental conditions tested. However, the materials do not give perfect protection when used alone at lengthy exposure times.
EXAMPLE 2
[0058] The purpose of this example was to optimize diesel fuel resistance of two-component coatings. In these experiments, porous paper, S&S paper type #404 (Schleicher & Schuell, Dassel, Germany), was used to simulate porous ammonium nitrate particles. Upon examination using a low-power microscope, the porous paper had generally similar porosity to that of high porosity ammonium nitrate. The porous paper had the added advantage of being of substantially uniform porosity whereas the ammonium nitrate granules were of varying shape and porosity.
[0059] In the first experiment, the optimal percent of polymer solids in a coating was determined. The polymer coatings tested were polymaleic acid, sodium polymaleate at pH 3.5, itaconic acid homopolymer, polyacryilc acid, and BC acid polymer. The coating was applied to an 80×80 mm area on a sheet of porous paper by placing small drops of aqueous coating solution to the paper and spreading them to cover the test area using an inert plastic ruler. The coating was allowed to dry. Next, diesel fuel was dripped onto the coated area and the penetration, or lack thereof, was noted. It was determined that the range of polymer solids in the coating could be about 5-70% by weight, with the range about 10-30% by weight being preferred.
[0060] The next experiments involved addling polyvinyl alcohol, PVA, (Celvol 103 by Celanese Chemicals, Dallas, Tex.), a chemical known for its resistance to hydrocarbon diffusion, to the BC acid polymer coating in order to increase the coating's resistance to diesel fuel penetration. BC acid polymer was used because its performance was superior to the other coatings in the porous paper test described above. Because PVA is much more expensive than BC acid polymer it was desirable to determine the optimal ratio of PVA to BC acid polymer. The optimal ratio of PVA to BC acid polymer was about 1:3 by weight. The optimal mixture was prepared at about 20% w/w total dissolved solids by mixing appropriate amounts of water and BC acid polymer solution at room temperature. In this solution, PVA was dissolved or dispersed and the solution subsequently heated to about 90-95° C. with very vigorous, non-aerating agitation. The mixture was cooled to room temperature, at which time it had a consistency suitable for making coatings. The coating was applied to porous paper in the manner described above. The coating was hard, low-color, smooth to the touch after drying, non-hygroscopic and easily dissolved in water. The percent solids used is dictated by the compatibility with the application technique chosen. In practice, any percent solids solution can be used as long as the coating solution is sufficiently mobile under application conditions to create useful coatings. A useful coating is one that provides an effective barrier to fuel infiltration by being a thin film that coats and covers the particle surface.
[0061] Through these experiments, and for the chosen application method, it was determined that a 1:3 weight ratio of PVA to BC acid polymer was the most effective coating in preventing diesel fuel infiltration.
EXAMPLE 3
[0062] In this example, an alternative method of applying the polymer coating to the fertilizer particles was explored. The method involved placing a piece of flat round filter paper (S&S paper type #404) into a 5.5 inch diameter petri dish so that the paper occupies the entire bottom of the dish. About 2.9 g of the 20% w/w solution prepared in Example 2 is spread onto the paper until the paper is saturated with the liquid, but not to the point where there is liquid on the paper surface. The filter paper should be slightly moist to the touch. About 13 g of ammonium nitrate particles are poured onto the paper surface and rolled around the petri dish for about 1 minute, then removed. The particles are allowed to dry for 15 minutes in the air. This method was found to be highly effective as particles coated using this method do not tend to stick together and are dry and smooth to the touch.
[0063] Any method of particle coating known in the art, such as spraying, may be employed to apply the coating to the ammonium nitrate granules so long as the method results in a sufficient fraction of the surfaces of the fertilizer particles being coated to a sufficient degree. It is preferable to have particles coated with a relatively thin layer of coating so as to reduce the expense involved, preserve fertilizer analysis values, reduce water levels added to the fertilizer and reduce material handling requirements.
EXAMPLE 4
[0064] In this experiment, small particle size, high porosity ammonium nitrate granules coated with a factory applied anti-dusting agent, Galoryl, were tested for diesel fuel infiltration.
[0065] Typically, porous materials with high surface area per unit weight are very difficult to coat effectively, in addition, such material is optimized for high and very rapid uptake of fuel.
[0066] The granules, obtained from El Dorado Chemical Company (St. Louis, Mo.), were first tested without applying any polymer coating according to the diesel fuel absorption method described in Example 1. The particles retained about 49% of the diesel fuel added to them, and had a fuel content of about 5% w/w after a solvent wash as described in Example 1.
[0067] Another batch of granules were tested after removal of the factory applied anti-dust coating. The anti-dust coating was removed by washing the particles several times in THF and subsequently drying the particles under vacuum overnight at 50° C. The de-coated particles had very similar fuel absorption characteristics to those with the factory applied anti-dusting coating.
[0068] Next, samples of both factory coated and de-coated particles were coated with the 1:3 weight ratio PVA to BC polymer described in Example 2 and tested for diesel fuel infiltration using the method described in Example 1, however the exposure time was increased to 15 minutes rather than 5 minutes after the 10 minute mix time. The diesel infiltration for de-coated particles was below 0.2-0.3% of the particle weight with less than 3% of the original fuel being retained. The factory coated particles did not absorb any detectable diesel fuel.
[0069] This experiment illustrates the high barrier performance of the composition and coating application method under conditions which are generally very favorable for diesel fuel absorption and retention, such as small particle size, high surface area per unit weight, and high porosity. It is understood that for standard agricultural grades of ammonium nitrate, which is normally non-porous and has large particle sizes with low surface areas, this coating method would be even more effective.
EXAMPLE 5
[0070] This example demonstrates that treatment with water alone substantially improves the inhibition of hydrocarbon infiltration into fertilizer particles. The procedure of Example 1 was followed with two exceptions. The first exception was that the particles for this example were soaked in diesel fuel for 10 minutes. The second exception was that the particles were washed with methylene chloride rather than THF. Generally, diesel fuel was added to El Dorado Chemical's low density Ammonium Nitrate coated with Galoryl. Particles with no additional coating were then compared with particles which were sprayed with a 0.5 gal/ton coating of the previously described 50% BC polymer, particles which were sprayed with a 1.0 gal/ton coating of the previously described 25% BC polymer, and with particles that were sprayed (treated) with 0.5 gal/ton of water. The particles were then soaked with diesel fuel for 10 minutes and washed with methylene chloride before being tested for their differences in diesel fuel oil retention. The results of this example are provided below in Table 3.
TABLE 3 Concentration % Difference in Diesel Oil Retention Treating Agent (Gal/ton) Compared With The 50% BC Polymer CK-None — 100 50% BC 0.5 0.00 25% BC 1.0 0.03 Water 0.5 25.00
[0071] As shown by these results, simply spraying the particles with water helps to increase their resistance to hydrocarbon penetration in this manner, water does not serve as a coating. Instead, the particle surface is melted away, thereby permitting less intrusion of hydrocarbons into pore spaces. | Coatings for agricultural grade fertilizer particles and industrial grade ammonium nitrate are provided which when applied to particles form a protective film which acts as a barrier to inhibit or prevent hydrocarbon infiltration of the fertilizer particle pores and also to physically separate the fertilizer particles and hydrocarbon materials. In so doing, the coating greatly reduces the efficacy of the fertilizer particles as an oxidizing agent for use in incendiary devices, thereby deterring or preventing the use of agricultural grade fertilizers or industrial grade ammonium nitrate in creating weapons of terror. | 2 |
ORIGIN OF THE INVENTION
The invention described herein was made in the performance of work under a NASA contract and subject to the provisions of Section 305 of the National Aeronautics and Space Act of 1958, Public Law 85-568 (72 Stat. 435; 42 U.S.C. 2457).
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to flame-resistant polyimide foam insulation prepared from polyisocyanates and aromatic polycarboxylic compounds.
2. Description of the Prior Art
The preparation of polyimide foams from polyisocyanates and aromatic polycarboxylic acid derivatives has generally been accomplished heretofore in the presence of various catalysts and with suitable heating. Rosser, for example, teaches in U.S. Pat. No. 3,772,216 that such foams may be prepared at temperatures of about 90° to 300° C. in the presence of an alkanolamine. While the products thus obtained possess excellent fire-retarding properties, their application has had to be restricted to situations where the required heating is practical. Other processes have been disclosed by which this type of foam can be prepared without recourse to external heat, thus allowing the material to be formed in situ, e.g. between walls, on walls or in similar places. This has been accomplished by the use of catalysts of a tertiary amine and an aliphatic alcohol containing one to six carbon atoms (McLaughlin, U.S. Pat. No. 3,620,987) or a monomeric homocyclic polyepoxide (Grieve, U.S. Pat. No. 3,644,234).
More recently, tertiary amines have been used with furfuryl alcohol as catalyst for condensing a polyisocyanate with a suitable active-hydrogen compound to obtain foam containing carbodiimide and isocyanurate linkages (Narayan et al, U.S. Pat. No. 3,894,972.
Strong organic acids such as formic acid and chloroacetic acid, have been used with aromatic isocyanates and carboxylic acids to produce amide rather than urea linkages (Phillips et al, "Polyurethanes", 1964, pages 108-110). Sulfuric acid, interalia, has been used with teriary alcohols and polycarboxylic acids to form an intermediate alkyd resin which is then foamed with a polyisocyanate (Hindersinn et al, U.S. Pat. No. 2,865,869). It is interesting to note that this process is said to greatly reduce the heat normally liberated during foaming and thus prevent the charring which often occurs in lightweight foams. La Spina et al., (U.S. Pat. No. 3,931,059), have disclosed the preparation of polycarbodiimide foams from a polyisocyanate, using a pH 1 to 8 protonic acid and an alcohol in the presence of a phosphine oxide or sulfide catalyst, while Stierling, on the other hand, formed expanded-in-place cellular bodies from a thermosetting phenolaldehyde resin and an exothermic mixture of hydrogen peroxide and, e.g., sulfuric acid or phosphoric acid.
The object of the present invention is to provide a simple quick process to form polyimide foams in situ from components which have shown a tendency to char when brought together in the presence of a strong acid. Another object is to obtain low density cellular products that have excellent flame resistance and insulation properties.
SUMMARY OF THE INVENTION
It has now been discovered that uniform lightweight flame resistant thermally stable polyimide foams of acceptable mechanical strength and integrity can be produced from an aromatic polycarboxylic acid dianhydride and an aromatic polyisocyanate in the presence of furfuryl alcohol and an inorganic acid. The alcohol and the acid, e.g., phosphoric acid, produce a vigorous exothermic reaction which provides all the heat necessary for the formation of the polyimide structure. External heating is eliminated, thereby allowing formation of the foam in any shape and location desired.
DETAILED DESCRIPTION OF THE INVENTION
The foams of the present invention are made from aromatic polycarboxylic dianhydrides in the presence of furfuryl alcohol and a strong inorganic acid such as phosphoric acid, polyphosphoric acid, hydrochloric acid, nitric acid and sulfuric acid. Some of these acids, especially the last two named, may have to be diluted with water to control the exothermic reaction that they produce and to avoid carbonization of certain foam components.
The aromatic acids or anhydrides which can be used to prepare the foams of this invention comprise such polycarboxylic compounds as can form intramolecular anhydride and, after reaction with an isocyanate group, imide linkages. Example of such compounds include the following polycarboxylic acids and their anhydrides: pryomellitic acid, trimellitic acid, mellophanic acid, benzene-1,2,3,4-tetracarboxylic acid, benzene-1,2,3-tricarboxylic acid, diphenyl-3,3',4,4'-tetracarboxylic acid, diphenyl-2,2',3,3'-tetracarboxylic acid, naphthalene-2,3,6,7-tetracarboxylic acid, naphthalene-1,2,4,5-tetracarboxylic acid, naphthalene-1,4,5,8-tetracarboxylic acid, as well as similar tetracarboxylic derivatives of phenanthrene, perylene, diphenyl methane, diphenyl sulfone, diphenyl ether, benzophenone, and the like.
As polyisocyanates, there may be used aromatic compounds that contain at least two isocyanate groups and are normally liquid or can become liquid at reaction temperatures. The preferred compounds have at least two aromatic rings with one isocyanate group on each ring. These rings may be connected together as in biphenyl, or interconnected by either carbonyl, sulfone, methylene or oxygen linkages. Examples of suitable compounds are: diphenylmethane-4,4'-diisocyanate, 3,3'-dimethyldiphenylmethane-4,4'-diisocyanate, 3, 3'-dimethyldiphenylmethane-4,4'-diisocyanate, biphenyl diisocyanate, diphenylsulfone diisocyanate, and the like. Particularly useful are polymethylenephenylene polyisocyanate and 4,4'-diphenylenemethylene diisocyanate. Examples of monophenylene polyisocyanates are toluene diisocyanate, m-phenylene diiosocyanate, and xylylene diisocyanate.
Ratios of polyisocyanates to aromatic acid derivatives are conventionally adjusted so that there is not a large excess of either component. In a suitable formulation, the equivalent weight ratio of the polyisocyanate to the polyfunctional aromatic acid derivative is about 0.6 to 4.0. Thus, in accordance with the present invention satisfactory foams can be prepared by mixing 100 parts by weight of an aromatic anhydride, such as pyromellitic dianhydride, with 100 to 500 parts by weight of an aryl polyisocyanate, such as poly(methylenephenylene) polyisocyanate. Preferred ratios of diisocyanate to dianhydride are about 150 to 300 parts by weight to 100 parts by weight, respectively.
While it has been found that the preferred ratio of acid to furfuryl alcohol is about 1:10, with both compounds constituting about 52% of the foam starting ingredient mix, both these ratios and contents may be varied to accomodate various mixtures of monomers of differing nature. With this in mind, these components may vary between about 2 and 10%, for the acid, and about 43 and 55%, for the furfuryl alcohol.
The compositions also contain a silicone oil surfactant which may be a block copolymer of a polysiloxane and a polyalkylene oxide such as are commercially available as Dow Corning DC 193 or 195, and are disclosed in U.S. Pat. No. 3,518,288, U.S. Pat. No. Re. 25,727 and German Pat. No. 1,923,679. At least 2% by weight, preferably about 2 to 10% of such silicone foam stabilizers is employed in the reaction.
In addition to the essential ingredients just described, it is contemplated that various other materials may be incorporated in the formulations to achieve certain particular effects deemed desirable for certain particular uses. Thus, there may be added organic and inorganic fibers, particulate fillers, coloring agents, fungicides and other preservatives, waterproofing substances, and the like, all in conventional quantities to accomplish conventional purposes.
The foams of the invention can be produced in situ by mixing the ingredients together and either pouring the mixture into a mold or spraying it onto a substrate.
When spraying is in order, a Gussmer Type FF system may be employed, which consists basically of: two-liter pressure pots; a positive displacement pump system with volume ratio controlled by using cylinders of different volume in appropriate combinations; flexible hoses leading from pots to pump intake and from pump outlet to spray gun; and combined mixing chamber and spray gun.
With a spraying system of this type, the two components required consist of stable mixtures of, for example (A) polymethylene polyphenyl isocyanate (PAPI 901) with phosphoric acid, and (B) furfuryl alcohol with pyromellitic dianhydride and foam stabilizer (DC 193). In this instance, the volume ratio of Component A to Component B is 1:2 so that a 30/60 cylinder combination would be used for pumping and metering. The short potlife of Component A at 25° C. requires that the isocyanate be chilled to 5° C. prior to mixing with the acid and that the resulting mixture in the pressure pot be kept in an ice bath. Component B is stirred constantly, e.g. with a magnetic stirrer, during spraying in order to maintain a uniform dispersion of the pyromellictic dianhydride powder. Component A hose and the mixing chamber, on the other hand, are each heated to about 40° C. to counteract the effect of the prechilling. Alternatively, the acid may be kept separate from the isocyanate until final mixing with Component B, thus giving a three component system with a pot life sufficiently increased so that the need for cooling is eliminated.
The process of the invention wil now be illustrated with several embodiments, including the best mode of practicing the invention as presently conceived.
As summarized in Table 1, various compositions have been used which contain different levels of phosphoric acid (Example 1 to 3), dilute sulfuric acid (Example 4), hydrochloric acid (Example 5), polyphosphoric acid (Example 6), and dilute nitric acid (Example 7).
TABLE -FOAM COMPOSITION USING VARIOUS ACIDS WEIGHT (GRAMS) EXAMPLESINGREDIENTS 1 2 3 4 5 6 7__________________________________________________________________________Polymethylene polyphenylisocyanate, PAPI 91* 30.4 14.4 30.4 30.4 30.4 30.4 30.4Pyromellitic Dianhydride 15.3 28.7 14.0 15.3 15.3 15.3 15.3Silicone Surfactant, DC 193** 2.3 3.0 2.3 2.3 2.3 2.3 2.3Furfuryl Alcohol 47.3 47.9 44.5 47.3 47.3 47.3 47.3Phosphoric Acid, concentrated 4.7 6.0 9.5 -- -- -- --Sulfuric Acid/Water: 50/50 -- -- -- 4.7 -- -- --Hydrochloric Acid, concentrated -- -- -- -- 4.7 -- --Polyphosphoric Acid, 83% as P.sub.2 O.sub.5 -- -- -- -- -- 4.7 --Nitric Acid/Water: 50/50 -- -- -- -- -- -- 4.7 100.0 100.0 100.7 100.0 100.0 100.0 100.0__________________________________________________________________________ *Described in U.S. Pat. 2,683,738 and German Patent 1,923,679 **Synthesis and Properties of SiloxanePolyether Copolymer Surfactant, Vol 6, No. 2, Industrial and Engineering Chemistry, Product Research and Development (June, 1967).
The foams produced with the components of Example 1 and 2 were subjected to fire tests to demonstrate the fire burn-through resistance of such internally heated polyimide foams. The tests were carried out in the NASA T-3 Fire Facility which consists essentially of a firebrick box provided with an oil-burner, a chimney, and means to expose a sample to be tested to a controlled flux of heat originating from a combination of radiant and convective heat sources. In the present instance, a JP-4 jet fuel flame was used to generate temperatures of about 1000° C. and a heat flux of about 110 to 120 w/m 2 at the surface of a 12×12×12 inch sample. A more detailed description of the equipment and the test can be found in the Journal of Fire and Flammability, Volume 6, pages 205-221 (April 1975).
The results of the burn-through tests are summarized in Table 2.
TABLE 2______________________________________COMPARISON OF JP-4 FUEL BURN-THROUGH TESTSFoam Density Burn-ThroughType (g/cc) Time (sec.) Comments______________________________________Prior Art.sup.a 0.048 474 Fissures, shrinkageFoam distortion, burn- throughExample 1 0.016 405.sup.b Stable No burn-throughExample 2 0.008 191.sup.b Stable No burn-through______________________________________ .sup.a U.S. Pat. No. 3,722,216 Example 1. .sup.b Test terminated, no obvious deterioration.
As the results demonstrate, the polyimide foams prepared with internal heat provided by the incorporation of furfuryl alcohol and phosphoric acid are resistant to burn-through penetration of a JP-4 fuel fire even though their density is only one-third and one-sixth, respectively, of that of prior art foam prepared with external heating.
Other properties of the foam products made with the five acids shown in the examples were investigated and the results obtained are shown in Table 3 and Table 4. In these examples (1 and 4 to 7), as shown in Table 1, the same quantities of isocyanate, pyromellitic dianhydride, furfuryl alcohol, and acid were used, namely 30.4, 15.3, 47.3, and 4.7 parts by weight, respectively. In addition, the thermogravimetric properties of these foams were compared to those produced with the help of another of the exothermic reaction systems disclosed by McLaughlin et al., U.S. Pat. No. 3,620,987. Of the different amine alcohol pair suggested in that patent, triethylene diamine and methyl alcohol were selected for the simple reason of ready availability. These prior art preparations, therefore, were identical to those just described, except that the acid and the furfuryl alcohol were replaced with 2 parts triethylene diamine and 4 parts methyl alcohol, in one instance (Example 8), and half these quantities in another instance (Example 9). In both cases, a friable porous mass was produced which was unsatisfactory for insulation purposes.
TABLE 3__________________________________________________________________________PROPERTIES OF FOAM GENERATED WITH VARIOUS ACIDS AND A BASEAcid or Density Char Yield Initial Decomposition Char RecessionExampleBase g/cc 800° C..sup.a Temp., ° C..sup.a % Weight Loss cm .sup.b__________________________________________________________________________1 Phosphoric 0.008 54 325 19 .594 Sulfuric 0.008 48 370 25 .645 Hydrochloric 0.008 48 340 23 .366 Polyphosphoric 0.010 58 250 19 .447 Nitric 0.011 51 350 21 .278 Trimethylene -- 36 190 -- --diamine9 Trimethylene -- 34 190 -- --diamine__________________________________________________________________________ .sup.a Obtained from thermogravimetric analysis at heating rate of 10° C./min. under nitrogen. .sup.b Obtained from propane torch flame impinging on a 7.6 cm × 7. cm × 2.5 cm foam specimen mounted 3.5 cm from tip of flame for 2 minutes.
As these results demonstrate, the acid furfuryl alcohol process of the invention yields foams of very low density that posses the excellent thermal properties indicative of aromatic polyimide linkages. In contrast, the significantly lower char yields and initial decomposition temperatures shown by foams produced with the triethylenediamine/methyl alcohol exothermic system would seem to indicate that at least with pyromellitic dianhydride and polymethylene polyphenyl isocyanate, the system fails to achieve the extent of reaction necessary to achieve the desired thermal properties.
Some of the mechanical properties of the foam of the invention were determined and found to be statisfactory for the products to be handled in a normal manner and serve as insulation. These properties are summarized in Table 4. It should be noted that the foams of Examples 8 and 9, made with the amine/methanol system, were not tested because of their lack of structural integrity.
TABLE 4______________________________________SOME MECHANICAL PROPERTIES OFFOAMS GENERATED WITH VARIOUS ACIDS Compres- Compressive Ultimate sive Strength, psi. Strength, Modulus,Example Acid Type 10% 50% psi. psi.______________________________________1 Phosphoric 3.77 7.11 1.80 20.234 Sulfuric 4.12 6.58 1.86 20.125 Hydrochloric 3.35 5.05 1.30 15.876 Polyphosphoric 3.20 6.42 1.60 15.07______________________________________ | Flame and temperature resistant polyimide foams are prepared by the reaction of an aromatic dianhydride, e.g., pyromellitic dianhydride, with an aromatic polyisocyanate, e.g., polymethylene polyphenylisocyanate (PAPI) in the presence of an inorganic acid and a lower molecular weight alcohol, e.g., dilute sulfuric acid or phosphoric acid and furfuryl alcohol.
The exothermic reaction between the acid and the alcohol provides the heat necessary for the other reactants to polymerize without the application of any external heat. Such mixtures, therefore, are ideally suited for in situ foam formation, especially where the application of heat is not practical or possible. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to diaphragm pumps, and in particular, to those pumps mountable within a sewing machine for use with a pneumatic needle threading assist.
Needle threading is a desirable feature to have on a sewing machine. Of the various types of needle threaders available, pneumatic needle threaders, as described in U.S. Pat. No. 3,486,472 of R. M. Kaplan, uses an air vacuum to pull the thread end through the eye of a sewing needle. While a manual pump may be used to supply the air vacuum, diaphragm pumps are available for this purpose having an actuating mechanism external to the pump itself. Bearing in mind the limited amount of space within the frame of a sewing machine, it becomes necessary to mount the pump and its actuating mechanism outside of the sewing machine frame, which in the case of industrial machines is acceptable. However, with respect to household sewing machines, it is desirable to mount the entire pump mechanism within the frame of the sewing machine.
SUMMARY OF THE INVENTION
An object of this invention is to provide a diaphragm pump compact enough to fit within the frame of a sewing machine. This object is achieved by a pneumatic pump having a housing with an open recess therein, the recess being closed by a diaphragm, means through which a pumping medium may enter and exit the recess, and means within the recess for oscillating the diaphragm.
A further object of this invention is to provide for effective heat dissipation from the linear actuator by circulating the pumped medium thereover.
DESCRIPTION OF THE DRAWINGS
With the above and additional objects and advantages in view as will hereinafter appear, the invention will be described with reference to the drawings of the preferred embodiment in which:
FIG. 1 is a front elevational view, partly in section, of a sewing machine showing the invention incorporated therein;
FIG. 2 is an exploded perspective view of one embodiment of the invention;
FIG. 3 is a full cross-sectional view of the embodiment shown in FIG. 2;
FIG. 4 is a full cross-sectional view of another embodiment of the invention; and
FIG. 5 is a schematic, in block diagram form, of an electronic circuit which may be used with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, a sewing machine is generally referred to by the reference 10. The sewing machine 10 includes a bed 12, a hollow standard 14 extending upwardly from the bed 12, and a bracket arm 16 projecting horizontally from the standard 14 overhanging the bed 12 and terminating in a sewing head 18. A downwardly biased presser bar 20 is carried in the sewing machine and has removably attached thereto a presser foot 22 for urging the material being sewn into engagement with a feed mechanism as evidenced by feed dog 24. A needle bar 26 is also carried within the sewing head 18 and is arranged for substantially vertical reciprocatory motion. A sewing needle 28 having a thread carrying needle eye 30 is removably mounted to the end of the needle bar 28. For assisting in the threading of the needle eye 30, a pneumatic needle threader assist 32 is carried in the sewing head 18 and may be stored therein, accessing the same through a door 34 pivotally mounted to the sewing head 18. The pneumatic needle threader assist 32, which may be substantially similar to the one disclosed in U.S. Pat. No. 3,486,472 of R. M. Kaplan to which reference may be had for greater detail, includes a pneumatic vacuum line 36 carried in the bracket arm 16 and the standard 14 and terminating at the diaphragm pump 40 of this invention.
The diaphragm pump 40 includes a housing 42 having vertical side walls 44 and a base 46 defining two intersecting cavities, a cylindrical pump cavity 48 and a rectangular valve cavity 50. A cylindrical electrical coil 52, having a central opening 54 therein, is mounted to the base 46 centrally located within the pump cavity 48. Two lead wires 56, connected to the coil 52, exit from the pump cavity 48 through a hole 58 formed in the wall 44 of the housing 42. An annular ring 60 having a central bore 62 is fitted within the coil central opening 54 and includes a plurality of axial recess 64 therein for housing bar magnets 66 each of which has been magnetized through the thickness thereof and positioned in each of said recesses 64 such that the same pole of each magnet 66 faces the central bore 62 of the annular ring 60. A cap 68 is provided for covering the recesses 64 thereby capturing the magnet 66 therein. The cap 68 is formed with a central hole 70 which is coaxial with, and of the same diameter as, the central bore 62 of the annular ring 60. The coil 52 may be enclosed in a casing 72 rendering the coil 52 along with the magnets 66 impervious to the medium being circulated through the pump 40.
A diaphragm support plate 74 is mounted over the housing 42 and includes an opening 76 therein congruent to the pump cavity 48 and two circular holes 78 overlying the valve cavity 50. A support post 80 is mounted to the housing base 46 mid-way the intersection of the pump cavity 48 and the valve cavity 50 and extends upwardly to provide additional support to the diaphragm support plate 74.
An elastomeric diaphragm 82 overlies the diaphragm support plate 74 and has an overall shape generally congruent to the outline of the support plate 74. An armature 84 is mounted to the diaphragm 82 by a screw 86 passing through a hole 88 formed in the diaphragm 82 sandwiched between two washers 90. The armature 84 is located on the diaphragm 82 such that it is coaxial with the central bore 62 of the annular ring 60 mounted in the housing 42, and to this end, the armature 84 is slidably received by said central bore 62. The armature 84 along with the magnets 66 and the coil 52 form the linear actuator for vibrating the diaphragm 82 of this invention. The diaphragm 82 is also formed with two holes 92 which are coaxial with and of substantially the same diameter as the holes 78 in the support plate 74.
Overlying the diaphragm 82 is a clamping plate 94. The clamping plate 94 has a circular opening 96 therein coaxial with the housing pump cavity 48. A rectangular section 98 of the clamping plate 94 covers the holes 92 and 78 in the diaphragm 82 and the support plate 74, respectively. Carried within the rectangular section 98 is the valve assembly 100 including inward and outward ports, 102 and 104 respectively, a butterfly valve 106 and a valve retainer 108 held in place by screw 110. Screws 112 are used to fasten the clamping plate 94, the diaphragm 82 and the support plate 74 to the pump housing 42 and for this purpose pass through holes 114 formed in each of the parts.
As can be seen in the foregoing description, the base 46 of the housing 42 forms a structural support for the linear actuator thereby precluding the need for external supporting means. This enables the manufacturing of a diaphragm pump which occupies a significantly smaller volume than the pumps found in the prior art. Also with the linear actuator located within the pump cavity 48, the pumped medium, as it circulates within the pump cavity 48, carries heat away from the linear actuator thereby giving improved heat dissipation therefor.
An electronic circuit 120, shown in block diagram form in FIG. 5, may be used for driving the linear actuator in the diaphragm pump 40. The circuit 120 requires both a plus and a minus 15 volt D.C. input at terminals 122 and 124 respectively, and supplies a variable frequency plus and minus 15 volts square wave output at terminals 126 to the lead wires 56, connected to the electrical coil 52 of the linear actuator in the pump 40. The electronic circuit 120 includes a variable frequency oscillator 128 of known design controlled by a variable resistor 130 to vary the frequency from 4 to 200 hertz and a bi-polar square wave amplifier 132, preferrably solid state, also of known design. The variable resistor 130 allows the operating frequency to be adjusted to attain optimum performance. This optimum frequency varies dependent upon such factors as the size of the diaphragm 82 in relation to the volume of the pump cavity 48, the natural frequency of the diaphragm 82 and the linear actuator, and the orifice size in the needle threading assist 32. Once these design parameters have been established, the variable resistor 130 may be replaced with one having an optimized fixed valve.
An advantage in using a square wave output, which is in essence a switching constant voltage output, lies in the fact that in a low inductance circuit, the output voltage is proportional to the output current. By keeping the output current at a maximum during each phase of the output cycle, a maximum amount of force is transmitted through the linear actuator to the pump diaphragm 82 thereby allowing for highly efficient operation. Also, by using a square wave output, the output transistors of the amplifier 132 may be chosen such that they are either saturated or turned off. When operated as so described, the output transistors are most efficient and dissipate a minimum amount of power thereby allowing the use of less expensive components and reducing the input power demand of the electronic circuit 120.
FIG. 4 shows a second embodiment of a diaphragm pump 40 wherein the linear actuator uses a wrap around flexible magnet on the armature as described in U.S. Pat. No. 4,065,739 of Jaffe et al. In this embodiment, a shaft 140, of magnetizable material, is mounted to the base 46' and extends vertically therefrom along the central axis of the coil 52'. A plastic spool 142 mounted to the diaphragm 82', has mounted thereto a flexible magnet 144, magnetized through the thickness thereof. The spool 142 has a hole 146 formed therein and is arranged to slidably move along the shaft 140 within the central opening 54' of the coil 52'.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to a preferred embodiment of the invention which is for the purpose of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. | A pump is disclosed having a housing with a recess therein, an elastomeric diaphragm stretched across said recess forming a pump cavity in which the medium being pumped is circulated, and inlet and outlet valves. An electronically controlled linear actuator is attached to the diaphragm within the pump cavity thereby allowing compactness in the construction of the pump and improved heat dissipation from the linear actuator. The pump fits within the frame of a sewing machine and creates an air vacuum for assisting in needle threading. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to European patent application, Serial No. EP08290468.1, filed on May 20, 2008. Priority to the European application is expressly claimed, and the disclosure of which is hereby incorporated herein by reference in its entirety.
FIELD
[0002] The present disclosure relates to magnetic memories, especially non-volatile random-access magnetic memories used to store and read data in electronic systems. More particularly, the present disclosure relates to Magnetic Random Access Memories, referred to as MRAM, based on magnetic tunnel junctions and an improvement of the shape of the memory cell used in a tunnel junction based MRAM using a thermally assisted write scheme.
BACKGROUND
[0003] Magnetic random access memories (MRAMs) have been the object of a renewed interest with the discovery of magnetic tunnel junctions (MTJ) having a strong magnetoresistance at ambient temperature. These MRAMs present many advantages such as speed (a few nanoseconds of duration of writing and reading), nonvolatility, and insensitivity to ionizing radiation. Consequently, they are increasingly replacing memory that uses more conventional technology based on the charge state of a capacitor (DRAM, SRAM, FLASH).
[0004] In conventional MTJ based MRAM, the memory cell includes a magnetic tunnel junction that comprises a stack of several alternatively magnetic and non-magnetic metallic layers. Examples of conventional MTJ-based MRAM devices are described in U.S. Pat. No. 5,640,343. In their simplest forms, the magnetic tunnel junctions of MTJ-based MRAM are formed from two magnetic layers of different coercivity that are separated by an insulating thin layer. The first layer (or reference layer) of the magnetic tunnel junction is characterized by a fixed magnetization; whereas, the second layer (or storage layer) is characterized by a magnetization direction that can be changed. When the respective magnetizations of the reference layers and the storage layer are antiparallel, the resistance of the magnetic tunnel junction is high. On the other hand, when the respective magnetizations are parallel, the resistance of the magnetic tunnel junction becomes low.
[0005] Preferentially, the reference layer and the storage layer are made of 3d metals such as Fe, Co or Ni or their alloys. Eventually, boron can be added in the layer composition in order obtain an amorphous morphology and a flat interface. The insulating layer typically comprises alumina (Al 2 O 3 ) or magnesium oxide (MgO). Preferentially, the reference layer itself can be formed from several layers as described, for instance, in U.S. Pat. No. 5,583,725, in order to form a synthetic antiferromagnetic layer. A double tunnel junction as described in the paper by Y. Saito et al., Journal of Magnetism and Magnetic Materials Vol. 223 (2001), p. 293, can also be used. In this case, the storage layer is sandwiched between two thin insulating layers with respective reference layers located on the opposite sides of the thin insulating layers.
[0006] FIG. 1 shows a memory cell 1 of a conventional MTJ-based MRAM. The memory cell 1 includes a magnetic tunnel junction 2 that comprises a storage layer 21 , an insulating layer 22 and a reference layer 23 . The magnetic tunnel junction 2 is illustrated as being disposed between a selection CMOS transistor 3 and a word current line 4 . A bit current line 5 is placed orthogonal with the word current line 4 . When electrical currents flow in the word and bit current lines 4 , 5 , word and bit magnetic fields 41 and 51 are respectively produced. Electrical currents are typically short current pulses from 2 to 5 nanoseconds having a magnitude on the order of 10 mA. An additional control current line 6 is applied to control the opening and/or the closing of the transistor 3 to address each memory cell 1 individually.
[0007] During a writing process, the transistor 3 is in the blocked mode (OFF), and no current flows through the magnetic tunnel junction 2 . The intensity of the current pulses and their synchronization are adjusted so that only the magnetization of the storage layer 21 located at the crossing of the word and bit current lines 4 , 5 can switch under the combined effect of the word and bit magnetic fields 41 and 51 .
[0008] During a reading process, the transistor 3 is in the saturated mode (ON) and a junction current will flows through the magnetic tunnel junction 2 allowing the measurement of the junction resistance of the memory cell 1 . The state of the memory cell 1 is determined by comparing the measured resistance with the resistance of a reference memory cell. For example, a low junction resistance will be measured when the magnetization of the storage layer 21 is parallel to the magnetization of the reference layer 23 corresponding to a value of “0.” Conversely, a magnetization of the storage layer 21 , antiparallel to the magnetization of the reference layer 23 , will yield a high junction resistance corresponding to a value of “1.”
[0009] Basic structural details for this type of conventional MTJ-based MRAM are described in U.S. Pat. Nos. 4,949,039 and 5,159,513; while, U.S. Pat. No. 5,343,422 discloses an implementation of a random-access memory (RAM) based on a MTJ based MRAM structure.
[0010] To help ensure that this architecture is working properly during the writing process, it is necessary to use memory cells 1 with an anisotropic form having high aspect ratios, typically 1.5 or more. Such geometry is required to obtain bi-stable functioning of the memory cell 1 , a good writing selectivity between the selected memory cell and the half-selected cells located on the same line/column, and good thermal/temporal stability of the information.
[0011] According to U.S. Pat. No. 5,959,880, the aspect ratio of a memory cell can be reduced by increasing the magnetocrystalline anisotropy of the material that forms the storage layer. By doing this, the system is stable in time and temperature, and both states of the memory cell are well defined. On the other hand, the writing field required to reverse the magnetization of the memory cell from one stable state to another is significant and therefore the power consumed during the writing process is large. Conversely, if the magnetocrystalline anisotropy is low, the power consumed at writing is also low, but thermal and temporal stability of the storage layer are no more ensured. In other words, U.S. Pat. No. 5,959,880 teaches that it is not possible to simultaneously ensure low power consumption and thermal and temporal stability.
[0012] A thermally assisted writing switching (TAS) process for the above-referenced MTJ-based MRAM structure is described in United States Patent Application Publication No. US 2005/0002228 A1. The particularity of the magnetic tunnel junction of the TAS MTJ based MRAM is that both the reference layer and the storage layer are exchange biased. More precisely, the reference and storage layers are pinned by interaction with an adjacent antiferromagnetic reference layer and antiferromagnetic storage layer respectively. During a thermally assisted writing process, for example, a junction current pulse is sent through the magnetic tunnel junction rising the temperature of the magnetic tunnel junction and the magnetic coupling between the ferromagnetic storage layer and antiferromagnetic storage layer disappears. The magnetic tunnel junction is then cooled while a moderate magnetic field is applied by making a current to flow in the word current line, allowing for the reversal of the magnetization of the storage layer.
[0013] In contrast with the conventional MTJ-based MRAM, the TAS MTJ based MRAM structure is characterized by a considerably improved thermal stability of the storage layer due to the pinning of the antiferromagnetic storage layer. An improved writing selectivity is also achieved due to the selective heating of the memory cell to be written in comparison with the neighboring memory cells remaining at ambient temperature. The TAS MTJ-based MRAM structure also allows for a higher integration density without affecting its stability limit, and reduced power consumption during the writing process since the power required to heat the memory cell is less than the one needed to generate magnetization in the conventional MTJ-based MRAM structure.
[0014] A further improvement of the TAS MTJ-based MRAMs in terms of power consumption has been described in United States Patent Application Publication No. US 2006/0291276 A1. Here, the writing field is further reduced by selecting a circular geometry of the memory cell junction. In this case, the writing field is only given by the magnetocrystalline anisotropy of the storage layer and there is no contribution from the shape anisotropy. However, the use of a circular geometry does not allow for simultaneously low power consumption and thermal and temporal stability of the storage layer.
[0015] The benefit of using a circular magnetic tunnel junction can be better understood by expressing the energy of the magnetic barrier height that has to be overcome to write the cell from a state “0,” of low electrical resistance, to a state “1,” of high electrical resistance. The barrier energy per volume unit, E b , can be expressed as set forth in Equation 1.
[0000]
E
b
=
K
+
A
R
-
1
L
tM
s
2
(
Equation
1
)
[0016] In Equation 1, the first term, K, is the magnetocrystalline anisotropy and the second term corresponds to the shape anisotropy. In the second term, AR is the aspect ratio of the magnetic tunnel junction, defined as the ratio of the length to the width L of the magnetic tunnel junction; t is the thickness of the storage layer; and M s its saturation magnetization. The ellipticity can be defined as (AR-1), expressed in percentage terms.
[0017] The limitations of the prior art can be understood by considering that the barrier energy E b increases with decreasing the size of the magnetic tunnel junction (L decreases and AR is constant), resulting in a significant increase in power consumption. In the other hand, the barrier energy E b decreases with decreasing AR (L being constant), resulting in a loss of thermal and temporal stability.
[0018] In the case of a TAS MTJ-based MRAM with an exchange-biased storage layer, the storage layer stability at working temperatures is ensured by the pinning of the ferromagnetic storage layer with the antiferromagnetic layer, while, at writing temperatures, the pinning disappears and the memory cell can be written with a low writing field. In the case of a circular cell junction, a low writing field is obtained only by the low magnetocrystalline anisotropy. A low writing field and good thermal stability can then be obtained simultaneously by combining the junction geometry with the TAS MTJ-based MRAMs.
[0019] However, usual MRAM fabrication processes cannot guarantee perfectly circular magnetic tunnel junctions over a large array of memory cells, due to, for example, accuracy limitations in the pattering of the different junction layers. In addition, the magnitude of writing fields is strongly dependant on variations in the junction ellipticity. FIG. 2 shows the dependence of the writing field H R of the storage layer, on the aspect ratio of the magnetic tunnel junction for a conventional TAS MTJ-based MRAM cell. For example, the magnitude of the writing field more than doubles when the junction aspect ratio is increased from AR=1.0 to 1.1, representing a 10% variation typical from a usual fabrication process. The inset of FIG. 2 shows a top view of magnetic tunnel junctions with aspect ratio comprised between 1.0 and 1.1.
[0020] Such a variation of the aspect ratio results in a large dispersion of the writing field and a significant increase of the power consumption in a magnetic memory device containing an array of memory cells with circular junctions. In addition, electromigration effects in the current lines that occur for large electrical currents at high writing field may not be avoided.
SUMMARY
[0021] The disclosed magnetic tunnel junction (MTJ)-based magnetic random access memory (MRAM) cell with a thermally assisted switching (TAS) writing procedure advantageously provides a reduced dependence of the dispersion of the writing field on the junction aspect ratio due to the fabrication process.
[0022] As illustrated by the preferred embodiments, the TAS MTJ-based MRAM cell can include a magnetic tunnel junction. The magnetic tunnel junction can be formed from a ferromagnetic storage layer, a reference layer, and an insulating layer that is disposed between the storage and reference layers. The ferromagnetic storage layer can have a magnetization that is adjustable above a high temperature threshold; whereas, the reference layer can be provided with a fixed magnetization. Preferably, the magnetic tunnel junction is formed with an anisotropic shape, and a magnetocrystalline anisotropy of the ferromagnetic storage layer can be oriented essentially perpendicular to a long axis of the anisotropic shape of the magnetic tunnel junction. In one embodiment, the magnetocrystalline anisotropy of the ferromagnetic storage layer and the long axis of the anisotropic shape of the magnetic tunnel junction can form an angle within a preselected range, such as within a range between eighty degrees (80°) and ninety degrees (90°), inclusive.
[0023] The magnetic tunnel junction can be formed with any suitable anisotropic shape and/or dimension, such as an aspect ratio. In one illustrative embodiment, for example, the anisotropic shape of the magnetic tunnel junction can comprise an elliptical shape, a rectangle shape, a crescent shape, a semi-ellipse shape, and/or a diamond shape without limitation. In another illustrative embodiment, the magnetic tunnel junction can have an anisotropic shape with an aspect ratio comprised between approximately 1.0 and 1.5. For instance, the aspect ratio of the magnetic tunnel junction can be comprised within a first range between 1.0 and 1.1 and/or a second range between 1.0 and 1.05.
[0024] The present application likewise discloses a method of writing data in the TAS MTJ-based MRAM cell, the cell further comprising a select transistor being coupled with the magnetic tunnel junction and controllable via a word line, a connecting current line electrically connected to the magnetic tunnel junction, and a word current line; the method comprising:
[0025] heating the magnetic tunnel junction until it has reached a high temperature threshold;
[0026] aligning the magnetization of the ferromagnetic storage layer in a direction essentially parallel or antiparallel with the magnetization orientation of the reference layer; and
[0027] cooling down the magnetic tunnel junction to a low temperature threshold at which the magnetization of the ferromagnetic storage layer is pinned.
[0028] In the context of the patent application, the expressions “ellipse,” “elliptical,” and “ellipticity” generally refer to any closed shapes having an anisotropic form such as ellipses, crescents, semi-ellipses, diamonds, rectangles, etc.
[0029] Advantages of the TAS MTJ-based MRAM cell comprise limiting the effects of dispersion in the magnetic tunnel junction shape anisotropy coming from the fabrication process, a lower power consumption, and facilitated cell scaling down, compared with the MTJ-based MRAM and TAS MTJ-based MRAM cells of the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The preferred embodiments will be better understood with the aid of the description of an embodiment given by way of example and illustrated by the figures, in which:
[0031] FIG. 1 shows a schematic view of a conventional magnetic tunnel junction (MTJ)-based magnetic random access memory (MRAM) cell;
[0032] FIG. 2 shows a dependence of the writing field of the storage layer on the aspect ratio of the magnetic tunnel junction for the TAS MTJ-based MRAM cell of FIG. 1 ;
[0033] FIG. 3 illustrates an embodiment of a TAS MTJ-based MRAM cell comprising an exemplary magnetic tunnel junction;
[0034] FIG. 4 illustrates an exploded view of the exemplary magnetic tunnel junction of the TAS MTJ-based MRAM cell of FIG. 3 ;
[0035] FIG. 5 illustrates an exemplary variation of the writing field with the magnetic tunnel junction aspect ratio for a magnetocrystalline anisotropy axis of the ferromagnetic storage layer being parallel and perpendicular to the long axis of the magnetic tunnel junction; and
[0036] FIG. 6 illustrates a top view of a conventional magnetic tunnel junction with an aspect ratio of 1.5, and two magnetic tunnel junctions with aspect ratios of 1.0 and 1.05 respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] FIG. 3 illustrates one embodiment of a thermally assisted switching (TAS) magnetic tunnel junction (MTJ)-based magnetic random access memory (MRAM) memory cell 1 . The TAS MTJ-based MRAM cell 1 comprises a magnetic tunnel junction 2 placed between a selection CMOS select transistor 3 and a connecting current line 7 for passing a junction current pulse 31 flowing through the magnetic tunnel junction 2 when the transistor 3 is in the saturated or open mode (ON). A control current line 6 is used to control the opening and the closing of the transistor 3 to address each memory cell individually. The TAS MTJ-based MRAM cell 1 also comprises a word current line 4 , shown above and perpendicular to the connecting current line 7 in the example of FIG. 3 . Other configurations of the word current line 4 are however possible. For example the word current line 4 can be placed parallel with the connecting current line 7 and/or on the side of or below the magnetic tunnel junction 2 .
[0038] An exploded view on the exemplary magnetic tunnel junction 2 is shown in FIG. 4 . The magnetic tunnel junction 2 contains a storage layer 21 preferably comprising a ferromagnetic storage layer 21 a and an antiferromagnetic storage layer 21 b . The ferromagnetic storage layer 21 a has a thickness typically of the order of 1 to 10 nm and is made of a material having a planar magnetization, typically selected from the group Permalloy (Ni 80 Fe 20 ), CO 90 Fe 10 or other alloys containing Fe, Co or Ni. The ferromagnetic storage layer 21 a is exchange-coupled by the antiferromagnetic storage layer 21 b made of a manganese-based alloy, for example, of IrMn or FeMn. The antiferromagnetic storage layer 21 b has a blocking temperature T BS sufficiently high to ensure that at a low temperature threshold below T BS , for example, at standby temperature, i.e., in the absence of heating, magnetization of the ferromagnetic storage layer 21 a is sufficiently pinned to be able to preserve its magnetization over a period of several years but not so high as to make it necessary to heat the magnetic tunnel junction 2 excessively during every the writing process that could yield to material degradation and high power consumption. Here, a T BS in the range of, for example, 120 to 220° C. is suitable.
[0039] The magnetic tunnel junction 2 also contains a reference layer 23 preferably comprising a first ferromagnetic reference layer 23 a and a second ferromagnetic reference layer 23 c , both formed of a Fe, Co or Ni based alloy. The two ferromagnetic reference layers 23 a , 23 c are antiferromagnetically coupled by inserting between them a non-ferromagnetic reference layer 23 b made, for example, of ruthenium. An antiferromagnetic reference layer 24 , preferably formed of a Mn based alloy such as PtMn or NiMn and characterized by a blocking temperature T BR higher than T BS , is provided below the second ferromagnetic reference layer 23 c . The antiferromagnetic reference layer 24 orients the magnetic moment of the first ferromagnetic reference layer 23 a , and a pinning field is generated that fixes the magnetic moment of the second ferromagnetic reference layer 23 c . The reference layer structure described above is well known in the state of the art under the name of synthetic antiferromagnet pinned layer. Other configurations of the storage layer 23 are also possible. For example, the reference layer 23 can comprise a single ferromagnetic reference layer pinned by the antiferromagnetic reference layer 24 described above.
[0040] An insulating layer 22 playing the role of a tunnel barrier and preferably made of a material selected from the group comprising Al 2 O 3 and MgO is inserted between the storage layer 21 and the reference layer 23 . The tunneling resistance of a magnetic tunnel junction 2 depends exponentially on the insulating layer thickness and is measured by the resistance-area product (RA) of the magnetic tunnel junction 2 . The RA should be sufficiently small to flow the junction current 31 through the magnetic tunnel junction 2 , sufficiently high to raise the temperature of the antiferromagnetic storage layer 21 b above its blocking temperature T BS . In order to force a current density in the range of 10 5 A/cm 2 to 10 7 A/cm 2 , typically required to raise the temperature of the magnetic tunnel junction 2 up to 100° C., the RA value should be of the order of 1 to 500 Ω·μm 2 .
[0041] In another embodiment, the magnetic tunnel junction 2 , at least one thermal barrier layer (not shown) made typically of BiTe or GeSbTe and having a very low thermal conductivity can be added at the top and at the bottom of the magnetic tunnel junction 2 . The purpose of these additional layers is to increase the heating efficiency of the junction current 31 flowing through the magnetic tunnel junction 2 while limiting the diffusion of the heat towards the electrode (not shown) ensuring the electrical connection between the magnetic tunnel junction 2 and the connecting current line 7 . Here, the thermal barrier itself is electrically connected to the electrode directly or via a conductive layer, for example made of TiN or TiWN.
[0042] During the thermally assisted writing process, the junction current pulse 31 having a magnitude comprised between 10 5 A/cm 2 and 10 7 A/cm 2 and lasting several nanoseconds is sent through a connecting current line 7 and the magnetic tunnel junction 2 (with transistor ON), rising the temperature of the magnetic tunnel junction 2 to a high temperature threshold of about 120 to 220° C., lying between T BS and T BR where the magnetic coupling between the ferromagnetic storage layer 21 a and antiferromagnetic storage layer 21 b disappears and the magnetization of the ferromagnetic storage layer 21 a , being no more pinned, can be freely adjusted. The magnetic tunnel junction 2 is then cooled while a moderate word magnetic field 41 is applied by flowing a current in the word current line 4 , allowing for the aligning of the magnetization of the ferromagnetic storage layer 21 a in a direction according to the magnetic field 41 orientation, essentially parallel or antiparallel with the magnetization orientation of the reference layer 23 . The magnetic tunnel junction 2 is then cooled down at a low temperature threshold below the blocking temperature T BS of the antiferromagnetic storage layer 21 b , where the magnetization of the ferromagnetic storage layer 21 a becomes pinned in its reversed direction, or written state.
[0043] The magnetic tunnel junction 2 preferably has an anisotropic shape, such as an elliptical shape, and the ferromagnetic storage layer 21 a has a magnetocrystalline anisotropy that is oriented essentially perpendicular to the long axis of the anisotropic shape of the magnetic tunnel junction 2 . In other words, in the TAS MTJ-based MRAM cell 1 , the magnetization of the ferromagnetic storage layer 21 a is oriented in a direction that is essentially perpendicular with the long axis, or easy axis, of the anisotropic shape of the magnetic tunnel junction 2 at a high temperature threshold, when the magnetization of the ferromagnetic storage layer 21 a can be freely adjusted. In one embodiment, the anisotropic shape of the magnetic tunnel junction 2 can have an irregular shape with a long axis that may not be well defined such that the long axis of the anisotropic shape may be not be strictly perpendicular to the magnetocrystalline anisotropy. Accordingly, the magnetocrystalline anisotropy of the ferromagnetic storage layer and the long axis of the anisotropic shape of the magnetic tunnel junction 2 can form an angle within a preselected range, such as within a range between eighty degrees (80°) and ninety degrees (90°), inclusive. In other words, the term “perpendicular” (or “perpendicularly”) as used herein can generally refer to forming an angle within the preselected range.
[0044] An advantage of using such a magnetic tunnel junction geometry and magnetocrystalline orientation can be seen from the variation in the writing (or coercive) field, H R , of the ferromagnetic storage layer 21 a with the junction aspect ratio. FIG. 5 compares the variation of the word magnetic field 41 , or writing field H R , with the junction aspect ratio AR for a conventional memory cell, where the ferromagnetic storage layer 21 a has a magnetocrystalline anisotropy axis parallel to the long axis of the ellipse (filled circles), and for the memory cell 1 , where the ferromagnetic storage layer 21 a has a magnetocrystalline anisotropy axis perpendicular to the long axis of the ellipse (open circles). Here, the variation of the writing field H R has been calculated for the junction anisotropic shapes having aspect ratios AR comprised between 1.0 and 1.1. The calculations were performed by means of micromagnetic simulations assuming standard material parameters corresponding to the ferromagnetic storage layer 21 a employed in a usual TAS MTJ-based MRAM cell 1 and assuming that the writing field H R is applied parallel to the magnetocrystalline anisotropy axis. The calculations also assumed that the writing field H R is not influenced by the dispersion in ellipticity and is essentially given by the magnetocrystalline anisotropy value corresponding, for example, to the writing field of a circular junction (AR=1.0).
[0045] The shape of the magnetic tunnel junction 2 is not limited to an elliptical shape but can have any shape that is anisotropic, such as a rectangle, crescent, semi-ellipse, diamond, etc., where the magnetocrystalline anisotropy axis is essentially perpendicular to the long axis of the anisotropic shape of the magnetic tunnel junction 2 .
[0046] As can be seen in FIG. 5 , the writing field H R increases approximately linearly with the memory cell aspect ratio AR, for a magnetocrystalline anisotropy axis of the ferromagnetic storage layer 21 a that is essentially parallel to the long axis of the ellipse. In this case, a variation in the memory cell aspect ratio AR due to the manufacturing process will result in an overall increase in the writing field H R and a larger power consumption of the magnetic memory device. Conversely, in the case of a magnetocrystalline anisotropy being essentially perpendicular to the long axis of the ellipse, the writing field H R decreases approximately linearly with the aspect ratio AR, and a variation in the memory cell aspect ratio AR will tend to diminish the overall writing field H R and power consumption of the magnetic memory cell 1 .
[0047] In a preferred embodiment, the magnetic tunnel junction 2 of the memory cell is characterized by an aspect ratio AR equal or above a value of 1.0, corresponding to a circular (or square, etc.) magnetic tunnel junction 2 , but preferably comprised between 1.0 and 1.5, and a magnetocrystalline anisotropy axis of the ferromagnetic storage layer 21 a perpendicular to the long axis of the ellipse.
[0048] A magnetic memory device (not represented) can be formed by assembling a matrix comprising a plurality of TAS MTJ-based MRAM cells 1 , where each magnetic tunnel junction 2 of each memory cell 1 is connected on the side of the storage layer 21 , or ferromagnetic storage layer 21 a , to the connecting current line 7 , and on the opposite side to the control current line 6 , placed perpendicular with the connecting current line 7 . When one of the memory cells 1 is to be written, a current pulse is sent in one or several control lines 6 to put at least one of the transistors 3 of the corresponding control lines 6 in mode ON, and a junction current pulse 31 is sent to each connecting lines 7 corresponding to the memory cells 1 to be written, i.e., the memory cells 1 placed at the intersection of the active connecting current lines 7 and active control lines 6 .
[0049] Using today's lithographic fabrication processes a maximal variation, Δ c , in the shape anisotropy of the magnetic tunnel junction 2 of about ±5% can be typically obtained. This corresponds, for example, to an aspect ratio AR of the magnetic tunnel junction 2 varying from 1.0 to 1.1 with an average aspect ratio of 1.05, for the memory cells 1 of the magnetic memory device. In the exemplary calculations of FIG. 5 , an anisotropic shape with an aspect ratio AR of 1.05 corresponds to a writing field H R of about 25 Oe, for the TAS MTJ-based MRAM cell 1 . This represents a decrease of about 30% in the writing field value compared to the one calculated for a magnetic tunnel junction 2 with an aspect ratio AR of 1.
[0050] In a preferred embodiment, the magnetic tunnel junction 2 of the memory cell 1 has an aspect ratio AR comprised within the maximum shape anisotropy variations allowed by the fabrication process used for the memory cell fabrication, and has a magnetocrystalline anisotropy axis of the ferromagnetic storage layer 21 a perpendicular to the long axis of the magnetic tunnel junction anisotropic shape. For example, the magnetic tunnel junction 2 of the memory cell 1 has an aspect ratio AR comprised between 1.0 and 1.1.
[0051] Continuous improvements in the fabrication processes may equally allow for smaller variations in the aspect ratio AR of the magnetic tunnel junctions 2 within the memory device. For example, using such advanced fabrication technologies, the magnetic tunnel junction 2 of the memory cell 1 could be characterized by an aspect ratio AR comprised between 1.0 and 1.05, or even smaller.
[0052] FIG. 6 compares schematically the top view of a conventional magnetic tunnel junction 2 with a field induced magnetic switching (FIMS) architecture having an aspect ratio AR of 1.5, with two magnetic tunnel junctions 2 of the TAS MTJ-based MRAM cell 1 having aspect ratios AR of 1.0 and 1.05 respectively.
[0053] In another embodiment, the variation of the junction aspect ratio AR is minimized by using an appropriate fabrication process and/or by a careful control of the fabrication process and/or by selecting fabricated memory cells 1 having the least variation possible in their aspect ratio AR. Here, the magnetic memory device containing such magnetic tunnel junctions 2 with an aspect ratio AR of about 1.0 or any other value, can be fabricated with no or a very small dispersion in the aspect ratio AR. Such memory device can have minimal variations of the writing field H R due to the combined effect of the small or inexistent dispersion, in the junction aspect ratios AR, and in the magnetocrystalline anisotropy axis of the ferromagnetic storage layer 21 a being essentially perpendicular to the long axis of the anisotropic shape of the magnetic tunnel junctions 2 .
[0054] In yet another embodiment, the magnetic tunnel junctions 2 of the memory device have a magnetocrystalline anisotropy axis of the ferromagnetic storage layer 21 a essentially parallel to the long axis of the junction anisotropic shape, the latter having a very small or no dispersion of the aspect ratio AR.
[0055] The fact that the magnetocrystalline anisotropy axis of the ferromagnetic storage layer 21 a is perpendicular to the long axis of the anisotropic shape of the magnetic tunnel junction 2 , gives rise to a competition between the magnetocrystalline anisotropy and shape anisotropy terms of the barrier energy, E b . For example, in the absence of an external applied magnetic field, the magnetic moments of the ferromagnetic storage layer 21 a may be tilted with respect to the magnetic moments of the reference layer 23 . This tilt can increase with increasing aspect ratios AR, translating in an important dispersion in the resistance value during the reading operation, and resulting in a loss in the read margin that corresponds to the difference between low and high resistance states.
[0056] With the TAS MTJ-based MRAM cell 1 , however, the writing sequence comprises a last cooling stage of the magnetic tunnel junction 2 , performed under the word magnetic field 41 , corresponding to the writing field H R . This word magnetic field 41 “freezes” the magnetic state of the ferromagnetic storage layer 21 a resulting in a much reduced tilt of the magnetic moments of the ferromagnetic storage layer 21 a with respect to the reference layer 23 , yielding to a much lesser influence in the read margin. For example, a loss of less than 20% for the read margin is expected in the case of the magnetic tunnel junction 2 with a shape anisotropy variation of 10%.
[0057] The disclosed embodiments are susceptible to various modifications and alternative forms, and specific examples thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the disclosed embodiments are not to be limited to the particular forms or methods disclosed, but to the contrary, the disclosed embodiments are to cover all modifications, equivalents, and alternatives.
[0058] For example, other configurations of the TAS MTJ-based MRAM cell 1 can be used in the context provided the magnetic tunnel junction 2 is fabricated with an isotropic (circular, square, etc.) or anisotropic (elliptical, rectangular, etc.) geometry and has a magnetocrystalline anisotropy axis of the ferromagnetic storage layer 21 a , essentially parallel to the long axis of the anisotropic shape of the magnetic tunnel junction 2 . An example of another TAS MTJ-based MRAM cell 1 configuration is the memory cell described in unpublished European patent application Serial No. EP07291520 by the present applicant, where the magnetic tunnel junction 2 comprises a writing layer added on top of the storage layer 21 . Another example is the magnetic tunnel junction described in the above-referenced United States Patent Application Publication No. US 2005/0002228 A1 of a general thermally assisted MRAM architecture, where the writing process is ensured by the combination of one magnetic field and a local heating, and the storage layer is exchanged biased with an antiferromagnetic layer.
REFERENCE NUMBERS
[0000]
1 memory cell
2 magnetic tunnel junction
21 storage layer
21 a ferromagnetic storage layer
21 b antiferromagnetic storage layer
22 insulating layer
23 reference layer
23 a first ferromagnetic reference layer
23 b non-ferromagnetic reference layer
23 c second ferromagnetic reference layer
24 antiferromagnetic reference layer
3 select transistor
31 junction current pulse
4 word current line
41 word magnetic field
5 bit current line
51 bit magnetic field
6 control current line
7 connecting current line
REFERENCE SYMBOLS
[0000]
AR aspect ratio of the memory cell
AR-1 ellipticity of the memory cell
E b barrier energy
H R writing (coercive) field of the ferromagnetic storage layer
L width of the magnetic tunnel junction
M s saturation magnetization of the memory cell
RA resistance-area product of the insulating layer
t thickness of the storage layer
T BS blocking temperature of the antiferromagnetic storage layer
T BR blocking temperature of the antiferromagnetic reference layer
Δ e maximal variation in the junction anisotropy | A magnetic tunnel junction (MTJ)-based magnetic random access memory (MRAM) cell with a thermally assisted switching (TAS) writing procedure and methods for manufacturing and using same. The TAS MTJ-based MRAM cell includes a magnetic tunnel junction that is formed with an anisotropic shape and that comprises a ferromagnetic storage layer, a reference layer, and an intermediate insulating layer. The ferromagnetic storage layer has a magnetization that is adjustable above a high temperature threshold; whereas, the reference layer has a fixed magnetization. The ferromagnetic storage layer is provided with a magnetocrystalline anisotropy that is oriented essentially perpendicular to a long axis of the anisotropic shape of the magnetic tunnel junction. The TAS MTJ-based MRAM cell advantageously limits the effects of dispersion in the magnetic tunnel junction shape anisotropy coming from the fabrication process and features a lower power consumption when compared with conventional MTJ-based MRAM and TAS MTJ-based MRAM cells. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This patent application is a divisional of co-pending U.S. application Ser. No. 13/502,657 having a §371(c)(1), (2), (4) date of May 15, 2012, which is a U.S. national stage entry under 35 U.S.C. §371 of International Patent Application No. PCT/JP2010/057585 filed on Apr. 28, 2010, which claims the benefit of foreign priority to Japanese Patent Application No. JP 2009-244667 filed on Oct. 23, 2009, and to Japanese Patent Application No. JP 2009-290346 filed on Dec. 22, 2009, the disclosures of all of which are hereby incorporated by reference in their entireties. The U.S. application Ser. No. 13/502,657 was published on Sep. 13, 2012, as US 2012/0228323 A1. The International Application was published in Japanese on Apr. 28, 2011, as International Publication No. WO 2011/048833 A1 under PCT Article 21(2).
BACKGROUND OF THE INVENTION
The present invention relates to a box-shaped sheet storage container to store any kind of dry sheet such as tissue paper, kitchen paper, cooking sheets and vinyl bags by folding back and overlapping each sheet one above the other one by one.
A conventional removing opening of a box-shaped tissue-paper storage box, made of paper and the like, includes: that in which a tissue-paper fixing sheet which is formed of a high polymer such as a plastic and which has a cut for opening at the center is pasted on the opening of the sheet storage box; that which has an excessive gap at the center of the opening and which is line symmetric or point symmetric, without the above-described fixing sheet being pasted at a sheet-removing opening; and that in which projections forming the rims of the opening are protruded to substantially the center of the opening and which prevents smooth removal of the tissue paper.
Furthermore, normally, the tissue paper is fixed in such a way that half of the tissue paper comes out from the opening and if that tissue paper is pulled out, the next tissue paper underneath is pulled out and is repeatedly fixed in the same way as the previous tissue paper.
Hereinafter, a line formed by folding the tissue paper is considered as a folded line and as illustrated in ( 1 ′) of FIG. 1 , the edge of the next tissue paper parallel to the folded line is considered as a joint line and when a plurality of tissue paper has been stored, the joint line and folded line are continued.
FIG. 1 is a diagram illustrating an example of a sheet wherein, (A) is a diagram illustrating an expanded sheet, (B) is a diagram illustrating a half folded sheet along the folded line ( 1 ′), ( 1 ) is a sheet, ( 1 ′) is a folded line of the sheet, a dotted line circle ( 1 R) is a portion near the right side facing the sheet and a dotted line circle ( 1 L) is the portion near the left side facing the sheet.
Conventionally, two-ply tissue placed on top of each other is considered as one sheet. Furthermore, conventionally there are various methods of folding the tissue paper such as a one time folding method or a two time folding method, and the size of each folded side of the tissue paper and the position of the folded line is not always uniform. The shape of the tissue paper is arbitrarily determined by a manufacturer, and the tissue paper comes in many kinds of shapes.
FIG. 2 is a diagram of a conventional tissue-paper storage box seen from obliquely upward wherein, ( 2 ) is a surface on which the tissue paper storage container has a removing opening, ( 3 ) is the tissue-paper removing opening obtained after detaching a top lid along the perforated line, ( 2 ′) is the top lid removed from ( 3 ), (A-A′) is a breadth of the storage box, (B-B′) is a length of the storage box, (C-C′) is a height of the storage box and (d) is a portion near the center of the opening. In a further description, these will also be used as the breadth of the box, length of the box, the height of the box and the portion near the center of the opening.
FIG. 3 is a diagram illustrating the is tissue-paper removing opening wherein, ( 2 ) is a surface of the storage box with the tissue-paper removing opening, (a-a′) is a line passing through the center of the opening which is parallel or substantially parallel to the folded line (I′) of the sheet, ( 3 ′ a ) at the top and bottom are the rims of the opening present at the line symmetric position at the time of rotating them by considering (a-a′) as an axis and ( 3 ′ b ) is the rim of the opening perpendicular to (a-a′) as well as the rim of the opening present at the line symmetric position at the time of rotating it by considering (a-a′) as the axis.
As explained in the preceding paragraph 0008, (a-a′) is a straight line passing through the center of the opening which is parallel or substantially parallel to the average folded line of sheets from the sheets stored to be removed from the opening. However, (a-a′) is synonymous with (a-a′) of FIG. 3 in the following paragraphs and the following figures as well. Furthermore, the straight line passing through the center of the opening perpendicular to (a-a′) is considered as (b-b′) and also used in the explanations below.
Paragraph 0011 to 0013 and FIG. 4 mentioned below explain the portion of the sheet to be pulled out, to which force is likely to be applied, paragraph 0014 to 0015 mentioned below explain the size of a projection, paragraph 0016 to 0017 and FIG. 5 mentioned below explain the positional relationship between the storage box and the opening and paragraph 0018 to 0021 mentioned below explain the size of the opening.
FIG. 4 is an example illustrating a case of pulling out a tissue paper from the opening of the sheet storage box wherein, (x) is a hand pulling out the tissue paper, (e) and (e′) illustrate the portions of the tissue paper to which force from the hand (x) is likely to be applied, (e) is the portion to which force is likely to be applied at the time of beginning to remove the tissue paper, in other words, at the time when half of the tissue paper is lying inside the storage box, (e′) is the portion to which force is likely to be applied at the time of continuous pulling out, (e) and (e′) are the portions where wrinkled strings are inserted into the tissue paper at the time of pulling out and there are single or a plurality of places generating a resistance near the string caused by friction at the tissue paper and opening.
At the time of beginning to pull the tissue paper, a resistance is generated near (e), which is nearest to the opening, just below the hand and as the tissue paper comes out of the storage box, the resistance with the opening shifts to the portion near both ends of the tissue paper and the shape of the string at that point in time becomes triangular having an apex near the hand.
Furthermore, at the time of pulling out the tissue paper, if the hand holding the tissue paper moves to the right or left, an apical position of (e) and (e′) also moves to the right or left.
As regards the size of the projection formed at the opening, when the projection is small or the width of the projection is narrow and sharp, it is easy to lose the smoothness of the tissue paper at a portion which contacts the rims of the opening due to an effect similar to the effect of spiked shoes depending on the portion of the opening wherein the projection is provided.
Furthermore, if a sharp projection exists at the position near (a-a′), it easily gets caught on a joint line of a newly appearing tissue paper and while pulling out the tissue paper, since the next appearing tissue paper lies over the pulling out tissue paper, if the joint line of the next tissue paper lies on the portion of the pulling out tissue paper where the largest force is applied, the tissue paper can easily fall into the storage box by getting caught.
FIG. 5 is an example illustrating the tissue-paper storage box wherein, (A) is a diagram of the tissue-paper storage box seen from obliquely upward, (B) is a cross sectional diagram of the storage box cut by a straight line parallel to (b-b′), (s) is the line on the surface with the opening parallel to (b-b′), (s) is the line passing through the apex of the projection of the opening, (t) intersects (s) at a right angle wherein, (t) and (s) become one straight line when the storage box is cut open and made flat.
In (B) of FIG. 5 , if the angle formed by (s) and (t) is a right angle, the length of (f) is nearly equal to the square root of the sum of the square of (s) and square of (t), however, if (f) is shorter than the half of the length of the sheet, some portion of the sheet can come out of the opening and the sum of (s) and (t) become longer than the length of (f). If the length of the sheet is longer than the sum of (s) and (t), then “Sheet length >(f)” is established and although it is the last remaining sheet in the storage box, only the portion equal to the length of the sheet comes out from the opening.
As regards the structure of the projection in the opening, when pulling out a tissue paper, as the apex of the projection of the opening moves to the position away from the (a-a′) of the opening, the space of the opening becomes wider and it is hard to abut on the joint line of the next appearing tissue paper.
Furthermore, if the apex of the projection of the opening is near (a-a′) of the opening, the space forming a gap of the opening becomes narrow and the joint line of the next appearing tissue paper abuts on the apex of the opposite projection when appearing from the gap at that instant.
In other words, when the apex of the projection forming the opening is at the center of the opposite facing opening, the space between the two apexes of the opposite facing projections gets closer if the location to place the projection is not taken into consideration and the space of the opening becomes narrow, and as a result the probability of the tissue paper falling into the storage box becomes higher.
Furthermore, in a rectangular parallelepiped storage box with a long side and a short side, the long side becomes the straight line parallel or substantially parallel to the ( 1 ′) and (a-a′).
The paragraph 0023 to 0032 mentioned below explain the conventional common sheet storage box of FIG. 6 to FIG. 9 .
FIG. 6 is a diagram illustrating an example of the conventional tissue-paper storage box seen directly from above wherein, ( 4 ) is a fixing sheet pasted near the opening similar to ( 3 ) of FIG. 2 , ( 5 ) is a crosswise cut (slit) provided in ( 4 ) to function as the opening for removing and fixing the tissue paper.
FIG. 7 is a diagram illustrating an example of the conventional tissue-paper storage box seen from above without a fixing sheet pasted on the tissue-paper removing opening wherein, ( 6 ) is the projection provided in ( 3 ) to fix the tissue paper, ( 3 ) is the line symmetric portion provided above and below the tissue-paper removing opening for fixing the sheet by the projection.
However, according to a method of fixing or removing the tissue paper illustrated in FIG. 7 , as the protruding projection is small with a very sharp curve forming the projection and a position held at the time of pulling out the tissue paper is not always at the center, if the tissue paper is held above the projection, there is a possibility of the paper falling into the storage box due to the joint line of the next appearing tissue paper getting caught on the portion where the projection is overlapped with the portion where the strength is concentrated at the narrow range of the tissue paper.
FIG. 8 is a diagram illustrating an example of the conventional tissue-paper storage box without the fixing sheet pasted on the tissue-paper removing opening seen from above wherein, the upper and lower portions of the lateral opening ( 3 ) have become narrower in shape by the projection ( 6 ), as viewed toward the outer side. Due to this structure, a moving range of the tissue paper is reduced and the tissue paper is fixed to the opening by using a repulsive force when the tissue paper tries to restore to a flat shape.
However, according to the method of removing or fixing the tissue paper as illustrated in FIG. 8 , at the time of pulling out the tissue paper, the next tissue paper is pulled out in such a way that it is placed above the tissue paper which is being pulled out from the storage container; however, as mentioned above, at the time of beginning to pull the tissue paper, the next appearing tissue paper falls into the storage box as the apex of the projection gets caught at the portion to which force is likely to be applied near the joint line where the next appearing tissue paper has reached.
According to the preceding paragraph 0027 mentioned above, if the amount of the tissue paper in the storage box decreases, the position of the next appearing tissue paper becomes relatively lower as compared to the position of the rim of the opening and thus the probability of tissue paper falling into the storage box becomes higher as the joint line of the tissue paper can easily abut on the projection of the rim of the opening.
Furthermore, the tissue paper from the box illustrated in FIG. 8 is removed from the wider openings on the right and left of the projection. At the time of removing the sheet, since the paper is drawn by inserting a finger from either the left or right side hole, it is obviously more difficult to take the paper out, because it is not possible to take the paper out evenly from the right or left, than a case where the center and its surrounding area are drawn, and the opening has to be reduced to some extent to fix the sheet, otherwise it is difficult to remove the tissue paper.
FIG. 9 is a diagram illustrating the conventional tissue-paper storage box without the fixing sheet pasted at the tissue-paper removing opening seen from above wherein, ( 6 ′) is the projection provided in ( 3 ) for fixing the tissue paper, ( 6 ″) is the projection provided in opening ( 3 ) for fixing the tissue paper by narrowing its moving range.
However, according to FIG. 9 , the tissue paper is fixed by narrowing the moving range but, similar to the preceding FIG. 8 , the opening has a shape having the apex of the projection near its center, and the same problem described above occurs.
Furthermore, in conventional sheet storage boxes, the projection is raised by inserting the folded line near the bottom of the projection opposite the apex of the projection but, if the projection is raised, the resistance at the time of removing a sheet is reduced and when a sheet falls into the storage box, it takes quite a bit of effort to pull it out since the projection abuts on the finger and if the shape of the projection is complicated, it requires even greater effort.
Paragraph 0034 to 0047 and FIGS. 10 to 16 mentioned below explain the tissue-paper storage box with a point symmetrical opening.
If the projection is placed at the point symmetric position of the opening, although the sheet is pulled from the front side of the sheet or back side of the sheet which is present above the opening, a wide space and narrow space are generated in the opening space of either the right side (( 1 R) of FIG. 1 )) or left side (( 1 L) of FIG. 1 ) of one sheet and it is possible to provide the portion that easily makes contact with the opening and the portion that easily appears from the opening on one sheet. Furthermore, if the shape of the projection is a smooth protruding curve, the sheet to be pulled out can be easily made to slide.
FIG. 10 is a diagram illustrating an example of a sheet-removing opening wherein, ( 7 ) is the sheet-removing opening which is of a point symmetric shape and nonlinear symmetric shape with respect to the (a-a′) axis, ( 7 a ) is the long side of the opening and ( 7 b ) is the short side of the opening.
Furthermore, the opening illustrated in FIG. 10 can be considered to be of the shape such that it can be moved in the clockwise or counterclockwise direction by considering the center of the opening as the axis and the length or inclination of ( 7 a ) and ( 7 b ) can be considered to be changed.
FIG. 11 is a diagram illustrating an example of the sheet-removing opening, the shape of which has become line symmetric with four sides of equal length illustrated in FIG. 10 wherein, the opening has a point symmetric shape and the rim of the opening with an equal length of upper and lower ( 7 R) and upper and lower ( 7 L) is line symmetric with respect to (a-a′).
FIG. 12 is a diagram illustrating an example wherein, the rim of the opening placed point symmetric with respect to the point has formed a curve on the basis of FIG. 11 and is a point symmetric opening with nonlinear symmetry.
Similar to FIG. 10 , the opening illustrated in FIG. 11 and FIG. 12 may be set in such a way to rotate it in the clockwise direction or counterclockwise direction by considering the center of the opening as the axis and the length or inclination of the rim of the opening can be changed.
FIG. 13 is a diagram illustrating an example of the sheet-removing opening wherein, an intersection of (a-a′) and (b-b′) is (d), (d′) is the circle near the center of the tissue-paper removing opening, an opening ( 7 ) has a depression ( 10 ) between the rims of the opening ( 9 ) and outside from the apex of the projection ( 8 ), the line symmetric rim of the opening has the nonlinear symmetric shape ( 11 ) by considering (a-a′) of ( 8 ) as the axis with the point symmetric sheet-removing opening.
Similar to the above opening, the opening having the shape so that the opening can be rotated in the clockwise direction or counterclockwise direction by considering (d) as the axis can be considered.
FIG. 14 is a diagram illustrating an example of the projected portion of the sheet-removing opening wherein, ( 12 ) shows that the apex of the projection does not exceed (a-a′), ( 12 ′) shows that the apex of the projection is of the same height as that of (a-a′) and ( 12 ″) shows that the apex of the projection exceeds (a-a′).
If the shape of the opening is point symmetric with nonlinear symmetry with respect to (a-a′), then a projection that exceeds (a-a′) can be used.
FIG. 15 is a diagram illustrating an example of the sheet-removing opening wherein, the opening is such that the height of the projection is perpendicular to the folding line of the sheet i.e., perpendicular to (a-a′) and the projection is formed from the two straight lines ( 13 ) and ( 13 ′).
Furthermore, the opening illustrated in FIG. 15 can be considered to be the opening the same as mentioned above wherein, the opening is set at the position to rotate it in the clockwise direction or counterclockwise direction.
FIG. 16 is a diagram illustrating an example of a cover made of a cloth to cover the sheet storage box wherein, ( 14 ) is the cover main body, ( 14 ′) is the sheet-removing opening provided on ( 14 ), and there is an opening designed to insert the storage box with rubber forming a ring at the bottom of ( 14 ). When the storage box is inserted at any position from the opening designed to insert the storage box, rubber of the opening designed to insert the storage box is shrunk and the cover is fixed but, many other styles also exist.
According to the point symmetric opening with nonlinear symmetry, the spatial gap between the projection of the opening and the rims of the opening opposite the projection across (a-a′) becomes wide and the sheet holding power by the rims of the opening becomes weak since the sheet moves too far away from the rims of the opening.
Hereinafter, “paragraph 0049 explains Japanese Published Unexamined Patent Application No. 2008-137686,” “paragraph 0050 to 0053 explain Japanese Published Unexamined Patent Application No. 2003-040361,” “paragraph 0054 explains Japanese Published Unexamined Patent Application No. 2005-225563,” “paragraph 0055 to 0057 explain Japanese Published Unexamined Patent Application No. 2006-016069,” “paragraph 0058 explains Japanese Published Unexamined Patent Application No. 2006-027648,” “paragraph 0059 and 0060 explain Japanese Published Unexamined Patent Application No. 2008-162623,” “paragraph 0061 and 0062 explain Japanese Published Unexamined Patent Application No. 2002-104549” and “paragraph 0063 to 0065 explain Domestic Republication WO2005/108238.”
In Japanese Published Unexamined Patent Application No. 2008-137686, it has been explained that a pair of projections are provided near the point symmetric position of the opening and the projections allow the sheets to be fixed and smoothly removed. However, the form mentioned in Japanese Published Unexamined Patent Application No. 2008-137686 has drawbacks mentioned in the preceding paragraph 0047 hereof wherein, the opening has only single direction inclination with respect to the front side or back side of the sheet and the opening needs to be extremely inclined to reduce the space of the opening. When the cover made of cloth, etc., is used to cover the sheet storage box as illustrated in FIG. 16 , the central portion of the sheet becomes difficult to remove from the opening and the sheets again slide and fall into the storage box due to the poor method of removing the sheets.
In Japanese Published Unexamined Patent Application No. 2003-040361, it has been explained that the two pairs of flaps are provided wherein, these two pairs of flaps are intended to be different in shape when facing opposite each other and similar in shape when placed diagonally and forms the point symmetry with respect to the center point of the opening in the planar view (Refer to page 4, left column, line 1 to line 5, and FIG. 2 of the publication). Furthermore, Japanese Published Unexamined Patent Application No. 2003-040361 also explains that, the space to insert the finger tips is formed by a half space to insert the finger tip positioned at one side and a half space to insert the finger tip positioned at the other, side across a horizontal central line passing through the center of the opening and the half spaces to insert the finger tips are formed by displacing them by a specified distance respectively toward alternate sides (Refer to the page 4, left column, line 15 to line 20 of the publication).
According to Japanese Published Unexamined Patent Application No. 2003-040361, it is understood that picking sheets one after another needs to be made easy by providing different projections for the opening of a wet tissue storage box wherein, a convex surface and a concave surface face each other and elastic deformation must be made easy by partially thinning the projection to pull out the sheets easily, since wet tissues tend to stick to each other because of moisture and also tend to slip at the opening of the storage box because of moisture.
In other words, according to Japanese Published Unexamined Patent Application No. 2003-040361, a total two pairs of projections having different shapes are formed at two opposite corners of the opening wherein, one pair of projections has a sharp angle and another pair of projections has a depression. The main method for fixing the sheets is determined by partially pushing the sheet by the projections and since the four projections are not formed by convex curves, tissue paper cannot be fixed or moved without rendering too much resistance to the tissue paper.
Furthermore, as regards the finger tip insertion space present in the opening with the flap mentioned in Japanese Published Unexamined Patent Application No. 2003-040361, the opening with a flap mentioned in the “prior art in the specification and FIG. 11 of Japanese Published Unexamined Patent Application No. 2003-040361” also has the finger tip insertion space and it is understood that the finger tip insertion space mentioned in Japanese Published Unexamined Patent Application No. 2003-040361 is present only in the opening with a flap mentioned in Japanese Published Unexamined Patent Application No. 2003-040361.
In Japanese Published Unexamined Patent Application No. 2005-225563, it has been mentioned that the sheet-removing opening has a slit and the shape is point symmetric with nonlinear symmetry. However, if the sheet is inserted too much into the slit depending on the shape, the sheet is torn at the time of removing and the space for removing the sheets become too large if a slit is not used and this resulted in a drawback similar to the drawback mentioned in paragraph 0047 hereof.
In Japanese Published Unexamined Patent Application No. 2006-016069, it has been mentioned that “the slit on the nonlinear line consists of a substantially circular curve formed substantially at the center of the upper plate and a straight line of specified length toward a substantially corner portion of the upper plate from both ends of the curve (Refer to page 3, line 50 to page 4, line 3 of the publication). However, this opening has a shape such that it always comes in contact when projections are formed on the same plane.
In Japanese Published Unexamined Patent Application No. 2006-016069, it has been mentioned in paragraph 0027, page 6 of the publication that the flap is closed when the tissue paper is pulled out and it has been mentioned in paragraph 0029, page 7 of the publication that if the flap loses resistance it does not work properly. There are two apexes of projections on one side rim and one apex on the opposite side rim and if the flap does not work properly, the tissue paper may get caught near the apex of the projection.
In Japanese Published Unexamined Patent Application No. 2006-016069, it has been mentioned in paragraph 0025, page 6 of the publication that the flap is slightly opened and fingers are inserted inside. However, the flap of the opening is like a covering lid and the flap may get in the way of fingers at the time of removing tissue paper in the storage box which makes it difficult to remove the tissue paper. Care must be exercised so as not to open the flap excessively and lose return of the flap.
According to Japanese Published Unexamined Patent Application No. 2006-027648, a pair of point symmetric projections is present near the center of the opening; however, the tissue paper must be removed from either the right opening space or left opening space due to the narrow center of the opening. Furthermore, the central projection may hinder movement of the tissue paper.
In Japanese Published Unexamined Patent Application No. 2008-162623, it has been mentioned on the page 2, claim 1, line 10 to line 12 of the publication that “the rim of the removing opening has . . . a pair of first rim portions facing each other across a longitudinal central line.”
In other words, the opening is such that, at the time of beginning to pull out the sheets from the storage box, the next sheet is likely to get caught as the apex of the projection is present near the portion to which force is likely to be applied on the sheet and since the wide finger tip insertion space cannot be provided in the center of the opening as it is not point symmetric, it requires quite a bit of effort to insert fingers in the storage box from the opening when the sheet falls into the storage box.
In Japanese Published Unexamined Patent Application No. 2002-104549, it has been mentioned on page 2, left column, claim 1, line 10 to line 12 of the publication that “Each rim portion facing the opening, has a plurality of curve shape convex portions formed by flat surfaces projecting toward inside the opening” and according to the diagram, it is understood that the plurality of projections present in the opening are present at the position the same as or similar to the line symmetry.
In other words, if there are two pairs of projections opposite each other with acute angles, the shape similar to or the same as that mentioned in the preceding FIG. 7 is formed and the same problems as that mentioned in the preceding FIG. 7 occur. If there are more than two pairs of projections, although there is no problem with wet sheets, the movement of the next appearing dry tissue paper is readily hindered.
In Domestic Republication WO2005/108238, it has been mentioned on page 2, claim 1, line 7 to line 11 of the publication that “the removing opening has . . . a pair of supporting portions to support . . . and the rim of each of the support portions is facing toward the center in the longitudinal direction and forms a uniform bulge with a gentle curvature.” From this description it is understood that, this portion is the same as or similar to the projections described in FIG. 8 and FIG. 9 .
Furthermore, in Domestic Republication WO2005/108238, it has been mentioned on page 2, claim 8 and FIG. 7 of the publication that, a pair of projections has a wavy line shape and this portion has problems the same as or similar to the problems described in paragraph 0061 and 0062 hereof.
Furthermore, in Domestic Republication WO2005/108238, it has been mentioned on page 2, line 12 to line 14 of the publication that “can be raised . . . of the rim of the supporting portion” and it has been mentioned on page 2, line 48 to line 50 of the publication that “at the outer location in the width direction of the rim of the supporting portion, . . . , the supporting portion can be raised upward respectively by considering a compressed line designed for raising as the raising line.” From this description it is understood that although it is indicated to raise the projection, it takes quite a bit of effort to take the tissue paper since the projection abuts on a hand or a finger when the tissue paper decreases in number and falls into the storage box if the projection is raised.
As mentioned above, although pasting the sheet-fixing sheet on the sheet-removing opening is suitable for removing the sheets, it is wasteful from the point of view of resources.
As mentioned above, when the sheet-fixing sheet is not pasted on the opening of the sheet storage box, the fixing of sheets becomes weaker as the opening itself becomes larger due to the excessively wide rim of the opening and when the rims of the opening are made too close, the rim of the opening partially becomes smaller and the resistance to remove the sheets becomes too large.
In order to solve the above-mentioned problems of the conventional sheet storage boxes, an object of the present invention is to effectively configure a portion by which the sheet can be stuck smoothly and a portion where the sheet can be easily taken from the opening by making the shape of the rim of the sheet-removing opening of the sheet storage box such that the movement of the sheet is reduced by adequately reducing the spatial area of the opening and converting the rim of the opening to a convex shape smooth curve so as to slide the sheets easily and by changing the height of the projection of similarly shaped face-to-face rims of the opening of two pairs of main rims of the opening at opposite corners.
SUMMARY OF THE INVENTION
To achieve the object mentioned above, there is provided a sheet storage box of the present invention, wherein
two pairs of smooth convex shape curved opening rims are provided at corners by considering the center of the opening as a center point, wherein
the two pairs of the opening rims are set one after the other and the height of the apexes of the opening rims present at the corners is the same or substantially the same and the height of the apexes of the adjacent or opposite opening rim is different,
an open space is formed as a result of constant absence of the opening rim or lid at three places i.e., within a circle of 3 mm in diameter at the center of the opening and within the circle of 2 mm in diameter at both ends of the opening, wherein
the two pairs of smooth convex shape curved opening rims are formed to be positioned in the spaces at the three places,
the opening rims forming the space at both ends of the opening are the depressions placed opposite each other across the convex shape curved opening rims and the rims of the opening forming the space including the center of the opening have depressions between the adjacent convex shape curved rims of the opening present at both sides and these depressions are placed opposite each other at the corners of the rims of the opening forming the space including the center of the opening, and
the opening rim is provided which takes the shape of nonlinear symmetry when the opening is rotated at 180 degrees by considering the straight line passing through the center of the opening, which is parallel or substantially parallel to the average folded line of sheets stored to remove sheets from the opening, as the axis and takes the shape of point symmetry or substantially point symmetry when the opening is rotated at 180 degrees by considering the center of the opening as the axis.
Furthermore, the sheet-removing opening of the sheet storage box of the present invention is characterized in that
the depressions opposite each other located at the corners of the opening rims forming the space including the center of the opening as mentioned in the preceding paragraph 0070 are
depressions formed by joining the adjacent smooth convex shape curves by using the folded line shape or folded convex shape curves.
The sheet-removing opening of the sheet storage box according to the present invention is characterized in that, in the depressions opposite each other located at the corners of the opening rims forming the space including the center of the opening as mentioned in the preceding paragraph 0070,
a depression being depressed by 1 cm or more in the direction parallel to the folded line of a sheet is absent at the lower side than the center rim of the opening of smooth convex shape curved opening rims which support the sliding of the sheet.
Furthermore, the sheet-removing opening of the sheet storage box of the present invention is characterized in that the depressions opposite each other located at the corners of the opening rims forming the space including the center of the opening as mentioned in the preceding paragraphs 0070 to 0072 comprise
one or a plurality of pairs of convex shape curved projections shorter than the height of the apexes of the convex shape curved opening rims present at both sides at the opposite corners of the depression forming the space including the center of the opening.
Furthermore, the sheet-removing opening of the sheet storage box of the present invention is characterized in that the pair of depressions which forms the opening rims outside the circle of 2 mm in diameter present at both ends of the opening as described in the preceding paragraph 0070 are
depressions themselves having the shape including the concave shape curve.
According to the operation as mentioned in the preceding paragraph 0070, the curved opening rims become the same kind of smooth convex shape and as there is no retroflexion of the depression in the projected portion used to slide the sheet, the projected opening rim and sheet come in contact with each other and the resistance can be decreased. There does not exist a large gap between the projections and the depressions of the opening rims opposite the projection, and therefore, the movement of the sheet can be suppressed at the time of pulling out the sheet. The sheets can be fixed smoothly by reducing the space pushed by the opening.
According to the operation as mentioned in the preceding paragraph 0071, as the joint portion provided through the contact between adjacent smooth convex shape curved opening rims suddenly becomes narrow, the sheets get stuck in the depression at the time of removal.
According to the operation as mentioned in the preceding paragraph 0072, as the depression present at the lower side than the center rim of the opening of smooth convex shape curved opening rims, which supports sliding of the sheet, does not have a depression being depressed by 1 cm or more in the direction parallel to the folded line of a sheet, the sheet is prevented from being guided toward an opening not intended.
According to the operation as mentioned in the preceding paragraph 0073, while pulling the sheet to the opening rim, a small folding line nearly similar to the shape of the projection can be put into the sheet by using the smooth projections on both sides and a small subordinate projection between them.
According to the operation as mentioned in the preceding paragraph 0074, the pair of depressions present at both ends of the opening itself are the depressions of shape including the concave shape curve due to which the ends of the sheet can be fixed smoothly.
According to the effect of the preceding paragraph 0070 mentioned above, the sheet can be pulled out smoothly and it can be fixed in such a way that it is difficult for the sheet to fall into the storage box.
According to the effect of the preceding paragraph 0071 mentioned above, the sheet can be pulled out in such a way that the sheet gets caught in the opening.
According to the effect of the preceding paragraph 0072 mentioned above, the movement of the sheet can be suppressed as the sheets are prevented from being guided toward an opening not intended.
According to the effect of the preceding paragraph 0073 mentioned above, as the small folding line nearly similar to the shape of the projection can be put into the sheet by using the smooth projections on both sides and a small subordinate projection between them, the sheet can be raised easily.
According to the effect of the preceding paragraph 0074 mentioned above, as the shape of both ends of the opening is made into the shape including the concave curve shape, the drawback is eliminated that, if both ends of the opening are an acute angle, the sheet gets stuck and the movement of the sheet is hindered, and the sheet can be caught smoothly in the depression due to the restoring force of the sheet itself.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below on the basis of FIG. 17 to FIG. 33 .
FIG. 17 is a diagram illustrating an example of sheet-removing opening rims of line symmetric shape by considering (a-a′) as the axis to explain the present invention wherein, ( 15 ) is the surface of the sheet-removing opening of the sheet storage box, ( 16 ) is the sheet-removing opening, ( 17 ) is the rim of the opening formed into a smooth convex shape curve, ( 18 ) is the depression of the opening rims forming the space including the center of the opening and ( 19 ) are the depressions formed at both ends of the opening.
FIG. 17 shows an opening having two pairs of the opening rims with opposite convex shape curves of ( 17 ) and the height of the apexes of the opposite convex shape projections is the same. However, it does not have a shape with which only from one side the sheet can be easily removed from the opening and at the other side the sheet can be fixed easily, due to which the fixing of the sheet becomes loose.
FIG. 18 is a diagram illustrating an example of the sheet-removing opening of the present invention wherein, the rim of the opening is at the position after rotating the preceding FIG. 17 in a counterclockwise direction, ( 15 ′) is the surface of the sheet-removing opening of the sheet storage box of the present invention, ( 16 ′) is the sheet-removing opening of the present invention, ( 17 ′) is the convex shape curved rim of the opening of the present invention which is at a high level as compared to ( 17 ″), ( 17 ″) is the convex shape curved rim of the opening of the present invention which is at a low level as compared to ( 17 ′), ( 18 ′) are the depressions of the present invention forming the space including the center of the rim of the opening, ( 19 ′) are the depressions of the present invention formed at the opposite ends of the rims of the opening.
The opening can also be formed by rotating the opening illustrated in FIG. 17 in a clockwise direction. There is no limit on the styles of the opening as long as the conditions of the present inventions are fulfilled.
FIG. 19 is a diagram illustrating an example of the sheet-removing opening of the present invention which is the same as in FIG. 18 mentioned above. However, ( 20 ) is the space with an open portion within the circle of 3 mm in diameter present at the center of the opening, ( 21 ) is the space with open portion within the circle of 2 mm in diameter present at both ends of the opening, ( 21 ) are the spaces opposite each other across the convex shape curved rims of the opening, furthermore, ( 20 ) has the depressions present between the adjacent convex shape curved rims of the opening which are present at both sides and these depressions are the spaces formed inside the depressions which are opposite each other at the corners of the rims of the opening forming the space including the center of the opening.
FIG. 20 is a diagram illustrating an example of the sheet-removing opening wherein, ( 22 ) is the depression that does not have a depression being depressed by 1 cm or more in the direction parallel to the folded line of a sheet at the lower side than the center rim of the opening of smooth convex shape curved opening rims ( 17 ′) and ( 17 ″) which support the sliding of the sheet. It suffices if an arrow between the dotted straight lines does not enter below ( 17 ′) by 1 cm. The same applies to ( 17 ″).
If ( 22 ) is large, the sheet is prevented from being guided to any direction and therefore, it is preferable that the depression entering below ( 17 ′) and ( 17 ″) are not present.
FIG. 21 is a diagram illustrating an example of the sheet-removing opening of the present invention wherein, ( 17 ′) is the convex shape curved rim of the opening of the present invention present at a high level, ( 17 ″) is the convex shape curved rim of the opening of the present invention present at a low level, ( 18 ′) are the depressions of the present invention and ( 19 ′) are the openings with the depressions present at both ends of the opening of the present invention.
FIG. 22 is a diagram illustrating an example of the sheet-removing opening of the present invention wherein, the opening is formed by rotating FIG. 21 in the counterclockwise direction, however, the opening can be formed by rotating it in the clockwise direction as long as the height of the projections illustrated in FIG. 21 does not become equal. There is no limit on the styles.
In FIG. 22 , ( 23 ) is a step formed by ( 19 ′) and ( 17 ′), ( 24 ) is a step formed by ( 19 ′) and ( 17 ″). If the step is present at ( 17 ′) side, the sheet can be fixed easily while the projected portion of ( 17 ′) is concealed below the sheet.
FIG. 23 is a diagram illustrating an example of a portion of the sheet-removing opening as mentioned in claim 2 and claim 4 of the present invention wherein, ( 1 ) illustrated by a dotted line is the tissue paper, ( 25 ) is the depression of the present invention formed by contacting the adjacent smooth convex shape curves by using the folded convex shape curve or folded line shape curves, ( 26 ) is the curved shape projection mentioned in claim 4 which is present at a lower level than the height of ( 17 ′) and ( 17 ″), ( 25 ′) is the depression formed adjacent to ( 26 ), (A) is the rim of the opening mentioned in claim 2 , and (B) and (C) are rims of the opening mentioned in claim 4 .
By passing the sheet through the vicinity of ( 25 ) or ( 25 ′), the sheet can be inserted in the narrow portion of the opening and by considering this portion as a force point, both ends of the sheet can be moved to the end of the opening. Furthermore, due to the shape of the opening of the present invention, although the sheet has not reached ( 19 ′), it can be fixed.
Furthermore, if the count of ( 26 ) is increased too much, an adhesion of the sheet to the rims of the opening becomes poor and thus it is better to have up to about two each on the upper and lower sides.
FIG. 24 is a diagram illustrating an example of a simplified diagram when (B) mentioned in the preceding FIG. 23 has been operated wherein, ( 1 ″) are the mountain fold strings formed in the sheet and the sheet can be easily raised by hollowing the space between the strings.
FIG. 25 is a diagram illustrating an example of the sheet-removing opening having (A) mentioned in FIG. 23 wherein, ( 25 ) can draw the sheet when sheets are to be pulled out.
FIG. 26 is a diagram illustrating the opening formed at a position when the sheet-removing opening illustrated in FIG. 25 is rotated in the counterclockwise direction wherein, the opening is formed in such a way that ( 17 ′) is concealed below the sheet and sheet is caught from below and can be held easily.
FIG. 27 shows the sheet-removing opening including ( 17 ′) and ( 17 ″) illustrated in FIG. 18 as mentioned in claim 2 .
FIG. 28 is a diagram illustrating an example of the sheet-removing opening with (B) illustrated in FIG. 23 .
FIG. 29 is a diagram illustrating the opening formed at a position when the sheet-removing opening illustrated in FIG. 28 is rotated in a counterclockwise direction.
FIG. 30 is the sheet-removing opening including ( 17 ′) and ( 17 ″) illustrated in FIG. 18 .
FIG. 31 shows a diagram illustrating an example of the sheet-removing opening with (C) illustrated in FIG. 23 .
FIG. 32 is a diagram illustrating the opening formed at a position when the sheet-removing opening illustrated in FIG. 31 is rotated in a counterclockwise direction.
FIG. 33 shows the sheet-removing opening including ( 17 ′) and ( 17 ″) illustrated in FIG. 18 .
As mentioned above, according to the embodiments of the present invention, the sheets which are effectively fixed and smoothly removed can be obtained.
The embodiments mentioned above are described to explain the present invention and according to the claims of the present invention, there is no limit on the types of the embodiments such as shape, material and structure.
EXAMPLES
FIG. 34 is a diagram illustrating an example of a top lid provided on the sheet-removing opening of the present invention wherein, ( 27 ) is the top lid which can be detached from the vicinity of to the center of the opening by dividing into half by using a perforated line, ( 28 ) is a thin portion of the top lid and ( 29 ) is a portion of the top lid with a perforated line wherein a hole can be made by inserting a finger.
The portion of ( 28 ) wherein, the top lid has become thin is made easier to move away from the surrounding perforated line by elongating the cut portion of the perforated line of ( 15 ′) and the top lid is made easier to move away by completely cutting the tip portion of the acute angle portion. Furthermore, double perforated lines may be provided. There is no limit on types such as shape, interval, and number of perforated lines.
FIG. 35 shows an example of the sides which forms the storage box that can be used in the present invention wherein, (A) is a diagram of a portion of a flattened storage box seen from the front side, (B) is the cross sectional diagram of (A), (C) is a diagram wherein, right and left inner surfaces of (B) are moved closer and fold down wherein, ( 30 ) is the front side surface of the storage box, ( 31 ) is a concave shape groove set up in ( 30 ), ( 30 ′) is an inner surface of the storage box and ( 31 ′) is a convex shape line placed on the opposite side of ( 31 ).
The side of the storage box may be formed by just folding down the flat surface once or it may be of the shape mentioned above in the preceding paragraph 0113. Furthermore, the shape of the storage box may be rectangular parallelepiped, cube or curved shape formed by curling up the sides or corners. There are various shapes formed by a polyhedron formed of a straight surface or curved surface and there is no limit on the styles.
FIG. 36 is a diagram illustrating an example of the portion of the sheet-removing opening as illustrated in FIG. 23 with some portions changed wherein, ( 32 ) is the portion with ( 25 ) or ( 25 ′) illustrated in FIG. 23 changed to a smooth concave shape, (A) is the portion with a space between ( 17 ′) and ( 17 ″) changed to ( 32 ), (B) is the portion with ( 25 ′) changed to ( 32 ) and (C) is the portion with ( 25 ′) present between ( 26 ) changed to ( 32 ).
The depression with a shape mentioned in the above ( 32 ) is not a desirable shape as the pulling force of the sheet at the time of pulling the sheet out is less.
FIG. 37 is a diagram illustrating an example wherein ( 25 ) is formed by contacting adjacent ( 17 ) mentioned in FIG. 17 . In the opening of this shape, since ( 17 ) facing each other are of same height, the rims of the opening cannot be too close to (a-a′) as the appearing tissue paper cannot make contact with the rims of the opening properly and therefore this is less effective as compared to the shape of the rims of the opening of the present invention.
FIG. 38 is a diagram illustrating an example of a pair of curved shape projections smaller than ( 17 ) provided between the adjacent ( 17 ) illustrated in FIG. 17 and with this shape also the effect the same as mentioned in the preceding paragraph 0117 is obtained.
FIG. 39 is a diagram illustrating an example of two pairs of curved shape projections smaller than ( 17 ) provided between the adjacent ( 17 ) illustrated in FIG. 17 , and with this shape also the effect the same as mentioned in the preceding paragraph 0117 is obtained.
FIG. 40 is a diagram illustrating an example of the rims of the opening forming the spaces ( 19 ′) at both ends of the opening of the present invention. Although the above-mentioned depression forming both ends of the opening of the present invention is formed by the arc shape or full arc shape curve, (A) shows the depression formed by combining the curve shape and straight line shape, (B) shows the depression formed by changing the end of the rims of the opening to the straight line shape and (C) is formed by the curved shape depression at both ends and the depression including the projection at the center.
In FIG. 40 , (A) shows the effect most similar to the effect of ( 19 ) used in the explanation above.
FIG. 41 is a diagram illustrating an example of the opening of the storage box of the present invention wherein, (n) and (m) are the symbols to indicate the ratio of the width of ( 17 ′) and ( 17 ″). As long as ( 17 ′) and ( 17 ″) fulfill the above-mentioned conditions of the present invention, the ratio of (n) and (in) may be the same or different without limiting the style.
The embodiments of the present invention are as follows.
1. As long as the tissue-paper removing opening of the present invention fulfills the conditions of the present invention, the ratio of the width of the projection running parallel to (a-a′) described in claim 1 of the present invention may be the same or different without limiting the style.
2. As long as the configured location of the subordinate projection mentioned in claim 4 fulfills the conditions of the present invention, it may be at a line symmetric position or point symmetric position without limiting the style.
3. There are various styles of the formation of the opening of the present invention such as forming the opening by slightly widening the pair of depressions present on the rims of the opening forming the space including the center of the opening so that it is easy to insert the finger tips or a combination with other effective shapes may be used to form the opening.
4. A cut to tuck the sheet and convexity or concavity giving resistance to the sheet may be provided at the rims of the opening of the present invention. A valley fold line may be provided using the convexity or concavity provided in the storage box in order to easily raise the projections of the rims of the opening of the present invention. The cut may be provided on the surface of the storage box below the projection of the present invention to soften the projection itself of the present invention. A perforated line and folded line may be provided to form the projection to be raised in the storage box by tucking the portion of the storage box separated by using a perforated line near the center of the bottom of the storage box to push the sheet upward used in the storage box of the present invention. The perforated line may be provided to easily break or collapse the storage box of the present invention. The opening of the present invention may be used in the storage box with another shape and effect. Other modifications can be adopted. There is no limit on styles in which the manufacturers may combine any other effective structure or material for the opening or the storage box of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a diagram illustrating an expanded sheet.
FIG. 1B is a diagram illustrating a half folded sheet along the folded line ( 1 ′).
FIG. 2 is a diagram of an example of the conventional tissue-paper storage box seen from obliquely upward.
FIG. 3 is a diagram of an example of the tissue-paper removing opening.
FIG. 4 is a diagram of an example when pulling out the tissue paper from the opening.
FIG. 5A is a diagram of the tissue-paper storage box seen from obliquely upward.
FIG. 5B is a cross sectional diagram of the storage box cut by a straight line parallel to (b-b′).
FIG. 6 is a diagram of an example of the conventional tissue-paper storage box seen from directly above.
FIG. 7 is a diagram of an example of the conventional tissue-paper storage box seen from above.
FIG. 8 is a diagram of an example of the conventional tissue-paper storage box seen from above.
FIG. 9 is a diagram of an example of the conventional tissue-paper storage box seen from above.
FIG. 10 is a diagram of an example of the sheet-removing opening.
FIG. 11 is a diagram of an example of the sheet-removing opening.
FIG. 12 is a diagram of an example of curved shape rim of the opening placed at the point symmetric position.
FIG. 13 is a diagram of an example of the sheet-removing opening.
FIG. 14 is a diagram of an example of the projected portion of the sheet-removing opening.
FIG. 15 is a diagram of an example of the sheet-removing opening.
FIG. 16 is a diagram of an example of a cover made of cloth to cover the sheet storage box.
FIG. 17 is a diagram of an example of line symmetric rim of the sheet-removing opening.
FIG. 18 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 19 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 20 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 21 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 22 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 23A is a diagram illustrating the rim of the opening mentioned in claim 2 .
FIG. 23B is a diagram illustrating the rims of the opening mentioned in claim 4 .
FIG. 23C is a diagram illustrating the rims of the opening mentioned in claim 4 .
FIG. 24 is a diagram of an example of the operation of B of FIG. 23 .
FIG. 25 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 26 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 27 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 28 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 29 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 30 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 31 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 32 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 33 is a diagram of an example of the sheet-removing opening of the present invention.
FIG. 34 is a diagram of an example of a top lid provided on the sheet-removing opening of the present invention.
FIG. 35A is a diagram of a portion of a flattened storage box seen from the front side.
FIG. 35B is the cross sectional diagram of FIG. 35A .
FIG. 35C is a diagram wherein, right and left inner surfaces of FIG. 35B are moved closer and fold down.
FIG. 36A is a diagram of the portion with a space between ( 17 ′) and ( 17 ″) changed to ( 32 ).
FIG. 36B is a diagram of the portion with ( 25 ′) changed to ( 32 ).
FIG. 36C is a diagram of the portion with ( 25 ′) present between ( 26 ) changed to ( 32 ).
FIG. 37 is a diagram of an example of the sheet-removing opening with main projection having line symmetric position.
FIG. 38 is a diagram of an example of the sheet-removing opening with main projection having line symmetric position.
FIG. 39 is a diagram of an example of the sheet-removing opening with main projection having line symmetric position.
FIG. 40A shows the depression formed by is combining the curve shape and straight line shape.
FIG. 40B shows the depression formed by changing the end of the rims of the opening to the straight line shape.
FIG. 40C shows the depression formed by the curved shape depression at both ends and the depression including the projection at the center.
FIG. 41 is a diagram of an example of the sheet-removing opening of the present invention.
REFERENCE SIGNS LIST
1 : Sheet,
1 ′: Folded line of a sheet
2 : Surface with an opening
2 ′: Top lid of the opening
3 : Tissue-paper removing opening
3 ′ a and 3 ′ b : Rims of the opening
4 : Fixing sheet pasted near the opening
5 : Slit provided in the fixing sheet pasted near the opening
6 , 6 ′, 6 ″: Projection for fixing the tissue paper
7 : Nonlinear symmetric and point symmetric sheet-removing opening
7 a : Long side of the opening
7 b : Short side of the opening,
7 L and 7 R: Rims of the opening
8 : Projection
9 : Rims of the opening
10 : Depression
11 : Rims of the opening
12 , 12 ′, 12 ″: Apex of the projection
13 , 13 ′: Projection forming the opening
14 : Cover main body
14 ′: Sheet-removing opening
15 : Surface of the sheet-removing opening
15 ′: Surface of the sheet-removing opening of the present invention
16 : Sheet-removing opening
16 ′: Sheet-removing opening of the present invention
17 : Rims of the opening
17 ′: Rim of the opening of the present invention with long height
17 ″: Rim of the opening of the present invention with short height
18 : Depression
18 ′; Depression of the present invention
19 : Depression
19 ′: Depression of the present invention
20 : Open space within the circle of 3 mm at the center of the opening
21 : Open space within the circle of 2 mm at both ends of the opening
22 : Concave depression at lower portion of rim of the opening of the present invention with long height and rim of the opening of the present invention with short height
23 : Step of rim of the opening of the present invention with long height and depression of the present invention
24 : Step of rim of the opening of the present invention with short height and depression of the present invention
25 : Folded line shape or folded convex shape curved depression
25 ′: Depression formed adjacent to curved shape projection at lower level than the height of rim of the opening of the present invention with long height and rim of the opening of the present invention with short height
26 : Curved shape projection at lower level than the height of rim of the opening of the present invention with long height and rim of the opening of the present invention with short height
27 : Top lid that can be detached by using perforated line
28 : Thin portion of the top lid
29 : Circular top lid portion with perforated line
30 : Front surface of the storage box
30 ′: Inner surface of the box
31 : Concave shape groove
31 ′: Convex shape line
32 : Smooth concave shape depression
A-A′: Breadth of the storage box
B-B′: Length of the storage box
C-C′: Height of the storage box
d: Portion near the center of the opening, intersection of a-a′ and b-b′
d′: Circle near the center of the tissue-paper removing opening
a-a′: Line parallel to the folding line of the sheet passing through the center of the opening
b-b′: Straight line passing through the center of the opening perpendicular to a-a′
x: Hand
e and e′: Portion of the tissue paper to which force is likely to be applied
s: Line parallel to b-b′ and passing through the apex of the projection of the opening
t: Intersecting line perpendicular to line parallel to b-b′ and passing through the apex of the projection of the opening
n, m: Ratio of rim of the opening of the present invention with long height and rim of the opening of the present invention with short height | Conventional sheet storage boxes have problems that the sheet storage box with a sheet-fixing sheet pasted on the sheet-removing opening is wasteful from the point of view of resources and that, in the case of the sheet storage box without the sheet-fixing sheet pasted on the opening, the fixing of sheet becomes weaker as the opening itself becomes larger due to the excessively wide rim of the opening and when the rims of the opening are made too close, the rim of the opening partially becomes smaller and the resistance to remove the sheets becomes too large. To solve the above problems of the conventional sheet storage boxes, the present invention provides a sheet-removing opening by effectively forming the portion to remove the sheet easily from the opening and the portion to easily catch the sheet wherein, the shape of the rims of the opening of the sheet storage box designed to remove the sheet is formed in such a way that the movement of the sheet is reduced by adequately reducing the spatial area of the opening and the rims of the opening are converted to convex shape smooth curves to smoothly slide the sheet. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to, and claims all benefits of priority under 35 U.S.C. §120 of U.S. Non-Provisional application Ser. No. 11/063,085, filed Feb. 22, 2005, which claims priority to U.S. Provisional Application No. 60/558,168 filed Mar. 31, 2004, each of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] This invention relates to a medical device and, in particular, a prosthesis for implantation within the human or animal body for the repair of damaged vessels such as blood vessels, and a method for implanting the same.
[0004] 2. Related Art
[0005] Throughout this specification, when discussing the aorta or other blood vessels, the terms distal and distally with respect to a prosthesis are intended to refer to the end of the prosthesis furthest away in the direction of blood flow from the heart. Similarly, the terms proximal and proximally are intended to mean the end of the prosthesis which when implanted would be nearest to the heart.
[0006] The functional vessels of humans, such as blood vessels and ducts, occasionally weaken or even rupture. For example, the aortic wall can weaken, resulting in an aneurysm. Upon further exposure to haemodynamic forces, such an aneurysm can rupture. A common surgical intervention for weakened, aneurismal or ruptured vessels is the use of a prosthesis to provide some or all of the functionality of the original, healthy vessel and/or preserve any remaining vascular integrity by replacing a length of the existing vessel wall that spans the site of vessel failure.
[0007] The deployment of intraluminal prostheses into the lumen of a patient from a remote location by the use of a deployment device or introducer has been disclosed in a number of earlier patents and patent applications. U.S. Pat. No. 4,562,596, entitled “Aortic Graft, Device and Method for Performing an Intraluminal Abdominal Aortic Aneurysm Repair” which is herein incorporated by reference, proposes the retention of a self expanding graft within a sleeve until it is to be deployed, at which time the sleeve is withdrawn and the graft is allowed to expand. U.S. Pat. No. 4,665,918, entitled “Prosthesis System and Method” which is herein incorporated by reference, proposes a system and method for the deployment of a prosthesis in a blood vessel. The prosthesis is positioned between a delivery catheter and an outer sheath and expands outwardly upon removal of the sheath.
[0008] U.S. Pat. No. 4,950,227, entitled “Stent Delivery System” which is herein incorporated by reference, proposes the delivery of a stent by mounting the stent to the outside of an inflatable catheter and retaining the ends of an unexpanded stent by fitting a sleeve over either end of the stent. Expansion of the stent is caused by inflation of the catheter between the sleeves so that the ends of the stent are withdrawn from the respective sleeves and the stent released and expanded into position.
[0009] U.S. Pat. No. 5,387,235 entitled “Expandable Transluminal Prosthesis for Repair of Aneurysm”, discloses apparatus and methods of retaining grafts onto deployment devices. These features and other features disclosed in U.S. Pat. No. 5,387,235 could be used with the present invention and the disclosure of U.S. Pat. No. 5,387,235 is herein incorporated by reference.
[0010] U.S. Pat. No. 5,720,776 entitled “Barb and Expandable Transluminal Graft Prosthesis for Repair of Aneurysm” discloses improved barbs with various forms of mechanical attachment to a stent. These features and other features disclosed in U.S. Pat. No. 5,720,776 could be used with the present invention and the disclosure of U.S. Pat. No. 5,720,776 is herein incorporated by reference.
[0011] U.S. Pat. No. 6,206,931 entitled “Graft Prosthesis Materials” discloses graft prosthesis materials and a method for implanting, transplanting replacing and repairing a part of a patient and particularly the manufacture and use of a purified, collagen based matrix structure removed from a submucosa tissue source. These features and other features disclosed in U.S. Pat. No. 6,206,931 could be used with the present invention and the disclosure of U.S. Pat. No. 6,206,931 is herein incorporated by reference.
[0012] PCT Patent Publication Number No. WO99/29262 entitled “Endoluminal Aortic Stents” discloses a fenestrated prosthesis for placement where there are intersecting arteries. This feature and other features disclosed in PCT Patent Publication Number No. WO99/29262 could be used with the present invention and the disclosure of PCT Patent Publication Number No. WO99/29262 is herein incorporated by reference.
[0013] PCT Patent Publication Number No. WO03/034948 entitled “Prostheses for Curved Lumens” discloses prostheses with arrangements for bending the prosthesis for placement into curved lumens. This feature and other features disclosed in PCT Patent Publication Number No. WO03/034948 could be used with the present invention and the disclosure of PCT Patent Publication Number No. WO03/034948 is herein incorporated by reference.
[0014] United States Patent Application Publication No. 2003/0233140 entitled “Trigger Wire System” discloses release wire systems for the release of stent grafts retained on introducer devices. This feature and other features disclosed in United States Patent Application Publication No. 2003/0233140 could be used with the present invention and the disclosure of United States Patent Application Publication No. 2003/0233140 is herein incorporated by reference.
[0015] United States Patent Application Publication No. 2004/0098079 entitled “Thoracic Deployment Device” discloses introducer devices adapted for deployment of stent grafts particularly in the thoracic arch. This feature and other features disclosed in United States Patent Application Publication No. 2004/0098079 could be used with the present invention and the disclosure of United States Patent Application Publication No. 2004/0098079 is herein incorporated by reference.
[0016] United States Patent Application Publication No. 2004/0054396 entitled “Stent-Graft Fastening” discloses arrangements for fastening stents onto grafts particularly for exposed stents. This feature and other features disclosed in United States Patent Application Publication No. 2004/0054396 could be used with the present invention and the disclosure of United States Patent Application Publication No. 2004/0054396 is herein incorporated by reference.
[0017] PCT Patent Publication Number No. WO03/053287 entitled “Stent Graft with Improved Graft Adhesion” discloses arrangements on stent grafts for enhancing the adhesion of such stent grafts into walls of vessels in which they are deployed. This feature and other features disclosed in PCT Patent Publication Number No. WO03/053287 could be used with the present invention and the disclosure of PCT Patent Publication Number No. WO03/053287 is herein incorporated by reference.
[0018] PCT Patent Publication Number No. WO98/53761 entitled “A Prosthesis and a Method and Means of Deploying a Prosthesis”, which is herein incorporated by reference, discloses various embodiments of an introducer for positioning an expandable endovascular prosthesis in a lumen of a patient.
[0019] One issue that arises with the use of an intraluminal prosthesis is where the damage in a vessel is at or near a branching vessel. For example, an abdominal aortic aneurysm can exist near the renal arteries, and a thoracic aortic aneurysm can exist near the left subclavian, common carotid, and/or innominate arteries. It would be desirable to prevent the prostheses from obstructing such a branch vessel. It may also be desirable to include a fenestration in a wall of an intraluminal prosthesis to allow fluid communication between the interior cavity of the prosthesis and a branch vessel adjacent to the prostheses. It may be further desirable to maintain an alignment between such a fenestration and an opening to a branch vessel.
SUMMARY
[0020] An intraluminal prosthesis is provided for strengthening a main lumen and a branch lumen in direct fluid communication with the main lumen. The prosthesis comprises a first tubular graft having a first flexible body, which includes a wall with a fenestration having a linear dimension. The prosthesis also comprises a second tubular graft having a second flexible body. The second tubular graft also includes a self-expanding stent with a terminal loop coupled that is coupled to a longitudinal end of the second flexible body. The self-expanding stent, when in an expanded state, has curvature such that the terminal loop is substantially in the same plane as the longitudinal end of the second flexible body. The second tubular graft is configured for endoluminal coupling with the first tubular graft.
[0021] An intraluminal prosthesis is provided for strengthening a branch lumen. The intraluminal prosthesis can comprise a flexible body made from a graft material and having a tubular interior passage. The prosthesis can also comprise a plurality of self expanding stents coupled along the length of the flexible body. A terminal stent can be coupled to and extend substantially radially outwardly from the proximal end of the flexible body.
[0022] A method of assembling a prosthesis intraluminally is also provided. The method can include providing a first tubular graft that has an inner passage, an outer surface, and a fenestration through the outer surface to the inner passage. The method can further include providing a second tubular graft having an inner passage, an outer surface, and a proximal end. The method can also include inserting the proximal end of the second tubular graft into the fenestration of the first tubular graft, and coupling the second tubular graft to the first tubular graft so that the inner passage of the second tubular graft is in fluid communication with the inner passage of the first tubular graft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like referenced numerals designate corresponding parts throughout the different views.
[0024] FIG. 1A is an exploded perspective view of an introducer a prosthesis partially deployed.
[0025] FIG. 1B is detail perspective view of a portion of the prosthesis shown in FIG. 1A .
[0026] FIG. 2 is a sectional view of a portion of the introducer around the proximal end of the prosthesis.
[0027] FIG. 3 is a sectional view of a portion of the introducer around the distal end of the prosthesis.
[0028] FIG. 4 is a sectional view of a portion of the introducer around the haemostatic seal.
[0029] FIG. 5 is a sectional view of a portion of the introducer around the trigger wire release mechanisms.
[0030] FIG. 6 is a sectional view of a portion of the introducer around the pin vise clamp and the medical reagent introduction tube.
[0031] FIG. 7 is an exploded sectional view of the introducer of FIG. 1A fully loaded and ready for introduction into a patient.
[0032] FIG. 8 is an exploded view partially in section of the introducer of FIG. 7 in the next stage of deployment of the prosthesis.
[0033] FIG. 9 is an exploded view partially in section of the introducer of FIG. 7 with the release of the proximal end stage of deployment.
[0034] FIG. 10 is an exploded view partially in section of the introducer of FIG. 7 with the release of the distal end stage of deployment.
[0035] FIG. 11 is an exploded view partially in section similar to FIG. 10 showing the advancement of the distal attachment mechanism to the proximal attachment mechanism.
[0036] FIG. 12 is an exploded view partially in section similar to FIG. 10 showing the withdrawal of the introducer.
[0037] FIG. 13 is a perspective view of a second introducer with a branch prosthesis partially deployed.
[0038] FIG. 14 is a sectional view of a portion of the introducer of FIG. 13 around the proximal end of the branch prosthesis.
[0039] FIG. 15 is a sectional view of a portion of the introducer of FIG. 13 around the distal end of the branch prosthesis.
[0040] FIG. 16 is an isometric view of the branch prosthesis shown in FIG. 13 .
[0041] FIG. 17 is an elevation view of a main lumen and a branch lumen in fluid communication with the main lumen.
[0042] FIG. 18 is a sectional view of the main lumen and the branch lumen of FIG. 17 after the prosthesis of FIGS. 1A and 1B has been implanted.
[0043] FIG. 19 is a sectional view of the main lumen and the branch lumen of FIG. 17 after the branch prosthesis of FIG. 13 has been implanted in the prosthesis of FIG. 1A through the fenestration shown in FIG. 1B .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] FIG. 1A shows an endoluminal prosthesis 20 , and an endovascular deployment system, also known as an introducer, for deploying the prosthesis 20 in a lumen of a patient during a medical procedure. The term “prosthesis” means any replacement for a body part or function of that body part. It can also mean a device that enhances or adds functionality to a physiological system. The terms “intraluminal” and “endoluminal” describes objects that are found or can be placed inside a lumen in the human or animal body. A lumen can be an existing lumen or a lumen created by surgical intervention. This includes lumens such as blood vessels, parts of the gastrointestinal tract, ducts such as bile ducts, parts of the respiratory system, etc. “Endoluminal prosthesis” or “Intraluminal prosthesis” thus describes a prosthesis that can be placed inside one of these lumens.
[0045] The introducer shown in FIG. 1A includes an external manipulation section 1 , a distal positioning mechanism attachment region 2 and a proximal positioning mechanism attachment region 3 . During the medical procedure to deploy the prosthesis 20 , the distal and proximal attachment regions 2 and 3 will travel through the lumen to a desired deployment site. The external manipulation section 1 , which is acted upon by a user to manipulate the introducer, remains outside of the patient throughout the procedure.
[0046] The prosthesis 20 comprises a tubular graft material 50 , with self expanding stents 19 attached thereto. The term “graft” means the generally cannular or tubular member which acts as an artificial vessel. A graft by itself or with the addition of other elements can be an endoluminal prosthesis. The term “stent” means any device or structure that adds rigidity, expansion force or support to a prosthesis.
[0047] The tubular graft material 50 is preferably non-porous so that it does not leak or sweat under physiologic forces. The graft material is preferably made of woven DACRON® polyester (VASCUTEK® Ltd., Renfrewshire, Scotland, UK). The tubular graft can be made of any other at least substantially biocompatible material including such materials as other polyester fabrics, polytetrafluoroethylene (PTFE), expanded PTFE, and other synthetic materials known to those of skill in the art. Naturally occurring biomaterials, such as collagen, are also highly desirable, particularly a derived collagen material known as extracellular matrix (ECM), such as small intestinal submucosa (SIS).
[0048] Other examples of ECMs are pericardium, stomach submucosa, liver basement membrane, urinary bladder submucosa, tissue mucosa, and dura mater. SIS is particularly useful, and can be made in the fashion described in U.S. Pat. No. 4,902,508 to Badylak et al.; U.S. Pat. No. 5,733,337 to Carr; 17 Nature Biotechnology 1083 (November 1999); and WIPO Publication WO 98/22158 of May 28, 1998, to Cook et al., which is the published application of PCT/US97/14855. All of these patents and publications are incorporated herein by reference.
[0049] Irrespective of the origin of the graft material (synthetic versus naturally occurring), the graft material can be made thicker by making multi-laminate constructs, for example SIS constructs as described in U.S. Pat. No. 5,968,096, U.S. Pat. No. 5,955,110, U.S. Pat. No. 5,885,619, and U.S. Pat. No. 5,711,969. All of these patents are incorporated herein by reference. In addition to xenogenic biomaterials, such as SIS, autologous tissue can be harvested as well, for use in forming the graft material. Additionally elastin or elastin-like polypeptides (ELPs) and the like offer potential as a material to fabricate the graft material.
[0050] The self expanding stents 19 cause the prosthesis 20 to expand following its disengagement from the introducer. The prosthesis 20 also includes a self expanding zigzag stent 21 that extends from its proximal end. When it is disengaged, the self expanding zigzag stent 21 anchors the proximal end of the prosthesis 20 to the lumen.
[0051] One or more fenestrations 17 can be provided in the tubular graft material 50 . Radiographic markers 18 can be attached to the tubular graft material 50 adjacent to the fenestration 17 as shown in FIG. 1B in order to aid in the alignment of the fenestration 17 with a branch vessel. For example, the radiographic markers 18 can be small rings of metal, such as stainless steel, sewn to the tubular graft material 50 with suture, not shown.
[0052] FIG. 2 shows the proximal attachment region 3 in greater detail. The proximal attachment region 3 includes a cylindrical sleeve 10 . The cylindrical sleeve 10 has a long tapered flexible extension 11 extending from its proximal end. The flexible extension 11 has an internal longitudinal aperture 12 . The longitudinal aperture 12 facilitates advancement of the tapered flexible extension 11 along an insertion wire 13 . The aperture 12 also provides a channel for the introduction of medical reagents, which will flow through openings 14 . For example, it may be desirable to supply a contrast agent to allow angiography to be performed during placement and deployment phases of the medical procedure.
[0053] A thin walled tube 15 , which can be made of metal, is fastened to the extension 11 . The thin walled tube 15 is sufficiently flexible so that the introducer can be advanced along a relatively tortuous vessel, such as a femoral artery. The thin walled tube 15 also facilitates manipulation longitudinally and rotationally of the proximal attachment region 3 . The thin walled tube 15 extends through the introducer to the manipulation section 1 , terminating at a connection means 16 , as shown in FIG. 6 .
[0054] Regarding the introduction of reagents, FIG. 6 also shows that the connection means 16 is adapted to accept a syringe to facilitate the introduction of reagents into the tube 15 . The tube 15 is in fluid communication with the aperture 12 of the flexible extension 11 . Therefore, reagents introduced into connection means 16 flow through the aperture 12 and emanate from the apertures 14 .
[0055] As shown in FIG. 3 , a tube 41 , which can be made of plastic, is coaxial with and radially outside the thin walled tube 15 . The tube 41 is “thick walled”, that is to say the thickness of its wall is several times that of the thin walled tube 15 . A sheath 30 is coaxial with and radially outside the thick walled tube 41 . The thick walled tube 41 and the sheath 30 extend distally to the manipulation region 1 , as shown in FIG. 5 .
[0056] FIGS. 2 and 3 illustrate distal and proximal retention and release mechanisms of the introducer, respectively. During the placement phase of the medical procedure, the prosthesis 20 is retained in a compressed condition by the sheath 30 . The sheath 30 extends distally to a gripping and haemostatic sealing means 35 of the external manipulation section 1 , shown in FIG. 4 .
[0057] During assembly of the introducer, the sheath 30 is advanced over the cylindrical sleeve 10 of the proximal attachment region 3 while the prosthesis 20 is held in a compressed state by an external force. A distal attachment retention section 40 is formed in the thick walled tube 41 to retain the distal end of the prosthesis 20 . Alternatively, the distal attachment section 40 can be a separate piece coupled to the thick walled tube 41 .
[0058] The self-expanding stent 21 is released by retracting the sheath 30 , removing the trigger wire 22 , and then sliding the proximal attachment region 3 , including the retention device 10 , proximally away from the stent 21 . Once the retention device 10 has cleared the self-expanding stent 21 , the stent 21 will expand. The trigger wire 22 and the proximal wire release mechanism 24 form a control member to selectively release the retention device 10 from the prosthesis 20 by holding the self-expanding stent 21 in the retention device 10 until the prosthesis 20 is positioned at a desired site in the lumen.
[0059] The distal end 42 of the prosthesis 20 is retained by the distal attachment section 40 of the thick walled tube 41 . The distal end 42 of the prosthesis 20 has a loop 43 through which a distal trigger wire 44 extends. The distal trigger wire 44 extends through an aperture 45 in the distal attachment section 40 into the annular region between the thin walled tube 15 and the thick walled tube 41 .
[0060] As shown in FIG. 5 , the distal trigger wire 44 extends through the annular space between the thick walled tube 41 and the thin walled tube 15 to the manipulation region 1 . The distal trigger wire 44 exits the annular space at a distal wire release mechanism 25 . The distal trigger wire 44 and the distal wire release mechanism 25 form a control member to selectively disengage the distal retention section 40 from the prosthesis 20 when it is positioned at a desired site in the lumen.
[0061] FIG. 4 shows the haemostatic sealing means 35 of the external manipulation section 1 in greater detail. The haemostatic sealing means 35 includes a haemostatic seal 27 and a side tube 29 . The haemostatic seal 27 includes a clamping collar 26 that clamps the sheath 30 to the haemostatic seal 27 . The haemostatic seal 27 also includes a silicone seal ring 28 . The silicone seal ring 28 forms a haemostatic seal around the thick walled tube 41 . The side tube 29 facilitates the introduction of medical reagents between the thick walled tube 41 and the sheath 30 .
[0062] FIG. 5 shows a proximal portion of the external manipulation section 1 . The release wire actuation section has a body 36 that is mounted onto the thick walled tube 41 . The thin walled tube 15 passes through the body 36 . The distal wire release mechanism 25 is mounted for slidable movement on the body 36 . Similarly, the proximal wire release mechanism 24 is mounted for slidable movement on the body 36 . A pair of clamping screws 37 prevent inadvertent early release of the prosthesis 20 .
[0063] The positioning of the proximal and distal wire release mechanisms 24 and 25 is such that the proximal wire release mechanism 24 must be moved before the distal wire release mechanism 25 can be moved. Therefore, the distal end 42 of the prosthesis 20 cannot be released until the self-expanding zigzag stent 21 has been released and anchored to the lumen. A haemostatic seal 38 is provided so the release wires 22 and 44 can extend out through the body 36 to the release mechanisms 24 and 25 without unnecessary blood loss during the medical procedure.
[0064] FIG. 6 shows a distal portion of the external manipulation section 1 . A pin vise 39 is mounted onto the distal end of the body 36 . The pin vise 39 has a screw cap 46 . When screwed in, the vise jaws 47 clamp against (engage) the thin walled tube 15 . When the vise jaws 47 are engaged, the thin walled tube 15 can only move with the body 36 , and hence the thin walled tube 15 can only move with the thick walled tube 41 . With the screw cap 46 tightened, the entire assembly, except for the external sleeve 30 , can be moved as one.
[0065] The prosthesis 20 can be deployed in any method known in the art, preferably the method described in WO98/53761 in which the devise is inserted by an introducer via a surgical cut-down into a femoral artery, and then advanced into the desired position over a stiff wire guide 13 , shown in FIGS. 2 and 3 , using endoluminal interventional techniques. For example, FIGS. 7 through 12 show various stages of the deployment of the prosthesis 20 during an illustrative medical procedure. A guide wire 13 is introduced into the femoral artery and advanced until its tip is beyond the region into which the prosthesis 20 is to be deployed.
[0066] In FIG. 7 , the introducer assembly is shown fully assembled ready for introduction into a patient. The prosthesis 20 is retained at each of its ends by the proximal and distal retaining assemblies respectively, and compressed by the external sleeve 30 . If it is an aortic aneurism which is to be grafted, the introducer assembly can be inserted through a femoral artery over the guide wire 13 in the form as shown in FIG. 7 , and positioned by well known radiographic techniques not discussed here. The fenestration 17 of the prosthesis 20 can be aligned with a branch vessel, such as a renal artery, during this positioning.
[0067] In FIG. 8 , the introducer assembly is in a desired position for deployment of the prosthesis 20 . The external sheath 30 is withdrawn to just proximal of the distal attachment section 40 . This action releases the middle portion of the prosthesis 20 so that it can expand radially. The proximal self-expanding stent 21 , however, is still retained within the retention device 10 . Also, the distal end 42 of the prosthesis 20 is still retained within the external sheath 30 .
[0068] By release of the pin vise 39 to allow small movements of the thin walled tubing 15 with respect to the thick walled tubing 41 , the prosthesis 20 can be lengthened or shortened or rotated or compressed for accurate placement in the desired location within the lumen. X-ray opaque markers, not shown, can be placed along the prosthesis 20 to assist with placement of the prosthesis.
[0069] In FIG. 9 , the proximal trigger wire 22 has been removed, allowing the retention device 10 to be separated from the self-expanding zigzag stent 21 , as explained above. At this stage, the proximal trigger wire release mechanism 24 and the proximal trigger wire 22 can be removed completely.
[0070] Also, the screw cap 46 of the pin vise 39 has been loosened so that the thin walled tubing 15 can been pushed in a proximal direction to move the proximal attachment means 10 in a proximal direction. When the proximal attachment means 10 no longer surrounds the self-expanding stent 21 at the proximal end of the prosthesis 20 , the self-expanding stent 21 expands. When the self-expanding stent 21 expands, the hooks or barbs 26 on the self-expanding stent 21 grip into the walls of the lumen to hold the proximal end of the prosthesis 20 in place.
[0071] At this point, the distal end 42 of the prosthesis 20 is still retained by the distal attachment means 40 , with the loop 43 retained therein. The external sheath 30 is then withdrawn to distal of the distal attachment section 40 to allow the distal end 42 of the prosthesis 20 to expand. At this point, the distal end 42 of the prosthesis 20 can still be moved. Consequently, the prosthesis 20 can still be rotated or lengthened or shortened or otherwise moved to for accurate positioning.
[0072] In FIG. 10 , the distal end 42 of the prosthesis 20 has been released by removal of the distal trigger wire 44 . At this stage, the distal trigger wire release mechanism 25 and the distal trigger wire 44 can be removed completely. This removal can be accomplished by passing the distal wire release mechanism 25 over the pin vise 39 and the connection means 16 . The loop 43 of the terminal distal self-expanding zigzag stent 19 is hence released, and the prosthesis 20 is now free to expand to the wall of the lumen. At this point, the introducer is ready to be removed.
[0073] In FIG. 11 , the first stage of removal is shown. First, the distal attachment section 40 is advanced until it is received in the rear of the proximal attachment device 10 . Next, the proximal attachment device 10 , the tapered flexible extension 11 , and the distal attachment device 40 are removed together, as shown in FIG. 11 .
[0074] In FIG. 12 , the sheath 30 has been advanced to uncover the joint between the proximal attachment device 10 and the distal attachment section 40 . The sheath 30 can be removed with the proximal attachment device 10 , the tapered flexible extension 11 , and the distal attachment device 40 . Alternatively, these items could be removed separately, followed by removal of the external sleeve 30 .
[0075] FIG. 13 shows an endoluminal branch prosthesis 120 , and an endovascular introducer for deploying the branch prosthesis 120 . The branch prosthesis 120 is configured to have an outer diameter approximately equal to the diameter of the fenestration 17 of the prosthesis 20 , so that the branch prosthesis 120 can be tightly coupled to the prosthesis 20 .
[0076] The introducer includes an external manipulation section 101 , a proximal positioning mechanism 102 and a distal positioning mechanism 103 . The deployment of the prosthesis 120 and the actions of the distal and proximal attachment regions 103 and 102 , and the manipulation section 101 are fundamentally the same as for the deployment of the prosthesis 20 described above.
[0077] As shown in FIGS. 14 and 15 , one major difference between the branch prosthesis 120 and the prosthesis 20 is that the branch prosthesis 120 is loaded into the introducer “backwards”, such that a self-expanding zigzag stent 121 is retained by the proximal positioning mechanism 102 . Additionally, the “proximal” end of the branch prosthesis 120 is nearest to the external manipulation section 101 , whereas the “proximal” end of the prosthesis 20 is farthest from the external manipulation section 1 .
[0078] The branch prosthesis 120 comprises a tubular graft material 150 , with self expanding stents 119 attached thereto. The tubular graft material 150 is preferably a non-porous material similar to the tubular graft material 50 . The self expanding stents 119 cause the branch prosthesis 120 to expand following its disengagement from the introducer.
[0079] The branch prosthesis 120 also includes a self expanding zigzag stent 121 that extends from its proximal end. When it is disengaged, the self expanding zigzag stent 121 anchors the proximal end of the branch prosthesis 120 to the internal wall of the prosthesis 20 .
[0080] FIGS. 14 and 15 illustrate proximal and distal retention and release mechanisms 102 and 103 of the introducer, respectively. During the placement phase of the medical procedure, the branch prosthesis 120 is retained in a compressed condition by a sheath 130 .
[0081] During assembly of the introducer, the sheath 130 is advanced over a cylindrical sleeve 110 of the distal attachment region 103 while the branch prosthesis 120 is held in a compressed state by an external force. A proximal attachment retention section 140 is formed in a thick walled tube 141 to retain the proximal end of the branch prosthesis 120 . Alternatively, the proximal attachment section 140 can be a separate piece coupled to the thick walled tube 141 .
[0082] FIG. 14 shows the proximal attachment region 102 in greater detail. The tube 141 is coaxial with and radially outside a thin walled tube 115 . The tube 141 is “thick walled”. The sheath 130 is coaxial with and radially outside the thick walled tube 141 . The thick walled tube 141 and the sheath 130 extend proximally and then distally to the manipulation region 101 , as shown in FIG. 13 .
[0083] The proximal end 142 of the prosthesis 120 , including the self-expanding zigzag stent 121 , is retained by the proximal attachment section 140 of the thick walled tube 141 . The proximal end of the self-expanding zigzag stent 121 has a loop 143 through which a proximal trigger wire 144 extends. The proximal trigger wire 144 extends through an aperture 145 in the proximal attachment section 140 and into the annular region between the thin walled tube 115 and the thick walled tube 141 .
[0084] FIG. 15 shows the distal attachment region 103 in greater detail. The distal attachment region 103 includes a cylindrical sleeve 110 . The cylindrical sleeve 110 has a long tapered flexible extension 111 extending from its distal end. The flexible extension 111 has an internal longitudinal aperture 112 . The thin walled tube 115 is fastened to the extension 111 .
[0085] The distal most stent 119 is released by retracting the sheath 130 , removing the trigger wire 122 , and then sliding the distal attachment region 103 , including the retention device 110 , distally away from the distal most stent 119 . Once the retention device 110 has cleared the distal most stent 119 , the distal most stent 119 will expand. The distal most stent 119 can include barbs, as shown in FIG. 16 , to facilitate anchoring the stent 119 to the lumen.
[0086] The trigger wire 122 and the distal wire release mechanism 124 form a control member to selectively release the retention device 110 from the prosthesis 120 by holding the distal most stent 119 in the retention device 110 until the prosthesis 120 is positioned at a desired site in the lumen.
[0087] FIG. 16 is an isometric view of the branch prosthesis 120 . As shown in FIG. 16 , when fully expanded the self-expanding zigzag stent 121 has a curvature to facilitate anchoring of the branch prosthesis 120 to an interior wall of the prosthesis 20 . Outer portions of the self expanding stent 121 are seen to extend substantially radially outwardly from the tubular graft 150 . The self-expanding zigzag stent 121 allows the branch prosthesis 120 to resist the force of blood flow, which may tend to dislodge the branch prosthesis 120 from the prosthesis 20 .
[0088] The self-expanding zigzag stent 121 can have a parabolic or round curvature so that an end 125 of a loop 126 is located in about the same plane as an opening 127 of the branch prosthesis 120 . The self-expanding zigzag stent 121 can be mounted near the opening 127 of the branch prosthesis 120 , so the curvature of one loop 126 of the stent 121 is between about 120° and 200°, and preferable between about 170° and 190°.
[0089] The distal most stent 119 can have barbs 128 attached thereto. The barbs 128 can anchor the stent 119 to the lumen so that the branch prosthesis 120 does not slide into the prosthesis 20 . As mentioned above, hydrostatic forces in arteries, where blood flows from main vessels to branch vessels, will be significantly greater in the proximal to distal direction than in the reverse direction. Therefore, the self-expanding zigzag stent 121 will resist the greater force, and the barbs 128 coupled to the stent 119 will resist the lesser force, so that the branch prosthesis 120 remains securely anchored within the fenestration 17 of the main prosthesis 20 .
[0090] Radiographic markers 129 can be attached to the self-expanding zigzag stent 121 , to one of the stents 119 or to the tubular graft material 150 . For example, the radiographic markers 129 can be small rings of metal, such as stainless steel, wrapped around the stent 121 or one of the stents 119 , or sewn to the tubular graft material 150 with suture. Preferably, at least one radiographic marker 129 is located near the opening 127 , so that the opening 127 can be aligned with the fenestration 17 of the graft 20 .
[0091] FIG. 17 is a front view of a main lumen 175 and a branch lumen 176 , wherein the lumens 175 and 176 are in fluid communication with each other. The main lumen 175 has an aneurism, or weakness, which exists at the attachment point of the branch lumen 176 . FIG. 18 shows the lumens 175 and 176 after the prosthesis 20 has been successfully implanted. The fenestration 17 is aligned with the opening of the branch lumen 176 .
[0092] FIG. 19 shows the lumens 175 and 176 after the prosthesis 120 has been successfully implanted. The prosthesis 20 reinforces the main lumen 175 . The branch prosthesis 120 performs two main functions. First, the branch prosthesis 120 keeps the fenestration 17 aligned so that the lumens 175 and 176 remain in fluid communication. Second, the branch prosthesis 120 reinforces the branch lumen 176 , which may also be weakened because of the aneurism.
[0093] Throughout this specification, unless the context requires otherwise, the words “comprise” and “include” and variations such as “comprising” and “including” will be understood to imply the inclusion of an item or group of items, but not the exclusion of any other item or group items.
[0094] While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. Furthermore, although various indications have been given as to the scope of this invention, the invention is not limited to any one of these but can reside in two or more of these combined together. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. | An intraluminal prosthesis is provided for strengthening a main lumen and a branch lumen that branches from the main lumen. The intraluminal prosthesis can comprise two tubular grafts. The first tubular graft can have a flexible body with a fenestration. The second tubular graft can have a flexible body that is configured for intraluminal coupling to the fenestration of the first tubular graft. The flexible body of the second tubular graft can have an outer dimension that is about equal to an inner dimension of the fenestration of the first tubular graft. The second tubular graft can also have a terminal stent that curves outwardly from a proximal end of the flexible body of the second tubular graft, whereby the terminal stent acts to couple the second tubular graft to the first tubular graft. | 0 |
FIELD OF THE INVENTION
The present invention relates generally to mobile communication devices, and more particularly to selecting antenna configurations in a mobile communication device.
BACKGROUND OF THE INVENTION
Users of mobile communication devices, such as cellular telephones, Personal Digital Assistants (PDAs) or laptop computers that include wireless capability, etc., often experience performance problems, such as dropped calls, poor call quality, and an inability to connect with the network. Such problems are often the result of interference from other wireless signals in the area. Additionally, however, such problems are often the result of what is called multipath interference.
The term multipath is a term that describes how a signal transmitted in a wireless environment travels along multiple paths from the transmission source to the destination or receiver. For example, when a base station transmits a signal to a mobile communication device, the energy comprising the signal spreads out. Some of the energy can travel along a direct line to the mobile communication device. This direct line is one path. Some of the energy can, e.g., reflect off a building and then reach the mobile communication device. The reflected signal path being a second path. Similarly, some of the energy can reflect off other buildings, mountains, or other structures before reaching the mobile communication device. The different paths traveled by the signal energy from the base station to the mobile device are referred to as multipaths, and the associated signal energies are referred to as the multipath signals, or sometimes multipath for short.
The multipath signals combine with each other in the mobile communication device receiver. At times the multipath signals will combine constructively, but at other times the signals will combine destructively, i.e., the signals will combine in such a manner that they at least partially cancel each other out, or interfere with each other. This is because the multipath signals can be out of phase with each other due to the different lengths of the paths traveled. Destructive multipath combining, or interference, can lower the signal-to-noise ratio in the receiver, and affect other signal parameters, causing the problems referred to above. Such destructive multipath interference is often referred to as fading, i.e., it causes the signal as seen by the mobile communication device receiver to fade out.
Spatial diversity has been used to combat the problem of destructive multipath interference, or fading. In its simplest form, spatial diversity comprises two antennas spaced a certain distance apart. The distance between the antennas should be related to the wavelength of the signal being received, e.g., a multiple or sub-multiple of the wavelength. The idea of spatial diversity is that the distance between the antennas allows each antenna to receive samples of the signal independent of the other antenna. While the signal at one antenna might be experiencing destructive interference, the signal at the other might be experiencing constructive interference.
The difference in position of the antennas will affect the phase of the multipath signals. The effect of the different path lengths can affect the phase of the multipath signals enough such that multipath signals that would have combined destructively at the first antenna, will now combine constructively at the second antenna. Thus, spatial diversity can improve performance and help overcome, e.g., the problems referred to above. Moreover, spatial diversity can extend to any number of antennas.
A mobile communication device can, therefore, be configured with a plurality of antennas and a means for changing between antennas when the received signal quality is degraded beyond a certain point, which can for example be measured in terms of received signal power. Accordingly, the mobile communication device can be configured to monitor the signal power of a signal received using a first antenna of a plurality of antennas. When the received signal power drops below a certain threshold, then the device can be configured to switch to another antenna that exhibits higher received signal power.
Since mobile communications devices are typically not large enough to implement true spatial diversity, polarization diversity can be implemented in order to improve performance in a mobile communication device. The polarization diversity case is similar to the spatial diversity case. Whereas spatial diversity relies on the separation of the antenna to get independent samples, polarization diversity relies on the different polarizations. For example a vertically polarized antenna will tend to see vertically polarized signals and tend to reject horizontally polarized signals; therefore, samples from a vertically polarized antenna will tend to be independent from samples from a horizontally polarized antenna. Spatial diversity can also be combined with polarization diversity, as in the case where a vertically polarized antenna and a horizontally polarized antenna are included in the same device. Because the two antennas are typically located at different locations within the device, they will exhibit at least some degree of spatial diversity.
Thus, a plurality of antennas can be incorporated into a communication device that comprises spatial diversity, polarization diversity, or both, such that the device can switch between different antennas and/or different polarizations in order to attempt to improve the received signal quality.
A smart antenna system is an antenna system that is capable of steering the antenna beam or is capable of beam forming. Examples of types of smart antennas would include a single active element with parasitic elements. By modifying the characteristics of the parasitic elements the beam can be steered, shaped, or both. Another example smart antenna can include multiple active elements where the phase of the signal between the elements can be changed to cause the beam to steer or change shape. Alternatively, a smart antenna can include multiple active elements that allow the signals to be applied to each independently and weighted to steer or form the beam. Processing for these smart antennas can, for example, be done in DSP.
In conventional devices, the device must check each antenna to determine if there is an antenna with better signal quality than the current configuration. Unfortunately, this can actually degrade device performance even further, since often many if not all of the other configuration will have worse signal quality than the current configuration. Thus, the device can spend significant time searching configuration that actually have worse performance than the current configuration, which degrades the device's overall performance during the searching period.
SUMMARY OF THE INVENTION
A mobile communication device comprising a plurality of antenna configurations is configured to selectively search the plurality of antenna configurations in order to reduce the likelihood that an antenna configuration exhibiting worse received signal quality than a current configuration will be searched, when the signal quality for the current configuration drops below a certain threshold. A threshold is associated with each configuration. Accordingly, when the signal quality for the current configuration drops below a certain threshold, then other configurations will be searched to determine if they exhibit better signal quality. If the searched configurations actually exhibit lower signal quality, then the threshold for this configuration can be altered making it less likely that the configuration will be searched in the future.
These and other features, aspects, and embodiments of the invention are described in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a diagram illustrating an example mobile communication device configured in accordance with one embodiment;
FIG. 2 is a flowchart illustrating an example method for changing antenna configurations using the mobile communication device of FIG. 1 ;
FIG. 3 is a flow chart illustrating another example method for changing antenna configurations using the mobile communication device of FIG. 1 ;
FIG. 4 is a flowchart illustrating an example method for changing antennas in the mobile communication device of FIG. 1 that uses timers in accordance with one embodiment;
FIG. 5 is a flowchart illustrating another embodiment that uses timers as part of the method for changing antenna configurations in a mobile communication device with multiple antennas; and
FIG. 6 is a flowchart illustrating another embodiment of a method for changing antenna configurations in a mobile communication device with multiple antennas.
DETAILED DESCRIPTION
FIG. 1 is a diagram illustrating an example mobile communication device 100 configured in accordance with one embodiment of the systems and methods described herein. For purposes of this discussion, it is assumed that mobile communication device 100 is a cellular telephone; however, it will be understood that the systems and methods described herein can apply to other types of mobile communication devices, such as PCS telephones, PDAs or laptops with wireless capability, or any other type of mobile communication device that uses an antenna to receive wireless signals.
Wireless communication device 100 comprises a plurality of antennas. For ease of discussion, wireless communication device 100 is shown to comprise two antennas 102 and 104 ; however, it will be clear, and will be discussed in more detail below, that any number of antennas can be included in device 100 . Antennas 102 and 104 are configured to transmit and receive wireless signals. Antennas 102 and 104 are illustrated extending external to device 100 . In other embodiments, however, one or both antennas can be internal to device 100 . Further, as can be seen, antennas 102 and 104 are separated by space (A). Depending on the embodiment, (A) can be a multiple or sub-multiple of the wavelength of the wireless signals received by antennas 102 and 104 .
Antennas 102 and 104 are interfaced with a switch, or multiplexer (MUX) 106 . MUX 106 is configured to interface one of antennas 102 or 104 with radio receiver 108 , depending on the position, or settings, of MUX 106 . The settings of MUX 106 are controlled by processor 110 as described below.
Radio receiver 108 comprises the functional components required to receive wireless radio signals via antennas 102 and 104 . Thus, radio receiver 108 can comprise the circuits required to convert a radio signal received via antennas 102 or 104 into a baseband signal that can be processed by processor 110 . It will be apparent that device 100 can also comprise a radio transmitter (not shown) that can comprise the circuitry necessary to convert a baseband signal produced by processor 110 into a radio signal that can be transmitted by antennas 102 or 104 . Such a radio transmitter may or may not be interfaced with MUX 106 . In general, it will be clear that device 100 comprises other known functional components, which will not be described here for the sake of brevity; however, the components illustrated in FIG. 1 should not be seen as limiting the embodiments described herein to any particular functional architecture or configuration.
Processor 110 comprises the functional components necessary to encode baseband signals for transmission and decode baseband signals received and produced by radio receiver 108 . In addition, processor 110 can comprise the functional components necessary to control the operation of device 100 . Thus, processor 110 can comprise the required hardware and software for performing the tasks described below, in particular controlling MUX 106 . Processor 110 can actually comprise multiple devices and/or processing circuits, such as Digital signal Processors (DSPs), audio processors, math coprocessors, microcontrollers, microprocessors, etc.
Device 100 also comprises memory 114 configured to store instructions that can be accessed by processor 110 . The instructions provide processor 110 with the instructions needed to control the operation of device 100 and perform the operations described below. Memory 114 can also be configured to store temporary and permanent date used by processor 110 to carry out the instructions stored in memory 114 .
Memory 114 can actually comprise multiple memory devices. For example, a typical cellular telephone comprises a Flash based memory device for storing operating instructions as well as a Static RAM (SRAM) device for storing variables and data required by the instructions. Cellular telephones will also often comprise an Electrically Erasable and Programmable ROM (EEPROM) device. All or some of these multiple memory devices can be incorporated into a single device or package. For example, in cellular telephones, the Flash and SRAM are often integrated into a single package. Alternatively, some or all of the memory devices can be included in separate devices or packages.
Processor 110 can be configured to monitor the quality of signals received via antennas 102 or 104 and radio receiver 108 and determine when the quality has dropped below a preferred threshold. When the signal quality drops below the preferred threshold, processor 110 can be configured to cause MUX 106 to switch from the antenna that is currently interfaced with radio receiver 108 to the other. Processor 110 can then check the signal quality for signals received by this antenna in order to determine whether the signal quality is better for this antenna than the previous one.
This process is described for the simple example of two antennas in the method of FIG. 2 . It should be noted than in addition to being spatially diverse, antennas 102 and 104 can also comprise different polarizations. The combination of position and polarization can be referred to as an antenna configuration. Thus, when processor 110 causes MUX 106 to switch, the switch can be referred to as a switch from one antenna configuration to another. Thus, the term antenna configuration will be used in the following discussion; however, this should not be seen as excluding the situation where the two antennas are simply spatially diverse. Further, while antenna configurations can include discrete configurations, i.e., changing from one discrete configuration to another, as in the example above, antenna configurations can also be ranges of solutions. For example, in one embodiment an antenna pattern can be shaped such that the antenna pattern can be pointed in any direction, not just some number of predetermined directions, by adjusting the relative phase between the antenna elements. In this embodiment, MUX 106 can be replaced by an antenna configuration control. The antenna configuration control can steer or point the antenna or select an antenna configuration from a plurality of antenna configurations.
In the process of FIG. 2 , it will be assumed that device 100 is using antenna 102 to receive wireless signals. In step 202 , processor 110 determines that the signal quality for signals being received via antenna 102 is below a threshold. In step 204 , processor 110 can control MUX 106 , via control line 112 , to switch from the antenna configuration of antenna 102 to the configuration of antenna 104 . Once the switch has occurred, processor 110 can assess, in step 206 , whether the signal quality for signals being received using the configuration of antenna 104 is worse than the signal quality for signals received using the antenna configuration of antenna 102 .
If the signal quality is not worse, i.e., the signal quality for the new configuration is better than of the old configuration, then processor 110 can be configured to continue the use of the new configuration, i.e., configuration 104 . The process can then start over, with processor 110 determining whether the received signal quality using configuration 104 drops below a certain threshold in step 202 . If on the other hand, the signal quality for configuration 104 is worse than the signal quality for configuration 102 , then processor 110 can control MUX 106 via control line 112 to switch back to the configuration of antenna 102 .
Once processor 110 has caused MUX 106 to switch back, processor 110 can update the threshold used in step 202 . For example, the threshold can be a value or set of values stored in memory 114 . Processor 110 can, for example, lower the threshold being used in step 202 . The lower threshold should make it less likely that processor 110 will cause the antenna configuration to switch in step 204 , because the signal quality will be less likely to drop below the new threshold. Once the threshold is altered in step 210 , then the process can revert to step 202 , where processor 110 can determine whether the signal quality for signals received via antenna configuration 102 has dropped below the new threshold.
It will be clear that different thresholds can be used and that in some embodiments, processor 110 will be checking, in step 202 , to determine whether a threshold has been exceeded. Further, processor 110 can be configured to raise such a threshold in step 210 .
Processor 110 can be configured to determine signal quality using a variety of parameters and/or combination of parameters. As mentioned above, receive signal strength or power can be used by processor 110 in step 202 . In addition, however, other parameters such as signal-to noise ratio, Signal Error Rate (SER), Bit Error Rate (BER), Frequency Error Rate (FER), or some subset or combination thereof can be used. Processor 110 can be configured to determine such parameters internally. In other embodiments, such parameters can be determined external to processor 110 , e.g., in radio receiver 108 , and communicated to processor 110 .
The amount of time that device 100 spends changing antenna configurations and checking signal quality for the new configuration is reduced, by altering the threshold in step 210 to make it less likely that processor 110 will determine that the threshold has been crossed in step 202 . This can result in improved performance, since it has already been determined in step 206 that the alternative antenna configuration is actually experiencing worse signal conditions. In effect, the process of FIG. 2 adds hysteresis to the changing process to avoid the condition where processor 110 is constantly causing the antenna configuration to be switched back and forth.
In certain embodiments, device 100 can also include a timer that can be used to define a time period for which the altered threshold of step 210 will be used. Since device 100 is a mobile device and will often be moving, the signal conditions for the various antenna configurations will likely change over time and the signal conditions for the alternative antenna configuration, or configurations, can become better. Using a timer ensures that these other configurations are checked at least periodically. Other embodiments that use a timer, or timers, will be discussed more fully below.
FIG. 3 is a flowchart illustrating an example method for changing antenna configurations in a mobile communication device with multiple antennas in accordance with one embodiment of the systems and methods described herein. Here, threshold values are set to default values in step 302 . The default values can, for example, be predetermined and preset when the communication device is manufactured. Such preset values can then be stored, e.g., in memory 114 . In step 304 , processor 110 can be configured to select an initial antenna configuration. Processor 110 can be configured to then monitor the received signal quality and determine whether it falls below a threshold in step 304 . If the current signal quality is not below the threshold, then the process can revert to step 304 in which processor 110 continues to monitor the received signal quality.
When the signal quality for the current antenna configuration falls below a threshold value, then processor 110 can be configured to cause MUX 106 to switch to each of the alternate antenna configurations in succession and to check the received signal quality for each alternate antenna configuration in step 306 . The antenna configuration with the best signal quality among the antenna configurations searched can then be selected in step 308 . In step 310 , processor 110 can be configured to determine whether the selected configuration has better or worse signal quality than the original configuration. If the signal quality for the selected configuration is worse than the signal quality for the original configuration, then in step 314 , processor 110 can lower the threshold used in step 304 and cause the original antenna configuration to be maintained in step 316 .
Lowering the threshold will reduce the likelihood that processor 110 will cause the other antenna configurations to be searched. Again, this can actually improve performance, since it has already been determined that all other configurations have worse signal quality than the current configuration. In other embodiments, some of which are discussed below, multiple thresholds can be used and altered to reduce the likelihood that some groups of antenna configurations will be searched more, while maintaining the same likelihood for other groups, or altering the likelihood for other groups differently.
In step 312 , processor 110 can cause the selected configuration to replace the current configuration when it is determined that the signal quality for the selected configuration is better than the signal quality for the current configuration. The process can then resume at step 304 where processor 110 can monitor the signal quality for the new configuration to determine whether it drops below the threshold. It should be noted that in addition to improving receiver performance, the improved receiver performance can also improve the forward link system capacity by reducing the base station resources allocated to each mobile. Additionally, in wireless systems, mobile communication devices are often handed off from one base station to another as they move throughout the system. In one embodiment, the threshold values can be reset, e.g., to a default value, each time a device undergoes such a handoff. In certain embodiments, the default values for each base station can actually be downloaded to the device upon handoff. In other embodiments, the default values can simply be stored and maintained on the device, e.g., in memory 114 .
FIG. 4 is flow chart illustrating an example method for selecting an antenna configuration that uses timers in accordance with the systems and methods described above. The use of a timer, or timers, was briefly referred to above. As with the methods of FIGS. 2 and 3 , the method FIG. 4 begins in step 402 with the signal quality for signals being received using a current antenna configuration being monitored, e.g., by processor 110 . Processor 110 then determines whether the signal quality has dropped below a certain threshold in step 404 . If the signal quality is not below the threshold, then processor 110 can continue to monitor the signal quality in step 402 .
If, on the other hand, the signal quality has dropped below the threshold, then in step 406 , processor 110 can select another antenna configuration in step 406 to determine, in step 408 , whether the other configuration provides better or worse signal quality. If the other configuration exhibits better signal quality, then in step 410 processor 110 can switch to the other antenna configuration and the process can continue in step 402 .
If the signal quality for the other antenna configuration is worse than the signal quality for the original antenna configuration, as determined in step 408 , then processor 110 can activate a timer in step 412 . The process will then continue on step 402 with the signal quality for the original antenna configuration being monitored and other antenna configurations being selected (step 406 ) when the signal quality drops below the threshold (step 404 ); however, once the timer is activated, in step 412 , then the associated antenna configuration, which was selected in step 406 and determined to provide worse signal quality in step 408 , can be excluded from the process for the time period defined by the timer. Use of the timer will ensure that the associated antenna configuration is not searched for at least the time period defined by the timer. This can improve receiver performance, since it has already been determined that the antenna configuration does not improve signal quality. If each configuration is associated with a timer, then other antenna configuration will not be affected. Thus, they can continue to be searched unless it is determined that these other configurations provide worse signal quality. Alternatively, the antenna configuration with the best signal quality can be selected in step 406 . In such embodiments, if it is determined that the signal quality for this antenna configuration is worse than the signal quality for the original antenna configuration, then the timer can be used to prevent any of the antenna configurations from being selected for the period defined by the timer, since it has been determine that none of them exhibit better signal quality than the current configuration. In still another embodiment, a group, or groups of antennas can be excluded for the time period defined by the timer, while others are not. Obviously, the timer, or timers can be configured to count up or down, depending on the embodiment.
Still another embodiment using timers is illustrated in FIG. 5 . In this embodiment, a timer is associated with each possible antenna configuration. The signal quality for all antenna configurations can be determined in step 502 . The length, or time, associated with each of the timers can then be altered, or set, in step 504 , based on the signal quality determined for the associated antenna configurations. The timers can then be activated in step 506 . The antenna configuration with the best performance can be selected in step 508 and be used to receive signals. The signal quality for that selected antenna configuration can then be monitored as before in step 510 .
Each of the other antenna configurations will be excluded for a time period that is related to the signal quality associated with the antenna configuration and defined by the associated timers. Of course, some antenna configurations may not be excluded. The process of FIG. 5 assures that all antenna configurations will eventually be searched but that some will be searched more often.
If the monitored signal level does drop below a certain threshold, then all of the antenna configurations can be checked again to see if one has better signal quality. In addition, depending on the embodiment, the timers can be reset with new values at this time.
FIG. 6 is a flowchart 600 illustrating an embodiment that uses timers and thresholds as part of the method for changing antennas in a mobile communication device with multiple antennas. Antenna configurations can be grouped based on the signal quality received at each antenna. Timers can be used so that the method does not have to search all of the antenna configurations when the signal quality falls below a threshold.
In step 602 , each antenna configuration can be initialized with default threshold values. The current antenna configuration can then be monitored in step 604 . In step 606 , it can be determined whether the signal quality for the current configuration has dropped below a threshold. In addition, a timer, i.e., timer 1 , can be set. If it is determined in step 606 that the signal quality is not below the threshold, then timer 1 can be checked to see if it has expired in step 608 . If timer 1 has not expired, then the signal quality can continue to be monitored in step 604 .
If timer 1 has expired, in Step 608 , or if the signal quality is below the threshold as determined in step 606 , then all of the alternative antenna configurations can be searched beginning in step 610 . Use of timer 1 in this fashion allows other antenna configurations to be searched periodically, even if the signal quality for the current antenna configuration does not go below the threshold. Since the default threshold needs to be selected based on network configurations and the location of the mobile communication device, it is not always practical to select one default threshold that would work well for all network configurations. Adding a timer, i.e., timer 1 , allows other antenna configurations to be searched. The time period associated with timer 1 can vary depending on the requirements of a particular implementation. For example, in certain implementations, it can be undesirable to change antenna configurations, or at least undesirable to change them often. In such embodiments, the length of timer 1 can be made longer. It can also be possible, depending on the embodiment, to update the default thresholds based on the requirements of a particular implementation. For example, in certain embodiments, data from past experience can be used to determine a more optimal default threshold and timer value.
In step 610 , the other antenna configurations can be searched and, in step 620 , the threshold can be calculated and the antenna configurations can be grouped. The idea is to partition the antenna configurations into multiple groups, e.g., based on signal quality so that not all the antenna configurations need to be searched when comparing against a threshold. For example, only antenna configurations belonging to group 1 need to be searched and compared against threshold 1 .
In step 612 , timer 2 and timer 3 can be reset. In the embodiment of FIG. 6 , multiple thresholds can actually be used. Thus, in step 614 , it can be determined if the signal quality, as determined in step 606 , is below a first threshold. If the signal quality is above the first threshold, then all antenna configurations associated with this threshold can be searched in step 616 . In step 618 , it can be determined whether the signal quality for any of the antenna configurations in this group is better than the signal quality determined in step 606 for the current antenna configuration.
If it is determined in step 618 , that the signal quality for an antenna configuration in this group is better than the signal quality for the current antenna configuration, then this antenna configuration can be selected in step 642 . In addition, however, a second timer (timer 2 ) can also be used and can be checked in step 638 to determine if it has expired. If it has expired, then all of the antenna configurations can be searched again in step 610 and the timers reset in step 612 , instead of selecting the alternative configuration in step 642 . Use of timer 2 in this fashion prevents excessive antenna configuration changes.
It should also be noted that in addition to changing the antenna configuration in step 642 , all or some of the threshold values can be recalculated. In addition, the transmit power can be monitored to ensure that changing antenna configurations will not cause the maximum transmit power for the mobile communication device to be exceeded. The signal quality for the new antenna configuration can then be monitored.
If it is determined, in step 618 , that none of the alternative antenna configurations in the group associated with the first threshold provides better signal quality than the current antenna configuration, then a third timer (timer 3 ) can then be checked to determine if it has expired. If timer 3 has expired, then all of the antenna configuration can be checked in step 610 , regrouped at 620 and the timers reset in step 612 . If the signal quality is above the new threshold 1 , then all antenna configurations associated with this threshold can be checked in step 616 . Timer 3 can be included to prevent an “infinite loop” scenario whereby if the 3 thresholds are chosen too high, the signal quality for the current antenna configuration will never fall below any of the thresholds and none of the other antenna configurations will be searched.
If, at any point, it is determined that the signal quality is not above threshold 1 in step 614 , then the other threshold values can be checked, e.g. in step 622 and 630 . If the signal quality is above one of these other threshold values, then all the associated antenna configurations can be checked, e.g., in steps 624 and 632 , and it can be determined if the signal quality is better for any of these other antenna configurations, e.g., in steps 626 and 634 . If the signal quality is not better for any of these other antenna configurations, then timer 3 can be checked in step 640 . If the signal quality is better for any of these alternative configurations, then timer 2 can be checked and, depending on the status of timer 2 , the alternative configuration with better signal quality can be selected (step 642 ) or all of the antenna configurations can be searched again (step 610 ).
It should be noted that each alternative antenna configuration can have its own threshold. Thus, if there are N antenna configurations, and therefore N−1 alternative antenna configurations, then there can be N−1 thresholds to be checked in steps 614 , 622 , 630 , etc. Alternatively, the number of thresholds used can be reduced by ranking and grouping the antenna configurations. In other words, if it is determined, e.g., in step 610 , that several of the antenna configurations exhibit similar signal quality, and then they can be grouped and assigned the same threshold. This can further limit the amount of time that the device spends searching alternative configurations, which as explained can actually reduce performance.
As mentioned above, the determination of the signal quality for a given antenna configuration can be based on a plurality of parameters. In certain embodiments, a combination of all or some of these parameters can be used to determine the signal quality. Moreover, these parameters can include forward link as well as reverse link parameters. In certain embodiments, the parameters can be weighted and then combined. The weighting can even vary in certain embodiments, e.g., depending on whether the device is engaged in data or voice communication. In the case of data communication, the Quality of Service (QoS) and forward and reverse link data rates can also be parameters that can be used to determine the signal quality and/or the appropriate weighting associated with various parameters.
While certain embodiments of the inventions have been described above, it will be understood that the embodiments described are by way of example only. Accordingly, the inventions should not be limited based on the described embodiments. Rather, the scope of the inventions described herein should only be limited in light of the claims that follow when taken in conjunction with the above description and accompanying drawings. | An improved smart antenna reception method and devices are provided that determine when to select a new antenna configuration in a multiple antenna configuration system. One embodiment attempts to eliminate unneeded configuration searching. Unneeded configuration searching can degrade overall signal quality and system performance. Configuration changing can be minimized by determining that a signal quality received from a first antenna configuration is below a threshold and changing antenna configuration. After changing antenna configuration, if the signal quality received from the second antenna configuration is lower than the signal quality received from the first antenna configuration the threshold can be lowered. By lowering the threshold, the probability of additional configuration changing can be reduced. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a regular application of U.S. Provisional Patent application Serial No. 60/330,127 filed on Oct. 19, 2001, the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to elevation and alignment variable gangways which extend and bridge a gap such as between two misaligned platforms.
BACKGROUND OF THE INVENTION
There are often situations where one must bridge a gap between discontinuous surfaces or platforms using a structural surface, like a gangway, which is sufficient to support cartage or passenger traffic. Gangways are used particularly in cargo or passenger loading between a dock and a boat, a ramp and an aircraft, or a loading platform and a vehicle.
One example is a situation where an access ramp is placed adjacent an airplane cabin access doorway. In order to insert a gangway, the ramp will usually have an exit platform which is adjusted approximately to the same elevation as the sill of the aircraft doorway. Further, the surface must usually be carefully positioned so as to be aligned with the doorway. In many instances, it is only important that the gangway reach the sill of the doorway's platform. However, the alignment is particularly important when there are fixed hand rails projecting from the doorway's platform; these rails act to constrain access. In such a case, the gangway must be precisely aligned to pass between the hand rails and reach the doorway's platform recessed through the rails.
Again in an aircraft context, the boarding and deplaning of disabled persons must be addressed and can be particularly challenging because neither the aircraft nor the boarding device can be accurately positioned. Unlike large commercial aircraft, smaller regional aircraft have aircraft cabin doors which cannot be aligned with the usual boarding tunnels and motorized bridges. Instead, the cabin doors comprise a pivoting door the inside of which is fitted with stairs for boarding and deplaning. When the door is pivoted outwardly from the aircraft fuselage to open the aircraft doorway, the distal end of the door reaches downwardly to the tarmac. The inside of the aircraft door forms a staircase and side hand rails pivot into an upright and supporting position. Certainly, the stairs are difficult to navigate by the mobility-impaired and impossible for accommodating wheelchairs. Further, the cabin door and particularly the side handrails, tend to block many of the usual apparatus adapted to provide elevated access to the aircraft doorway, including wheelchair lifts and inclined ramps. It is difficult to successfully extend outwards to bridge between the platforms while still being able to pass between the narrow, constricting side handrails. It is also important to be able to secure the gangway from slipping from the platform during use.
SUMMARY OF THE INVENTION
The difficulties associated with alignment between two, often narrow, passageways are obviated using a fully floating gangway. In one embodiment, the floating gangway is supported in a mobile ramp and comprises a movable frame sandwiched movably in an operating plane between lower and upper parallel bearing surfaces. A bridging element or gangway extends from the frame's front end for extending to another platform such as an aircraft doorway. Manipulation of the frame forwards, rearwardly, and rotationally enables the gangway to be aligned with the doorway. Further, the gangway can be pivotally connected to the frame so as to enable vertical adjustment of the gangway so to adapt to differential elevations of the proximal and distal ends of the gangway. In the case of aircraft or watercraft, this elevation can also vary during the boarding process. The floating gangway is equally adaptable to structures such as mobile ramps, stationary jet bridges, warehouse loading docks and the like.
In one aspect of the invention, a method for aligning a gangway between a first platform and a second platform is provided comprising the steps of:
supporting a frame between two spaced and parallel bearing surfaces which are positioned below the first platform, the frame being movable in an operating plane parallel to the bearing surfaces;
supporting a proximal end of a gangway from the frame and extending a distal end of the gangway to the second platform; and
manipulating the frame in the operating plane so as to align the supported gangway with the second platform.
Preferably, alignment is further aided by pivoting the proximal end of the gangway from the frame so as to align the elevation of the distal end of the gangway with the second platform. Preferably, in applications associated with the damage critical components of aircraft, it is advantageous to hand manipulate the gangway to minimize risk to the aircraft from insensitive powered movements. To this end, counterbalancing of the gangway about its pivot aids in easing the hand manipulation. Powered assisted manipulation can also be applied. Further, to provide enhanced continuity, one can independently bridge between gangway and the platform using a flap so as to provide a contiguous surface therebetween as the frame is being manipulated. Once manipulated, it is advantageous to lock the gangway to avoid movement in use, such a locking capability being particularly desirable in situations where there is a risk of movement and safety is an issue.
In a broad apparatus aspect, a gangway is supported by a movable frame positioned below a first platform and substantially parallel thereto, the frame having a front end and a rear end and movable at least to translate and rotate in an operating plane, and preferably laterally as well. Preferably, said operating plane is defined by movably supporting and sandwiching the frame between upper and lower bearing surfaces, the lower bearing surface positioned below the frame and parallel to the operating plane and the upper bearing surface positioned spaced above and parallel to the operating plane. A bridge extends forward from the frame's front end for extending between the frame and the second platform and so that, as the frame moves, the bridge also translates and rotates with respect to the second platform. Preferably, the bridge is pivotally connected at a hinge to the frame and is counterbalanced to make the frame easier to manipulate. A flap between the bridge and first platform forms a contiguous gangway and ensures continuity in all platform traffic situations.
In one embodiment, the frame is movably supported between the upper and lower surfaces by one or more first bearings, preferably laterally spaced swiveling castors, for moveably supporting the front end and one or more second bearings, such as another swiveling castor, positioned rearwardly of the first bearings. Bridge weight loads the front end of the frame and causes the front castors to bear against the lower bearing surface and causes the rear end of the frame to rotate upwardly so that the rear castor bears upwardly against the upper bearing surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side schematic view of one embodiment of the invention and an exploded plan view of one embodiment of a locking mechanism utilizing a perforated indexing locking plate; and further illustrating the frame, the indexing lock mechanism and two positions of the pivoting bridge;
FIG. 2 is a side schematic view of a ramp embodiment of the invention illustrating forward and rearward movement of the frame and pivoting action of the flap and the bridge;
FIG. 3 is a side schematic view of a loading dock embodiment of the invention illustrating forward and rearward movement of the frame and pivoting action of the flap and the bridge;
FIGS. 4 a - 4 c illustrate side schematic views accordingly to FIG. 2 and which show three stages of rearward movement of the frame with the gangway reaching three different extents on the target surface;
FIGS. 5 a and 5 b illustrate top schematic views accordingly to FIG. 2, FIG. 3 a illustrating the lateral, forward and rearward extent of the lower bearing surface shown in hidden lines under the ramp and the gangway;
FIGS. 6 a and 6 b illustrate top schematic views accordingly to FIG. 2 wherein the frame is translated both laterally and fore and aft so as to successfully position the gangway onto the target surface despite the ramp being offset to one side and alternatively being close to or spaced from the target surface respectively;
FIGS. 7 a and 7 b illustrate top schematic views accordingly to FIG. 2 wherein the frame is rotated and translated so as to successfully position the gangway onto the target surface despite the ramp being angularly misaligned from the target surface one way or the other respectively;
FIG. 8 is a partial perspective view of an embodiment of the invention having a frame using front castors bearing against a lower bearing surface and a rear castor bearing against the underside of the ramp, and having both a flap and a bridge forming the gangway;
FIG. 9 illustrates one application in which the invention is useful for enabling a gangway to aligning between narrowly spaced handrails of an aircraft cabin door; and
FIG. 10 is an alternate embodiment of the locking mechanism which locks all movement of the frame and supported gangway.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Having reference to FIG. 1, a structure 10 such as a mobile ramp 11 comprises a surface which forms a first platform 12 having a front end 13 positioned adjacent and spaced from a second surface forming a second platform 15 . While not shown in great detail, the structure 10 can be an aircraft access ramp 11 which is equipped with wheels (FIG. 2) so as to enable it to be mobile for positioning adjacent the second platform 15 , such as an aircraft entry or doorway (See FIG. 9 ).
A space or gap results between the first and second platforms 12 , 15 . The objective is to move pedestrian or other traffic between the first and second platforms 12 , 15 . Typically, the platforms 12 , 15 are only approximately arranged at the same elevation and are often misaligned.
A gangway 16 is used to bridge the gap. The gangway 16 comprises a bridge 17 mounted at a proximal end 18 to the structure 10 . The bridge 17 extends outwardly from the first platform 12 so that a distal end 19 reaches towards the sill 15 a of the second platform 15 . If there is some existing disparity or potential variation in elevations between the platforms 12 , 15 , the bridge 17 can be pivotally mounted to the first platform 15 at pivot point 20 .
For accommodating maximum flexibility in aligning the bridge 17 to the second platform 15 , the pivot point 20 is mounted to a movable frame 25 located beneath the first platform 12 . The frame 25 has a front end 26 and a rear end 27 . The frame 25 is movable relative to the first platform 12 and in an operational or operating plane 30 substantially parallel to the first platform 12 . The frame 25 can be translated and rotated within the operation plane in a least a forwards and rearwards direction. Lateral movement further adds alignment versatility to the gangway.
Due to the relative movement of the frame 25 and the first platform 12 , a small discontinuity can form between the bridge's pivot point 20 and the first platform 12 . This discontinuity can be bridged with an overlapping filler surface 31 including examples such as by using a forward extension of the first platform 12 , a rearward extension of the bridge 17 itself, a rearward extension from the front of the frame 26 , by a surface formed by the frame 25 itself if it is immediately adjacent beneath the first platform 12 , or preferably by a separate interfacing flap 32 . The filler surface 31 and first platform 12 form a contiguous surface but are moveable with respect to each other. The gangway 16 between platforms 12 , 15 therefore comprises the substantially continuous surfaces of the filler surface 31 and the bridge 17 .
As shown in FIG. 1 the filler surface 31 comprises an interfacing flap 32 extending rearwardly from the frame's front end 26 to the first platform 12 . The contiguous gangway 16 is completed by the portion of the bridge 17 which extends forwards from the frame's front end 26 at the pivot point 20 . The interfacing flap 32 can be a rearward extension which is cantilevered from the frame 25 and which is parallel to the first platform (FIGS. 1 and 3 ). Preferably, the interfacing flap 32 can be pivoted from the frame's front end 26 (FIG. 2) to improve maintenance access to the frame 25 or to provide a closer interface between the first platform 12 and the interfacing flap 32 . Note that a pivot point for each of the interfacing flap 32 and the bridge 17 may be the same pivot point 20 or independent and adjacent pivot points 33 , 20 .
The interfacing flap 32 and bridge's pivot point 20 are connected at the frame's front end 26 so that loads imposed on the gangway 16 are transferred into the frame's front end 26 . One or more first bearings 40 , preferably two bearings 40 a , 40 b , support the frame's front end 26 and act as a fulcrum, forcing the frame's rear end 27 to bear upwardly under load. At least one second bearing 41 restrains the reaction at the frame's rear end 27 , maintaining the frame substantially in its operating plane 30 . The first and second bearings 40 , 41 enable relatively frictionless freedom of movement of the frame 25 within the operating plane 30 . The first bearings 40 or 40 a , 40 b bear against and are supported upon a planer lower surface 42 which is supported in the structure 10 and is maintained parallel to the first platform 12 . The second bearing 41 bears against and is supported by a planer upper surface 43 supported in the structure 10 and which is maintained parallel to the first platform 12 . While usual in all cases, depending upon the particular structure 10 , the underside of the first platform 12 may conveniently serve as the upper surface 43 . The upper and lower surfaces 43 , 42 are located beneath the first platform 12 . The first and second bearings 40 , 41 sandwich the frame 25 between the upper surface 43 and the lower surface 42 and may comprise: lubricated facing surfaces; ball bearings in races or as shown in this embodiment, preferably some form of swiveling castors.
An operator can manipulate the movement of the bridge 17 and frame 25 by grasping the bridge directly or via a handlebar 45 which is affixed to the bridge 17 and extending laterally and conveniently to the side (also see FIG. 8 ). It is also possible to add drive means to aid the operator in manipulating the bridge.
Once the bridge 17 is in position, it is preferably secured with some form of locking means or mechanism 50 to avoid movement and slippage of the bridge 17 from the sill 15 a of second platform 15 . The frame 25 can be fitted with a first locking means 51 a and the structure 10 with a complementary second locking means 51 b . When engaged the first and second locking means 51 , 52 lock the frame's movement relative to the structure 10 and thus arrest or lock the bridge 17 movement. As shown in FIG. 1, one form of locking mechanism 50 comprises a combination of an indexed perforated plate 52 as the second locking means 51 b and one or more moveable pins 53 as the first locking means 51 a . If there is more than one pin 53 , the pins 53 , 53 . . . and perforations 54 in the plate 52 are cooperatively spaced so as to ensure engagement or one or more of the pins and perforations 53 , 54 regardless of the position of the frame 25 . Each pin 53 is actuable between a released position, free of the perforated plate 52 , and a locked position, engaged in one of the perforations 54 in the plate 52 . To further ensure safety in operation, a “deadman” or normally-locked system is employed. A spring 47 normally drives the pin 53 into the locked position which is only overcome and moved to the released position upon manual actuation by the operator manipulating the bridge 17 . A mechanism for releasing the pin 53 could include a sheathed cable 48 between a hand lever 46 and the pin or pins 53 as shown in the simplified schematic arrangement of FIG. 1 . The relative frame 25 or structure 10 mounting of the pins 53 and the perforated plate 52 could be reversed mounted.
As shown in FIG. 2, the first platform 12 is supported in a ramp 11 having means 14 for adjusting the elevation of the first platform's front end 13 . Accordingly, the angle of the ramp and first platform 12 can be varied. The interfacing flap 32 and bridge 17 rotate at their respective pivot points 33 , 20 so as to maintain continuity. The handle bars 45 and indexed locking system 50 are not shown in FIG. 2 so as to avoid obscuring additional of the embodiments of the invention. The bridge 17 may be fitted with handrails 71 (See FIG. 4 c .) which contributes to the bridge's weight. Accordingly and advantageously, some form of counterbalance means is provided for resisting the tendency of the bridge 17 to rotate abruptly under gravity when being lowered to the second platform 15 . A biasing means such as a form of spring 60 is shown at the juncture of the frame 25 and bridge 17 to counteract or balance the offset weight of the bridge 17 about its pivot pint 20 . A suitable spring 60 is a coil spring having its ends secured to the bridge 17 and the frame 25 respectively.
Another challenge posed by variable and increasing the angle of the first platform 12 is that the movable frame 25 inherently wishes to move down slope along its operating plane 30 under the increasing influence of gravity. As the angle of the first platform moves off horizontal and the angle increases, the operator must overcome increasing weight of the frame.
One approach is to use the handle bars 45 affixed to the bridge as shown in FIG. 1 and strongly manhandle the bridge 17 . While not essential, further assistance can be provided in manipulating or repositioning of the frame 25 by preferably providing a counterweight system 61 to counteracts the loads associated with the frame 25 . A planer counterweight supporting surface 62 is provided which is supported in the structure 10 and which is maintained parallel to the first platform 12 . A counterweight 63 is moveable on the counterweight support surface 62 , preferably on rollers 64 . A flexible tension member such as a cable 65 extends between the frame 25 , forwards around a turning bearing or pulley 66 and back for connection to the counterweight 63 . In operation, an increase in angle of the frame's operation plane 30 also increases the angle of the counterweight's supporting surface 62 , permitting the counterweight 63 to impose a frame-counterbalancing force, through the cable 65 .
Having reference to FIG. 3, as shown in an optional loading dock embodiment, where the first platform remains substantially horizontal, a frame counterweight system is of little assistance and is not provided.
In operation, and having reference now to FIGS. 4 a - 4 c , the bridge's pivot point 20 is a hinge 70 mounted to the frame's front end 26 . The hinge 70 is offset upwardly from the frame's operating plane 30 . Accordingly, in use, both the flap 32 and the bridge's hinge 70 lie substantially in the plane of the first platform 12 .
As shown in FIGS. 4 a - 4 c , due to a variety of constraints on the ground, the relative positioning of the platforms 12 , 15 , or merely the actions of the operator, the resulting relative end position of the first and second platforms 12 , 15 may be at any of a variety of locations, resulting in spacing or gaps of variable distance. Accordingly, for a large gap as shown in FIG. 4 a , the frame 25 is moved considerably forwards in its operating plane 30 , so as to translate the bridge 17 forwards to reach the second platform 15 . The bridge 17 is pivotally lowered to engage the second platform's sill 15 a . For medium and smaller gaps, the frame can be moved progressively forwards or rearwards so that the bridge engages the sill 15 a.
As is shown in FIG. 4 c , the ability to manipulate the bridge is particularly advantageous when there are lateral constraints as well. As illustrated, the bridge and any handrails 71 are manipulated to fit within a framed doorway 72 of the second platform 15 .
Having reference to FIGS. 5 a and 5 b , the first and second platforms 12 , 15 are shown in plan view with the gangway 16 extending therebetween. In FIG. 5 a , the outline of the entire planer surface of the lower support 42 is shown in hidden lines as necessary where it is obscured by the first platform 12 . In FIG. 5 b , the frame 25 and the first and second bearings 40 a , 40 b , 41 are shown in hidden lines beneath the first platform 12 and gangway 16 respectively. The frame 25 is shown as a triangular structure having two first bearings 40 a , 40 b at the frame's front end 26 and which are shown as being freely swiveling castors (see also FIG. 8 ). One freely swiveling castor is provided as the second bearing 41 at the frame's rear end.
Turning to FIGS. 6 a , 6 b , 7 a and 7 b , the extent of movement and the capability of the gangway 16 to be manipulated in the operating plane 30 through a variety of translations and rotations are shown. Throughout, the frame 25 is illustrated in hidden lines beneath the first platform 12 and gangway 16 .
FIG. 6 a illustrates translation of the gangway 16 and frame 25 forwards to reach a distant second platform 15 . FIG. 6 b illustrates translation of the gangway where the second platform 15 is more closely spaced. Both FIGS. 6 a and 6 b illustrate the capability for lateral translation which accommodates side to side misalignment of the first platform 12 and a dimensionally constricted second platform 15 (such as a framed doorway 72 —see FIGS. 4 c and 9 ).
FIGS. 7 a and 7 b illustrate angular misalignment of the first platform 12 , while permitting rotation of the frame 25 and gangway 16 to align properly with the second platform 15 .
Having reference now to FIG. 8, in one detailed embodiment of the invention, the frame's front end 26 is shown supported or bearing against the lower support on two laterally-spaced swiveling castors 40 a , 40 b . A form of the frame 25 having castors is illustrated, in a schematic form, in FIG. 5 b . The castors 40 a , 40 b are mounted to the underside of a cross member 25 x extending across the frame 25 . A single swiveling castor 41 is mounted to the top of the frame 25 adjacent its rear end 27 . The bridge 17 is pivoted outwardly from a first hinge 70 mounted to the top of a standoff 25 s extending upwardly from the frame's front end 26 . The handlebars 45 are shown secured to a side edge 73 of the bridge 17 . A frame lock actuator lever 16 is partially represented on the right-hand end of the handlebars 45 . The flap 32 is shown pivoted from a second hinge 70 b also mounted to the standoff 25 s.
As an example of a situation involving a constricted or constrained second platform, and referring to FIG. 9, one embodiment of the present invention enables access to the constricted doorway of a small commercial aircraft. The end of the bridge 17 is shown approaching the sill 15 a of the doorway platform 15 , while also accurately negotiating between fixed and narrow handrails 73 .
Having reference to FIG. 10, an alternate locking mechanism 50 comprises two of more arrays of spring loaded pins 53 . The pins 53 can be gang-retracted from their normal position using a mechanism to release the pins 53 from the perforated plate 52 and thereby unlock the frame 25 for movement. A cable 55 extending from a hand release 46 can pull a yoke 56 so as to simultaneously to retract all the pins 53 . When the yoke and pins 53 are released, biasing springs 57 driven the pins 53 towards the plate 52 so that one or more of the pins will engage a cooperating perforation 54 and provide a secure, safe and trustworthy lock. Each pin 53 is illustrated having a small shank 58 forming range of motion shoulders or stops 59 which cooperate with the yoke 56 .
It is understood that there are a variety of structures and platforms to which the method and apparatus of the floating gangway can be applied, whether the structure is mobile or stationary. There are many forms of frame support, bearings and braking mechanism which can be drawn from the prior art which enable the movement and locking of the frame in its operating plane. A variety of known drive mechanisms can be added to assist the operator in manipulating the various masses of the structure, frame and gangway and automating the alignment of the gangway. | A fully floating gangway comprises a movable frame sandwiched movably in an operating plane between lower and upper parallel bearing surfaces which are supported from and positioned below a first platform. A gangway extends from the frame's front end for extending to another platform such as an aircraft doorway so that the gangway can be aligned therewith by manipulating the frame in the operating plane. Preferably the frame and bearing surfaces are supported in a mobile structures such as passenger ramp. The gangway is preferably pivoted from the frame for adapting to differential elevations. The pivoting gangway can be counterbalanced for ease of manipulation. A braking system is provided to lock gangway against movement once positioned. | 4 |
This is a continuation, of application Ser. No. 531,991, filed Dec. 12, 1974. Now abandoned, which is a division of Ser. No. 431,598, filed Jan. 8, 1974, now U.S. Pat. No. 3,931,281.
BACKGROUND OF THE INVENTION
This invention relates to novel ester derivatives of prostaglandin A 2 (hereinafter identified as "PGA 2 "), 15-alkyl-PGA 2 , 15(R)-15-alkyl-PGA 2 , and their racemic forms, and to processes for producing them.
PGA 2 is represented by the formula: ##STR1## A systematic name for PGA 2 is 7-}2β-[(3S)-3-hydroxy-trans-1-octenyl]-5-oxo-1α-cyclo-3-pentenyl]-cis-5-heptenoic acid. PGA 2 is known to be useful for a variety of pharmacological and medical purposes, for example to reduce and control excessive gastric secretion, to increase the flow of blood in the mammalian kidney as in cases of renal dysfunction, to control spasm and facilitate breathing in asthmatic conditions, and as a hypotensive agent to reduce blood pressure in mammals, including humans. See Bergstrom et al., Pharmacol. Rev. 20, 1 (1968) and references cited therein. As to racemic PGA 2 , see for example J. Martel et al., Tetrahedron Lett. 1491 (1972).
The 15-alkyl-PGA 2 analog and its 15(R) epimer are represented by the formula: ##STR2## wherein Y' is ##STR3## following the usual convention wherein broken line attachment of hydroxy to the side chain at carbon 15 indicates the natural of "S" configuration and solid line attachment of hydroxy indicates the epi or "R" configuration. See for example Nugteren et al., Nature 212, 38 (1966) and Cahn, J. Chem. Ed. 41, 116 (1964). The 15-alkyl-and 15(R)-15-alkyl-PGA 2 analogs in their optically active and racemic forms are known. See for example Belg. Patent No. 772,584, Derwent Farmdoc No. 19694T. These analogs are also useful for the above-described pharmacological purposes.
Esters of the above compounds are known, wherein the hydrogen atom of the carboxyl group is replaced by a hydrocarbyl or substituted hydrocarbyl group. Among these is the methyl ester of PGA 2 (J.P. Lee et al., Biochem. J. 105, 1251 (1967)).
SUMMARY OF THE INVENTION
It is a purpose of this invention to provide novel ester derivatives of prostaglandin PGA 2 , 15-alkyl-PGA 2 , 15(R)-15-alkyl-PGA 2 , and their racemic forms. It is a further purpose to provide such esters derived from substituted phenols and naphthols. It is a further purpose to provide such esters in a free-flowing crystalline form. It is still a further purpose to provide novel processes for preparing these esters.
The presently described esters include compounds represented by the generic formula: ##STR4## wherein Z is the substituted phenyl or naphthyl group as defined immediately below, and Y is ##STR5## i.e. esters of PGA 2 , 15-methyl-PGA 2 , and 15(R)-15-methyl-PGA 2 , 15-ethylPGA 2 , and 15(R)-15-ethyl-PGA 2 ; and also the racemic compounds represented by each respective formula and the mirrow image thereof; Z being represented by ##STR6##
For example, PGA 2 , p-acetamidophenyl ester, is represented by formula III when Y is ##STR7## and Z is A, i.e. ##STR8## and is conveniently identified herein as the PGA 2 ester of formula III-A. Racemic compounds are designated by the prefix "racemic" or "dl"; when the prefix is absent, the intent is to designate an optically active compound. Racemic 15-methyl-PGA 2 , p-benzamidophenyl ester, corresponds to formula III wherein Y is ##STR9## and Z is B, i.e. ##STR10## including or course not only the optically active isomer represented by formula III but also its mirror image.
The novel formula-III compounds and corresponding racemic compounds of this invention are each useful for the same purposes as described above for PGA 2 and are used for those purposes in the same manner known in the art, including oral, sublingual, buccal, rectal, intravaginal, intrauterine, or topical administration.
For many applications these novel prostaglandin esters which I have obtained from certain specified phenols and naphthols have advantages over the corresponding known prostaglandin compounds. Thus, these substituted phenyl and naphthyl esters are surprisingly stable compounds having outstanding shelf-life and thermal stability. In contrast to the acid form of these prostaglandins, these esters are not subject to decomposition either by elimination of water, epimerization, or isomerization. Thus these compounds have improved stability either in solid, liquid, or solution form. In oral administration these esters have shown surprisingly greater efficacy than the corresponding free acids or lower alkyl esters, whether because of longer duration of biological activity or because of improved lipophilicity and absorption is not certain. These esters offer a further advantage in that they have low solubility in water and the body fluids and are therefore retained longer at the site of administration.
A particularly outstanding advantage of many of these substituted phenyl and naphthyl esters is that they are obtained in free-flowing crystalline form, generally of moderately high melting point, in the range 90°-180° C. This form is especially desirable for ease of handling, administering, and purifying. These crystals are highly stable, for example showing practically no decomposition at accelerated storage tests at 65° C., in comparison with liquid alkyl esters or the free acids. This quality is advantageous because the compound does not lose its potency and does not become contaminated with decomposition products.
These crystalline esters also provide a means of purifying PGA 2 , 15-methyl-PGA 2 , 15(R)-methyl-PGA 2 , 15-ethyl-PGA 2 , or 15(R)-15-ethyl-PGA 2 , which are first converted to one of these esters, recrystallized until pure, and then recovered as the free acid. One method of recovering the free acid is by enzymatic hydrolysis of the ester, for example with a lipase. See German Patent No. 2,242,792, Derwent Farmdoc No. 23047U.
To obtain the optimum combination of stability, duration of biological activity, lipophilicity, solubility, and crystallinity, certain compounds within the scope of formula III are preferred.
One preference is that Z is limited to either ##STR11##
Another preference is that Z is further limited to ##STR12## wherein R 1 is
--CH.sub.3 ##STR13## wherein R.sub.2 is ##STR14## Another preference is that Z is limited to ##STR15## Another preference is that Z is limited to ##STR16## wherein R.sub.3 is ##STR17## wherein R.sub.4 is ##STR18##
Especially preferred are those compounds which are in free-flowing crystalline form, for example:
p-benzamidophenyl ester of PGA 2
p-(p-acetamiphenyl ester of PGA 2 or
α-semicarbazono-p-tolyl ester of PGA 2
The substituted phenyl and naphthyl esters of PGA 2 , 15-alkyl-PGA 2 , and 15(R)-15-alkyl-PGA 2 encompassed by formula III wherein Z is defined by ester groups A through Y are produced by the reactions and procedures described and exemplified hereinafter. For convenience, the above prostaglandin or prostaglandin analog is referred to as "the PG compound". The term "phenol" is used in a generic sense, including both phenols and naphthols.
Various methods are available for preparing these esters, differing as to yield and purity of product. Thus, by one method, the PG compound is converted to a tertiary amine salt, reacted with pivaloyl halide to give the mixed acid anhydride and then reacted with the phenol. Alternately, instead of pivaloyl halide, an alkyl or phenylsulfonyl halide is used, such as p-toluenesulfonyl chloride. See for example Belgian patents Nos. 775,106 and 776,294, Derwent Farmdoc Nos. 33705T and 39011T.
Still another method is by the use of the coupling reagent, dicyclohexylcarbodiimide. See Fieser et al., "Reagents for Organic Synthesis", pp. 231-236, John Wiley and Sons, Inc., New York (1967). The PG compound is contacted with one to ten molar equivalents of the phenol in the presence of 2-10 molar equivalents of dicyclohexylcarbodiimide in pyridine as a solvent.
The preferred novel process for the preparation of these esters, however, comprises the steps (1) forming a mixed anhydride with the PG compound and isobutylchloroformate in the presence of a tertiary amine and (2) reacting the anhydride with an appropriate phenol or naphthol.
The mixed anhydride is represented by the formula: ##STR19## for the optically active PG compounds, Y having the same definition as above.
The anhydride is formed readily at temperatures in the range -40° to +60° C., preferably at -10° to +10° C. so that the rate is reasonably fast and yet side reactions are minimized. The isobutylchloroformate reagent is preferably used in excess, for example 1.2 molar equivalents up to 4.0 per mole of the PG compound. The reaction is preferably done in a solvent and for this purpose acetone is preferred, although other relatively non-polar solvents are used such as acetonitrile, dichloromethane, and chloroform. The reaction is run in the presence of a tertiary amine, for example triethylamine, and the co-formed amine hydrochloride usually crystallizes out, but need not be removed for the next step.
The anhydride is usually not isolated but is reacted directly in solution with the phenol, preferably in the presence of a tertiary amine such as pyridine.
The phenol is preferably used in equivalent amounts or in excess to insure that all of the mixed anhydride is converted to ester. Excess phenol is separated from the product by methods described herein or known in the art, for example by crystallization. The tertiary amine is not only a basic catalyst for the esterification but also a convenient solvent. Other examples of tertiary amines useful for this purpose include N-methylmorpholine, triethylamine, diisopropylethylamine, and dimethylaniline. Although they may be used, 2-methylpyridine and quinoline result in a slow reaction. A highly hindered amine such as 2,6-dimethyllutidine is not useful because of the slowness of the reaction.
The reaction with the anhydride proceeds smoothly at room temperature (about 20° to 30° C.) and can be followed in the conventional manner with thin layer chromatography (TLC), usually being found complete within 1-4 hours.
The reaction mixture is worked up to yield the ester following methods known in the art, and the product is purified, for example by silica gel chromatography.
Solid esters are converted to a free-flowing crystalline form on crystallization from a variety of solvents, including ethyl acetate, tetrahydrofuran, methanol, and acetone, by cooling or evaporating a saturated solution of the ester in the solvent or by adding a miscible non-solvent such as diethyl ether, hexane, or water. The crystals are then collected by conventional techniques, e.g. filtration or centrifugation, washed with a small amount of solvent, and dried under reduced pressure. They may be dried in a current of warm nitrogen or argon, or by warming to about 75° C. Although the crystals are normally pure enough for many applications, they may be recrystallized by the same general techniques to achieve improved purity after each recrystallization.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention can be more fully understood by the following examples.
All temperatures are in degrees centigrade.
Silica gel chromatography, as used herein, is understood to include chromatography on a column packed with silica gel, elution, collection of fractions, and combination of these fractions shown by thin layer chromatography (TLC) to contain the desired product free of starting material and impurities. "TLC", herein, refers to thin layer chromatography.
PREPARATION 1
p-Benzamidophenol
A solution of p-hydroxyaniline (20 g.) in 200 ml. pyridine is treated with benzoic anhydride (20 g.). After 4 hr. at about 25° C., the mixture is concentrated under reduced pressure and the residue is taken up in 200 ml. of hot methanol and reprecipitated with 300 ml. of water. The product is recrystallized from hot acetonitrile as white crystals, 8.5 g., m.p. 218.0°-218.5° C.
PREPARATION 2
p(p-Acetamiphenol
A solution of p-acetamidobenzoic acid (12.5 g.) in 250 ml. of tetrahydrofuran is treated with triethylamine (11.1 ml.). The mixture is then treated with isobutylchloroformate (10.4 ml.) and, after 5 min. at about 25° C., with p-aminophenol (13.3 g.) in 80 ml. of dry pyridine. After 40 min. the crude product is obtained by addition of 2 liters of water. The product is recrystallized from 500 ml. of hot methanol by dilution with 300 ml. of water as white crystals, 5.9 g., m.p. 275.0°-277.0° C.
EXAMPLE 1
p-Benzamidophenyl Ester of PGA 2 (Formula III-B)
A solution of PGA 2 (0.310 g.) and triethylamine (0.244 ml.) in 20 ml. of acetone is treated at -10° C. with isobutylchloroformate (0.236 ml.) whereupon triethylamine hydrochloride is precipitated. After 5 min. the mixture is treated with p-benzamidophenol (0.558 g.) in 5 ml. of pyridine for 0.25 hr. at about 25° C. The solvent is removed under reduced pressure and the residue is dissolved in ethyl acetate and washed with aqueous citric acid (2%) and water. The organic phase is dried over sodium sulfate, concentrated, and subjected to silica gel chromatography, eluting with acetonitrile-chloroform (1:4). The residue obtained by concentration of selected fractions, a solid on chilling, is the title compound, 0.293 g., having R f 0.6 (TLC on silica gel in acetonitrile-chloroform (1:4)). It is recrystallized from ethyl acetate-hexane as white free-flowing crystals, m.p. 56.5°-57.5° C.
EXAMPLE 2
p-(p-Acetamiphenyl Ester of PGA 2 (Formula III-C)
Following the procedure of Example 1 but using 0.308 g. of PGA 2 , 0.244 ml. of triethylamine, 0.236 ml. of isobutylchloroformate, and 0.714 g. of p-[(p-acetamidophenyl)carbamoyl]phenol (Preparation 2), there is obtained a crude solid residue. This residue is subjected to silica gel chromatography, eluting with ethyl acetate. The residue obtained by concentration of selected fractions, 0.260 g., is chromatographed again on silica gel, eluting with acetonitrile-chloroform (1:1) to yield 0.047 g. which is recrystallized from ethyl acetate-methanol-hexane (97:3:10) as the title compound, 0.044 g., white freeflowing crystals, m.p. 159.5°-160.0° C., having R f 0.42 (TLC on silica gel in ethyl acetate).
EXAMPLE 3
4-Biphenylyl Ester of PGA 2 (Formula III-G)
Following the procedure of Example 1 but using 0.561 g. of PGA 2 , 0.302 ml. of triethylamine, 0.286 ml. of isobutylchloroformate, and 0.570 g. of p-phenylphenol, there is obtained a crude oily residue. This residue is subjected to silica gel chromatography, eluting with ethyl acetate-hexane (2:3) saturated with water. The residue obtained by concentration of selected fractions, 0.381 g., an oil, is the title compound, having R f 0.5 (TLC on silica gel in ethyl acetate-hexane (2:3).
EXAMPLE 4
α-Semicarbazono-p-tolyl Ester of PGA 2 (Formula III-K)
Following the procedure of Example 1 but using 0.310 g. of PGA 2 , 0.244 ml. of triethylamine, 0.236 ml. of isobutylchloroformate, and 0.470 g. of p-hydroxybenzaldehyde semicarbazone, there is obtained a crude solid residue. This residue is subjected to silica gel chromatography, eluting with tetrahydrofuran-ethyl acetate (3:2). The residue obtained by concentration of selected fractions, 0.600 g., is crystallized from acetone-water (1:2) as the title compound, 0.376 g., as white free-flowing crystals. An analytical sample recrystallized from acetonitrile has m.p. 128.3°-129.0° C. and R f 0.5 (TLC on silica gel in ethyl acetate-methanol (95:5)).
Following the procedures of Examples 1-4 but employing the racemic forms of the PG compounds, there are obtained the corresponding esters of racemic PG compounds.
EXAMPLES 5-75
The substituted phenyl and naphthyl esters of PGA 2 , 15-methyl-PGA 2 , and 15(R)-15-methyl-PGA 2 of Tables I-III below are obtained following the procedures of Example 1, wherein the prostaglandin compound is reacted in the presence of triethylamine and isobutylchloroformate with the appropriate hydroxy phenyl or naphthyl compound, listed in the Table. These phenols or naphthols are readily available or prepared by methods described herein or known in the art. The crude products, obtained by concentration under reduced pressure, are purified by means described herein or known in the art, including partitioning, solvent extraction, washing, silica gel chromatography, trituration, or crystallization.
Following the procedures of Examples 5-75 but employing the racemic forms of the PG compounds, there are obtained the corresponding esters of the racemic PG compounds.
TABLE 1______________________________________Esters of PGA.sub.2 Hydroxy Phenyl or Product PGA.sub.2Ex. Naphthyl Compound Ester of formula:______________________________________5 p-acetamidophenol 111-A6 p-[(p-benzami-dophenyl)carbamoyl]- 111-D phenol7 p-hydroxyphenylurea 111-E8 p-hydroxy-1,3-diphenylurea 111-F9 p-tritylphenol 111-H10 N-acetyl-L-tyrosinamide 111-111 N-benzoyl-L-tyrosinamide 111-J12 p-hydroxyacetophenone 111-L13 p-hydroxybenzophenone 111-M14 p-hydroxybenzamide 111-N15 o-hydroxybenzamide 111-O16 N-(p-tritylphenyl)-p-hydroxybenzamide 111-P17 p-hydroxybenzoic acid, methyl ester 111-Q18 hydroquinone benzoate 111-R19 hydroquinone, p-acetamidobenzoic 111-S acid ester20 2,4-diacetamidophenol 111-T21 1-acetamido-4-hydroxynaphthalene 111-U22 1-benzamido-4-hydroxynaphthalene 111-V23 1-hydroxy-4-ureidonaphthalene 111-W24 2-naphthol 111-X25 1-hydroxy-5-naphthalenesulfonamide 111-Y______________________________________
TABLE II______________________________________Esters of 15-Methyl-PGA.sub.2 Product Hydroxy Phenyl or 15-Methyl-PGA.sub.2Ex. Naphthyl Compound Ester of formula:______________________________________26 p-acetamidophenol 111-A27 p-benzamidophenol 111-B28 p-[(p-acetamidophenyl)carbamoyl]-phenol 111-C29 p-[(p-benzamidophenyl)carbamoyl]-phenol 111-D30 p-hydroxyphenylurea 111-E31 p-hydroxy-1,3-diphenylurea 111-F32 p-phenylphenol 111-G33 p-tritylphenol 111-H34 N-acetyl-L-tyrosinamide 111-135 N-benzoyl-L-tyrosinamide 111-J36 p-hydroxybenzaldehyde semicarbazone 111-K37 p-hydroxyacetophenone 111-L38 p-hydroxybenzophenone 111-M39 p-hydroxybenzamide 111-N40 o-hydroxybenzamide 111-O41 N-(p-tritylphenyl)-p-hydroxybenzamide 111-P42 p-hydroxybenzoic acid, methyl ester 111-Q43 hydroquinone benzoate 111-R44 hydroquinone, p-acetamidobenzoic 111-S acid ester45 2,4-diacetamidophenol 111-T46 1-acetamido-4-hydroxynaphthalene 111-U47 1-benzamido-4-hydroxynaphthalene 111-V48 1-hydroxy-4-ureidonaphthalene 111-W49 2-naphthol 111-X50 1-hydroxy-5-naphthalenesulfonamide 111-Y______________________________________
TABLE III______________________________________Esters of 15(R)-15-Methyl-PGA.sub.2 Product 15(R)- Hydroxy Phenyl or 15-Methyl-PGA.sub. 2Ex. Naphthyl Compound Ester of formula:______________________________________51 p-acetamidophenol 111-A52 p-benzamidophenol 111-B53 p-[(p-acetamidophenyl)carbamoyl] -phenol 111-C54 p-[(p-benzamidophenyl)carbamoyl] -phenol 111-D55 p-hydroxyphenylurea 111-E56 p-hydroxy-1,3-diphenylurea 111-F57 p-phenylphenol 111-G58 p-tritylphenol 111-H59 N-acetyl-L-tyrosinamide 111-I60 N-benzoyl-L-tyrosinamide 111-J61 p-hydroxybenzaldehyde semicarbazone 111-K62 p-hydroxyacetophenone 111-L63 p-hydroxybenzophenone 111-M64 p-hydroxybenzamide 111-N65 o-hydroxybenzamide 111-O66 N-(p-tritylphenyl)-p-hydroxybenzamide 111-P67 p-hydroxybenzoic acid, methyl ester 111-Q68 hydroquinone benzoate 111-R69 hydroquinone, p-acetamidobenzoic acid 111-S ester70 2,4-diacetamidophenol 111-T71 1-acetamido-4-hydroxynaphthalene 111-U72 1-benzamido-4-hydroxynaphthalene 111-V73 1-hydroxy-4-ureidonaphthalene 111-W74 2-naphthol 111-X75 1-hydroxy-5-naphthalenesulfonamide 111-Y______________________________________ | Substituted esters of PGA 2 , 15-alkyl-PGA 2 , and 15(R)-15-alkyl-PGA 2 , and their racemic forms, and processes for producing them are disclosed. The products are useful for the same pharmacological and medical purposes as PGA 2 , 15-alkyl-PGA 2 , and 15(R)-15-alkyl-PGA 2 , and are also useful as a means for obtaining highly purified PGA 2 , 15-alkyl-PGA 2 , and 15(R)-15-alkyl-PGA 2 products. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a labelling machine which sticks a label on the external surface of an object having a planar or a curved surface, such as a bottle, a can, a paper cylindrical container, a recording tape cassette, etc (hereinafter referred to as a container).
2 Description of the Prior Art
The inventor of the device of the present application has already filed Japanese patent application No. 31403/76, Patent Laid-Open No. 115200/1977, for an invention relating to a labelling machine having improved labelling speed. The invention is characterized by an idea in which each label flies after being released from the label suction drum, until it is received by a label receiving member before it is urged against a container.
SUMMARY OF THE INVENTION
The present invention relates to a further improvement in labelling machines, which is accomplished based on another idea to remove the aforementioned disadvantages. An object of the present invention is to provide a labelling machine having an improved labelling speed, even when using a prior art label suction drum.
Labels tend to deviate from a horizontal position during the period in which they are taken by a label suction drum or during the period in which they are transferred from the surface of one drum to another. Such a tendency reduces, or even spoils, the commodity value of a container which has been struck with a label, particularly in the case where the label is long enough to fully encircle a cylindrical container.
Accordingly, another object of the present invention is to provide a labelling machine capable of sticking labels in an exact horizontal position around the external surface of a container.
The present invention is directed to a labelling machine which includes a plurality of label suction drums rotatably mounted on a bed plate and a plurality of label holders for supplying labels one-by-one to a corresponding label suction drum. A label applicator drum is positioned adjacent to the label suction drums for receiving labels carried by the label suction drums, and thereafter applying the labels to an object which may have either an arcuate or a planar surface. Each label suction drum is provided with a plurality of arcuately spaced projections and vacuum suction outlets between the projections. The labels are retained on a peripheral surface of each label suction drum between the projections by a vacuum applied through the vacuum suction outlets. An upper stop element is positioned adjacent the periphery of each label suction drum and the label applicator drum. The upper stop element, which is spaced from the bedplate by a distance corresponding to the height of the labels, corrects any horizontal misalignment of the labels relative to the label suction drum. A push mechanism urges the labels carried by the label suction drums towards the label applicator drum.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will become more fully apparent as the following description is read in conjunction with the drawings wherein:
FIG. 1 is an overall plan view of a labelling machine in accordance with the present invention;
FIG. 2 is a plan view of the label suction drum illustrating its positioning relative to the label applicator drum;
FIG. 3 is a perspective view of the label suction drum and a portion of the label applicator drum;
FIG. 4 is a vertical cross-sectional view of the label suction drum and a portion of the label applicator drum;
FIG. 5 is another perspective view of the label suction drum taken from a different position;
FIG. 6 is a vertical sectional view of a portion of the label suction drum illustrated in FIG. 5;
FIGS. 7 and 8 are schematic views illustrating the procedure in which a label is transferred from the label suction drum to the label applicator drum; and
FIG. 9 is a plan view of a prior art labelling machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A label applicator drum 1 rotates in the center of a labelling machine. A plurality of label suction drums 2 are arranged around the label application drum 1. A label holder 3 is positioned adjacent to each label suction drum 2. The label holders 3 are permitted a horizontal swing motion. A paste application drum 5 is arranged between the last one of the label suction drums 2 and the container to apply paste to the labels. A conveyor 4 is positioned adjacent to the label applicator drum 1 for conveying containers to the label applicator drum 1. At the instant when a container makes contact with the label sticking drum 1, a label held by suction applied along the external surface of the label applicator drum 1 is urged against an external surface of the container. As a result, a label is transferred to the container and sticks on the external surface of the container. As will be explained later, the present invention is directed to the action by which a label is transferred from the label suction drum 2 to the label application drum 1.
A number of air passages 7 are provided in the label applicator drum 1. The air passages form air suction holes 11, at one end, on the cylindrical surface of the label applicator drum 1. At their other end, the air passages 7 form a series of openings 8 arranged on the undersurface of the label applicator drum 1. An air suction groove 12 is arranged along the upper surface of a bed plate 14 on which the label sticker drum 1 is rotatably supported. The air suction groove 12 abuts the locus of the series of openings 8. A vacuum pump (not shown) is connected with the air suction groove 12. The air suction groove 12 extends from a position close to the first one of the label suction drums 2 to a position close to the conveyor 4, as shown by broken lines in FIGS. 1 and 2. Therefore, as the label applicator drum 1 rotates, vacuum is applied selectively to a limited number of the air suction holes 11 as they pass over and along the air suction groove 12.
The label suction drums 2 rotate around respective vertical shafts. A plurality of label suction drums 2 are arranged around the label applicator drum 1 as shown in FIG. 1. The cylindrical external surface of the label suction drum 2 is split into upper and lower portions 2a, 2b, respectively, by a circular groove 21 formed at the center of the generation line thereof, as shown in FIGS. 3-8. Pairs of projections 22 are provided at uniform angular intervals on both the upper and lower halves 2a, 2b of the label suction drum 2. A non-projected cylindrical portion, or horizontal groove 25, separates each pair of projections 22 as shown in FIGS. 5-7.
A number of air suction holes 23 are arranged on the cylindrical surface of the label suction drum 2. Air passages penetrate the label suction drum 2, beginning at the air suction holes 23 and ending at the holes provided in the undersurface of of the bottom of the label suction drum 2. An air suction groove 24 is arranged along the upper surface of the bed plate 14, on which the label suction drum 2 rotates. The air suction groove 24 abuts the locus of the aforementioned holes provided in the undersurface of the bottom of the label suction drum 2. A vacuum pump (not shown) is connected with the air suction groove 24. The air suction groove 24 extends from a position close to the position where a label holder 3 approaches the air suction drum 2 to feed a label to a position which is in advance, by a distance L, of the position where the line connecting the centers of the label applicator drum 1 and the label suction drum 2 drosses the peripheral surface of the label suction drum 2. The distance L is selected to be slightly shorter than the length of a label to be stuck on a container.
A label transfer mechanism 6, the most essential portion of the present invention, transfers a label from the label suction drum 2 to the label applicator drum 1. The label transfer mechanism comprises a bed plate 61, a guide plate 62, an upper stopper 63, a push roller 64 and the aforementioned projections 22 of the label suction drum 2.
The bed plate 61 consists of a plate supported in a horizontal position along which each label moves, thereby taking an upright position and, as a result, there is no possibility of the labels deviating from a horizontal position.
The guide plate 62 consists of a plate positioned close to the cylindrical surface of the label suction drum 2 within the horizontal groove 25 provided between each pair of projections 22. While each label in an upright position is pushed at the rear end by the projections 22 along the guide plate 62, the guide plate 62 guides and supports the label. In an embodiment shown in FIGS. 5-8, an end of a plate held in a horizontal position is utilized as the guide plate 62. Due to the horizontal groove 25, the guide plate 62 can be positioned extremely close to the cylindrical surface of the label suction drum 2 without interfering with the projections 22 as shown in FIG. 6. The tail end of the guide plate 62 is located close to a position where the line connecting the centers of the label applicator drum 1 and the label suction drum 2 crosses the peripheral surface of the label suction drum 2. The guide plate 62 must have a length close to, or longer than, that of the label.
The upper stop 63 consists of a guide member supported over the bed plate 61 at approximately the same height as a label above the upper surface of the bed plate 61, and it will be convenient if vertical adjustment is permitted by means of a screw 63a. The upper stop 63 is located close to a position where the line connecting the centers of the label applicator drum 1 and the label suction drum 2 crosses the peripheral surface of the label suction drum 2, and contacts the upper edge of a label moving toward the label applicator drum 1. The upper stop 63 performs two independent functions, one of which is to correct any deviation in the label position from the horizontal position. The other is to retard the progress of a label moving at a relatively high speed.
The push roller 64 is positioned inside the circular groove 21 of the label suction drum 2. The location corresponds to the position where a line connecting the centers of the label applicator drum 1 and the label suction drum 2 crosses the peripheral surface of the label suction drum 2. The push roller 64 is rotatably supported at one end of a support arm 65, the other end of which is fixed by a vertical shaft 66.
The vertical shaft 66 rotates in alterate directions simultaneously with the label receiving action of the label applicator drum 1. In other words, it cyclically repeats a swinging motion between a position where the push roller 64 urges a label against the cylindrical surface of the label sticker drum 1 and a position where the push roller 64 is located inside the circular groove 21 of the label suction drum 2.
The operation of a labelling machine constructed in accordance with the present invention will now be described.
At the instant when the label holder 3 contacts the label suction drum 2, the latter takes a label L located at the extreme front of the former by means of suction applied through the air suction holes 23. The Label L is held along an arbitrary portion of the cylindrical surface between the projections 22. In other words, the label suction drum 2, in accordance with the present invention, does not require that a label be fed exactly in a specific time, as is required in the case of the prior art. When the label L held along the peripheral surface of the suction drum 2 has moved to face the guide plate 62, the label L is released from the label suction drum 2 because the passages provided in the under surface of the bottom of the label suction drum 2 have passed by the air suction groove 24 arranged along the upper surface of the bed plate, thereby discontinuing the application of vacuum to the label suction drum 2. In this instance, a space A still remains between the end of the label L and a group of projections 22 located behind the label L. Even after being released, the label L keeps moving due to the inertia and remaining vacuum until the upper stopper 63 reduces the speed of the label L by making contact with the same and corrects the positional deviation, if any, of the label L. Thereafter, the projections 22, having proceeded by the distance A, push the label L forward.
In this manner, while being supported or guided from three directions (that is, upwardly by the bed plate 61, forwardly by the projections 22 and downwardly by the upper stopper 63), the label L is pushed toward the label applicator drum 1 by the push roller 64 and is sucked by vacuum applied through the air suction holes 11 provided along the cylindrical surface of the label applicator drum 1.
A photo-detector, detecting the arrival of a label L, causes the paste applicator drum 5 to apply paste on the rear surface of a label L. Thereafter, a previously known type mechanism is utilized for applying a label L to a container.
Thus, each label L is first released from the label suction drum 2 before it is taken up again by the label applicator drum 1, at a time, detected by the photo-detector, convenient for the paste applicator drum E to apply paste to the label L.
As explained above, the present invention is characterized by the procedure in which a label L is held and carried by the label suction drum 2 once it is released to a free condition to have any positional deviation thereof corrected and, thereafter, is urged by the push roller 64 toward the label applicator drum 1 to be taken up again by the same. As a result, the present invention has the following advantages:
(1) Since there is no possibility of any single label being simultaneously sucked by both drums 1 and 2, the speed of both drums can be selected independently, each from the other. In other words, it is possible to transfer a label from a label suction drum 2, which is rotating at a relatively low speed, to a label applicator drum 1, which is rotating at a high speed, which will usually be several times as high as that of the label suction drum 2.
(2) Since a label once released from the label suction drum 2 is transferred to the label applicator drum 1 by the activity of a push roller 64 in response to the signal of a photo-detector which detects the progress of the label, it is not necessarily important for the label suction drum 2 to receive a label from the label holder 3 at a precise position. That is, even if the label suction drum 2 takes a label from a label holder at an irregular position, it is possible to cause the label applicator drum 1 to receive the label at a required precise position.
(3) A satisfactory positional correction is feasible for a label L by the activities of the bed plate 61 and the upper stopper 63. As a result, it is possible to apply labels in a precise, horizontal position on the external surface of a container.
The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning and range of the equivalency of the claims are to be embraced therein. | A labelling machine which includes a plurality of label suction drums rotatably mounted on a bed plate and a plurality of label holders for supplying labels one-by-one to a corresponding label suction drum. A label applicator drum is positioned adjacent to the label suction drums for receiving labels carried by the label suction drums, and thereafter applying the labels to an object which may have either an arcuate or a planar surface. Each label suction drum is provided with a plurality of arcuately spaced projections and vacuum suction outlets between the projections. The labels are retained on a peripheral surface of each label suction drum between the projections by a vacuum applied through the vacuum suction outlets. An upper stop element is positioned adjacent the periphery of each label suction drum and the label applicator drum. The upper stop element, which is spaced from the bedplate by a distance corresponding to the height of the labels, corrects any horizontal misalignment of the labels relative to the label suction drum. A push mechanism urges the labels carried by the label suction drums towards the label applicator drum. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is U.S. bypass continuation of international patent application no. PCT/EP2012/051168, filed Jan. 25, 2012 designating the United States of America, the entire disclosure of which is incorporated herein by reference. PCT/EP2012/051168 claims priority to German patent application no. 10 2011 009 926.3, filed Jan. 31, 2011.
TECHNICAL FIELD
[0002] The invention concerns a filtering system for motor oil of an internal combustion engine, in particular of a motor vehicle, comprising a filter head that has a feed line is for motor oil to be filtered and a discharge line for filtered motor oil and a replaceable filter that is mounted releasably by means of a rotational and/or plug connection on the filter head and that comprises a housing with at least one inlet for the motor oil to be filtered that communicates with the feed line and at least one outlet for the filtered motor oil that communicates with the discharge line and in which a filter element is arranged that separates the inlet seal-tightly from the outlet.
[0003] Moreover, the invention concerns a replaceable filter of a filtering system for motor oil of an internal combustion engine that is releasably mountable by means of a rotational and/or plug connection on a filter head and that comprises a housing with at least one inlet for motor oil to be filtered and at least one outlet for filtered motor oil and in which a filter element is arranged that separates the inlet seal-tightly from the outlet.
BACKGROUND
[0004] Filtering systems for motor oil of an internal combustion engine that are known on the market have a filter head that has a feed line for the motor oil to be filtered and a discharge line for filtered motor oil. A replaceable filter is releasably screwed onto the filter head. The replaceable filter comprises a housing with an inlet for the motor oil to be filtered and an outlet for the filtered motor oil. When the replaceable filter is mounted, the inlet communicates with the feed line in the filter head and the outlet communicates with the discharge line in the filter head. In the replaceable filter, a filter element is arranged that separates the inlet seal-tightly from the outlet and that can be flowed through by the motor oil for filtering. When the replaceable filter is mounted at a slant or vertically from above on the filter head, the residual oil contained in the filter can undesirably reach the environment, in particular the engine compartment, upon removal of the replaceable filter.
[0005] The invention has the object to design a filtering system and a replaceable filter of is the aforementioned kind in which, by means of the replaceable filter, additionally an oil distribution in the filter head can be controlled. In particular, a no-drip removal of the replaceable filter should be made possible.
SUMMARY OF THE DISCLOSURE
[0006] This object is solved according to the invention in that the filter head has an auxiliary oil line and the replaceable filter has an outflow control element that automatically closes or releases, depending on an operating and/or mounting condition, the auxiliary oil line. In particular, the outflow control element is attached in such a way on the (remaining) replaceable filter that, upon removal of the replaceable filter from the filter head, it is removed together with the replaceable filter from the filter head. Thus, in particular an outflow control element that is fast with the replaceable filter is provided.
[0007] According to the invention, an auxiliary oil line is provided that is connected preferably with the feed line or with the discharge line. By means of the outflow control element, depending on the operating condition and/or the mounting condition, an oil flow into the auxiliary oil line or out of it is controlled. For characterizing the operating condition, in particular an oil temperature and/or an oil level can be used. The mounting condition relates to the mounting state of the replaceable filter at the filter head, that is wether the filter is completely and correctly mounted at the filter head. When using a replaceable filter that is not suitable and thus does not have the required outflow control element or in case of faulty or incomplete assembly, the oil flow in the auxiliary oil line is not controlled in the required way in order to preferably prevent a disruption of the internal combustion engine. The replaceable filter can be designed in a simple way in modular configuration together with the outflow control element so that the outflow control element can be exchanged and serviced together with the replaceable filter.
[0008] In an advantageous embodiment, the auxiliary oil line can be an oil drain for draining motor oil from the feed line or the discharge line upon removal of the replaceable filter and the outflow control element can be provided with at least one closure element that closes the oil drain when the replaceable filter is mounted and automatically releases the oil drain when the replaceable filter is removed. When the replaceable filter is mounted, the closure element closes off the oil drain so that even in case of the internal combustion engine standing still the oil circuit cannot drain empty. The oil drain can be guided in particular to the oilpan which is arranged at the lowermost point of the internal combustion engine. As soon as the replaceable filter is removed from the filter head, the closure element automatically releases an appropriate opening of the oil drain. The residual oil that is contained in the filter head, in particular in the feed line or the discharge line, can thus drain via the oil drain. In this way, a no-drip removal of the replaceable filter is possible.
[0009] In an alternative advantageous embodiment, the auxiliary oil line can be connected with an auxiliary oil circuit and the outflow control element can have at least one closure element that can be controlled depending on the operating condition and controls automatically an oil flow into the auxiliary oil circuit. The auxiliary oil circuit can contain in particular an oil radiator. In this way, depending on the operating conditions an auxiliary oil circuit can be automatically switched on or off with the outflow control element. When the correct outflow control element is not present, the auxiliary oil circuit remains open so that disturbances, in particular by overheating of the motor oil, are prevented.
[0010] Advantageously, the outflow control element can have a control unit, in particular a float or a wax thermostatic element that is functionally connected with the closure element for actuation thereof. With the control unit, the operating condition can be detected and the closure element can be actuated accordingly. The outflow control element with the control unit and the closure element can be of a modular configuration and can be exchanged simply with the removal of the replaceable filter. In this way, mounting and servicing expenditure is reduced.
[0011] In a further advantageous embodiment, the outflow control element can have a shaft on which the closure element is arranged and the filter head can have a shaft receptacle in which the shaft is inserted when the replaceable filter is mounted in such a way that the closure element can close off the auxiliary oil line at least partially. The shaft can be inserted simply into the shaft receptacle when mounting the replaceable filter in order to position the closure element at an opening of the auxiliary oil line.
[0012] Advantageously, the outlet or the inlet of the replaceable filter can have a through opening that is coaxial to a rotational/plug-in axis of the rotational and/or plug connection and the shaft can be arranged coaxially to the rotational/plug-in axis. In this way, the shaft can be guided simply in the shaft receptacle upon opening or closing of the rotational and/or plug-in connection, in particular upon screwing in or unscrewing the replaceable filter. The shaft can be mounted outside of the through opening on a cover of the housing of the replaceable filter or can extend through the through opening.
[0013] Moreover, advantageously the shaft can be connected with a central tube of the replaceable filter in a monolithic or two-part configuration, in particular by means of a snap connection. The shaft can be advantageously embodied monolithically with the central tube and can be passed through the through opening in the cover of the housing of the replaceable filter. A monolithic component can be produced in a simple and inexpensive way and is stable. A separate attachment of the shaft is not required. Alternatively, the shaft and the central tube can be of a two-part configuration. In particular, the shaft can be attached by means of a snap or clip connection on the central tube. In this way, the shaft can be separated from the replaceable filter housing and upon exchange of the replaceable filter can be re-used. This is in particular advantageous when the shaft is equipped with a complex outflow control element, in particular a temperature sensor or a float.
[0014] Moreover, advantageously the shaft can be a tube whose wall has a plurality of openings. In this way, motor oil can flow into the interior of the shaft and can flow out of it. The interior of the shaft can be connected in particular with the interior of the filter element. In this way, the shaft receptacle together with the shaft can act as a part of the feed line or the discharge line in the filter head.
[0015] In a further advantageous embodiment, the replaceable filter can be mounted spatially from above on the filter head. The replaceable filter can thus be mounted from above on the internal combustion engine in a space-saving way and so as to be simply accessible from the exterior. With the outflow control according to the invention, it is prevented in a simple way that residual oil can escape from the filter head upon removal of the replaceable filter.
[0016] The object is solved furthermore according to the invention in that the replaceable filter has an outflow control element that, when the replaceable filter is mounted, can automatically close or release an auxiliary oil line of the filter head depending on the operating and/or mounting conditions. The advantages and features that have been mentioned above in connection with the filtering system according to the invention apply likewise to the replaceable filter according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Further advantages, features and details of the invention result from the following description in which an embodiment of the invention will be explained in more detail with the aid of the drawing. A person of skill in the art will expediently consider the features disclosed in combination in the drawing, the description and the claims also individually and combine them to meaningful further combinations. It is shown in:
[0018] FIG. 1 schematically, one half in section, a filter system of an internal combustion engine with an exchangeable replaceable filter that has an outflow control element for an oil drain at a filter head;
[0019] FIG. 2 schematically a longitudinal section of the replaceable filter of the FIG. 1 ;
[0020] FIG. 3 an isometric illustration of the replaceable filter of FIGS. 1 and 2 .
DETAILED DESCRIPTION
[0021] In FIG. 1 , a section of a filtering system 9 for motor oil of an internal combustion engine, not shown otherwise, is illustrated, showing one half in longitudinal section. A replaceable filter 10 is screwed from above onto a filter head 12 of the filtering system 9 . The replaceable filter 10 as a whole is symmetrical to a symmetry axis 13 which forms also a rotational/plug-in axis for a screw connection 15 of the replaceable filter 10 with the filter head 12 .
[0022] The replaceable filter 10 comprises a cup 14 and a cover 16 . The cup 14 forms together with the cover 16 a housing 17 which substantially represents the outer geometry of the replaceable filter 10 . The cup 14 is connected by means of a fluid-tight crimp connection 18 with the cover 16 . The cup 14 comprises a closed cylindrical circumferential area which passes in the lower area of the cup 14 into a cup bottom 20 . In the area of the crimp connection 18 , a sealing groove 22 is arranged in which a seal 24 is positioned.
[0023] In the cover 16 , several inlet openings 26 are provided in distribution and through which the motor oil to be purified flows into the replaceable filter 10 . The inlet openings 26 are covered on the side that is facing the interior of the cup 14 with a no-return membrane 27 . Moreover, the cover 16 has a centrally arranged tubular socket-shaped outlet 28 with an outlet opening 29 that is coaxial to the symmetry axis 13 . The outlet 28 has at its radial outer peripheral side an outer thread 30 for screw-connecting the replaceable filter 10 to a socket 32 provided with an appropriate inner thread. The outer thread 30 and the inner thread are part of the screw connection 15 . The socket 32 is part of the filter head 12 .
[0024] In the interior of the housing 17 a filter element 34 is arranged such that the inlet openings 26 are seal-tightly separated from the outlet 28 . The filter element 34 comprises for this purpose a filter medium 36 which is folded in a zigzag shape and is closed to a star shape. Terminal disks 38 are arranged at the end face ends of the filter medium 36 .
[0025] The terminal disk 38 that is facing the cup bottom 20 is supported by support elements 40 on the cup bottom 20 .
[0026] In an opening that is provided in the terminal disk 38 facing the cup bottom 20 and that is coaxial to the symmetry axis 13 , a bypass valve 42 , not of interest in this context, is arranged which projects into the interior of the filter element 34 .
[0027] In the interior of the filter element 34 there is a skeleton-like central tube 44 onto which the filter element 34 is pushed. The central tube 44 is coaxial to the symmetry axis 13 and extends between the two terminal disks 38 .
[0028] A tubular shaft 46 that is coaxial to the symmetry axis 13 is extending through the outlet opening 29 . The shaft 46 is connected at one end approximately at the level of the upper terminal disk 38 by a clip connection 48 to the central tube 44 . A peripheral wall of the shaft 46 has a plurality of openings 50 through which the motor oil can flow out of the interior of the shaft 46 . At the free end of the shaft 46 a cup-shaped closure element 52 is formed whose open side faces the cover 16 of the replaceable filter 10 . The peripheral wall of the closure element 52 has several steps. The greatest diameter of the closure element 52 is located at the open side. The shaft 46 and the closure element 52 form an outflow control element 53 of the replaceable filter 10 .
[0029] In the vicinity of the end faces of the closure element 52 , respectively, there is provided in the radial outer peripheral side a circumferential groove with a respective annular seal 54 and 56 . With screwed-in replaceable filter 10 , the annular seals 54 and 56 close seal-tightly relative to appropriate sealing surfaces 57 a connecting opening 58 between an oil drain 60 and a shaft receptacle 62 of the filter head 12 .
[0030] The shaft receptacle 62 is part of a discharge line for filtered motor oil, not shown in detail. The shaft receptacle 62 is substantially coaxial to the symmetry axis 13 . When the replaceable filter 10 is mounted, the shaft 46 of the replaceable filter 10 is inserted into the shaft receptacle 62 in such a way that the connecting opening 58 to the oil drain 60 is closed by means of the closure element 52 .
[0031] The oil drain 60 extends in a way not of interest in this connection into an oilpan that is not shown in FIG. 1 .
[0032] On the cover 16 of the replaceable filter 10 radially within the seal 24 an annular projection 64 is arranged that is coaxial relative to the symmetry axis 13 and has a U-shaped profile. The open side of the U-shaped profile is pointing away from the cup bottom 20 in axial direction. When the replaceable filter 10 is mounted, the annular projection 64 engages an appropriate annular feed groove 66 in the filter head 12 . The feed groove 66 is located also radially within the seal 24 . The seal 24 is supported on an appropriate sealing surface 67 of the filter head 12 that outwardly surrounds the feed groove 66 in radial direction. The feed groove 66 is part of a feed line for motor oil to be filtered in the filter head 12 , the feed line not further described in the following.
[0033] Between the radial inner sidewall of the feed groove 66 and the radial inner exterior wall of the annular projection 64 , there is a gap 68 through which the motor oil to be filtered flows from the feed groove 66 into the inflow chamber 74 in the cover 16 and from there can flow into the inlet openings 26 .
[0034] Upon operation of the internal combustion engine, the motor oil to be filtered flows from the motor oil circuit into the feed groove 66 of the feed line of the filter head 12 . From there, the motor oil flows through the gap 68 into the inflow chamber 74 . is The motor oil flows through the inlet openings 26 into the housing 17 to a radial outer raw side 70 of the filter element 34 .
[0035] The motor oil to be filtered flows for filtration through the filter medium 36 radially from the exterior to the interior to a clean side 72 . The filtered motor oil passes through the opening of the skeleton-like central tube 44 into the interior of the filter element 34 . It flows towards the interior of the shaft 46 and exits the replaceable filter 10 through the outlet 28 . Through the openings 50 of the shaft 46 the filtered motor oil reaches the shaft receptacle 62 and thus the discharge line. Via the discharge line, the filtered motor oil returns into the motor oil circuit.
[0036] For removal, the replaceable filter 10 is unscrewed axially relative to the symmetry axis 13 from the filter head 12 . When doing so, the shaft 46 is pulled out from the shaft receptacle 62 axially relative to the symmetry axis 13 and the closure element 52 is pulled off the corresponding sealing surfaces 57 of the connecting opening 58 of the oil drain 60 . The closure element 52 thus automatically releases the connecting opening 58 to the oil drain 60 . Residual oil which is contained in the discharge line can thus drain via the oil drain 60 into the oilpan.
[0037] Simultaneous with unscrewing of the replaceable filter 10 , the annular projection 64 is moved out of the feed groove 66 . The residual oil contained in the inflow chamber 74 and still to be filtered is collected in the feed groove 66 .
[0038] As a whole, residual oil possibly still contained in the inflow chamber 74 , in the feed groove 66 and in the discharge line 62 will not reach the environment upon unscrewing the replaceable filter 10 so that a no-drip removal can be realized.
[0039] For mounting, the shaft 46 of the replaceable filter 10 is inserted so far into the shaft receptacle 62 that the outer thread 30 of the outlet 28 is contacting the inner thread of the socket 32 . Subsequently, the replaceable filter 10 is screwed on. When doing so, the closure element 52 automatically closes the connecting opening 58 between the shaft receptacle 62 and the oil drain 60 . In the final mounted state, the seal 24 rests seal-tightly on the sealing surface 67 of the filter head 12 .
[0040] In all of the described embodiments of a filtering system 9 and of a replaceable filter 10 the following modifications are possible inter alia.
[0041] The replaceable filter 10 can also be designed such that the clean side is located in radial direction outside of the filter medium 36 and the raw side is arranged within the filter medium so that the motor oil to be filtered flows in radial direction from the interior to the exterior. In this case, the shaft receptacle 62 is part of the feed line and a discharge groove corresponding to the feed groove 66 is part of the discharge line. The oil drain 60 is connected by means of connecting opening 58 with the feed line. The residual oil in the inflow chamber 74 is caught in the feed groove 66 upon removal of the replaceable filter 10 . The no-return membranes in this case are to be replaced by suitable no-return devices of a different kind.
[0042] The closure element 52 can also perform further control functions. For example, the closure element can be provided with a control unit, for example, a float or a wax thermostatic element with which the closure of the connecting opening 58 can be controlled, depending on operating conditions, for example, a motor oil temperature and/or motor oil level in the drain line.
[0043] In addition to the closure element 52 in or on the shaft 46 , a further control unit with a closure element for automatically closing or releasing a further auxiliary oil line, for example, of a separate oil radiator circuit, can be provided.
[0044] The replaceable filter 10 , instead of being mounted from above on the filter head 12 , can also be mounted thereon at a slant from above.
[0045] It is also possible to provide a different kind of filter element 34 which is provided with a differently shaped filter medium in place of the zigzag-shaped folded filter medium 36 .
[0046] Instead of being connected by means of the screw connection 15 , the replaceable filter 10 can also be detachably connected on the filter head 12 by means of a different kind of rotational and/or plug-in connection, for example, a bayonet-like connection.
[0047] Instead of being of a two-part configuration connected by a clip connection 48 , the shaft 46 can also be monolithically connected with the central tube 44 .
[0048] Instead of being coaxial, the shaft 46 can also be eccentrically arranged relative to the symmetry axis 13 and with one end, for example, by means of a universal joint-like connection, can be attached preferably on the housing 17 of the replaceable filter 10 . | A filtering system ( 9 ) includes a filter head ( 12 ) and a replaceable filter ( 10 ). The filter head ( 12 ) has a feed line ( 66 ) and discharge line ( 62 ). The replaceable filter ( 10 ) is removable and replaceably mounted onto the filter head ( 12 ) by a rotational and/or plug connection ( 15 ) and includes a housing ( 17 ) with at least one inlet ( 26 ) for oil to be filtered and at least one outlet ( 28 ). The inlet ( 26 ) communicates with the feed line ( 66 ). The outlet ( 28 ) communicates with the discharge line ( 62 ). The housing ( 17 ) has a filtering element ( 34 ) that sealingly separates the inlet ( 26 ) from the outlet ( 28 ). The filter head ( 12 ) includes an auxiliary oil line ( 60 ). The replaceable filter ( 10 ) has a flow control element ( 53 ) that automatically closes or releases the auxiliary oil line ( 60 ) dependent on an operation and/or assembly condition. | 1 |
FIELD OF THE INVENTION
[0001] This invention relates to decorative tubiform wired ribbon and to a method and apparatus for making the same. More specifically, the invention relates to tubiform fabric or plastic ribbons that are formed of two-ply fabric that is edged with wire and trimmed with an overlay of decorative thread and which can include a decorative insert.
BACKGROUND OF THE INVENTION
[0002] Decorative fabric ribbons are known, as are fabric ribbons that have been edged with wire. However, the prior art wire ribbons are made by laying a wire near the edge of a fabric ribbon, folding the edge of the ribbon over the wire, and sewing or gluing down the folded edge to hold the wire in place.
[0003] This type of construction provides a ribbon that will retain its shape when bent, but which suffers from several significant disadvantages.
[0004] The folded edge in these known ribbons produces an unsightly seam, which gives the ribbon a definite front and a back, and which makes if more difficult to fashion the ribbon into pleasing shapes.
[0005] When the fabric edge is sewn down, the wire is only loosely held within a fabric sleeve, and thus it can move apart from the ribbon. This makes it more difficult to shape the ribbon, and a sliding wire can result in excess wire at one end of the ribbon and no wire at the other end. The sliding wire also makes the ribbon more difficult to control, and the ribbon is less likely to retain its shape over time. Side to side slippage of the wire can also cause undesirable bunching and/or buckling of the fabric.
[0006] Similar problems arise when glue is used. Although some glues may help keep the wire firmly in place, in general the bond is weak and cannot withstand the stress of normal use. Thus, the wire will eventually separate from the glue and ribbon over time, or when the ribbon is bent, twisted or tied in use. In addition, the application of the glue and the remove of excess glue results in significant production and quality control problems. For example, excess glue can deface the fabric ribbon, and glues of sufficient strength to hold the wire in place can degrade the fabric.
[0007] Another known method involves loosely sealing a wire between two laminated and/or embossed surfaces, which disadvantageously requires the use of two independent fabric surfaces. These ribbons typically are bulky and have an unsightly rear face. Additionally, the two surfaces have a tendency to separate, which defeats the purpose of having a reliable wired ribbon.
[0008] In view of these disadvantages, a need has arisen for an improved decorative wired ribbon, especially one that provides a firm and integral union of fabric and wire, without the undesirable folds, seams and glue of prior ribbons.
SUMMARY OF THE INVENTION
[0009] Accordingly, it is an object of this invention to overcome the disadvantages of known wired ribbons, by providing a fabric or plastic tubular ribbon edged with wire and bound with trim, so that the wire is hidden from view and yet is firmly affixed to the ribbon without folds, seams or glue.
[0010] It is also another objective of the invention to show that after the ribbon has been made tubular it can be filled with electric lighting or any other product that allows for bending and shaping and creating a decorative tube or ribbon.
[0011] It is also another objective of the invention to provide a method of making tubular ribbons edged with wire and bound with decorative trim.
[0012] It is yet another objective to provide an apparatus for making the tubiform ribbons of the invention.
[0013] In accordance with one aspect of the present invention there is provided a tubiform wired ribbon that includes a first layer of ribbon material having a first edge and a second edge and a second layer of ribbon material having a first edge and a second edge. The first and second layers overlay one another such that their respective first and second edges are in substantial alignment and form a first ribbon edge and a second ribbon edge, respectively. The tubiform wired ribbon also includes a first wire filament aligned longitudinally adjacent the first ribbon edge. The first wire filament is attached to the ribbon by a first trim filament looped around said first wire filament and the first ribbon edge and a first binding filament that passes through the first and second layers of ribbon material for securing the first trim filament to said first and second layers of ribbon material adjacent the first ribbon edge. In this manner the first wire filament is held in place along said first ribbon edge and the first edges of the first and second layers of ribbon material are bound together. A second wire filament is attached to an opposite edge of the ribbon in the same manner.
[0014] In a preferred embodiment of the tubiform wired ribbon according to this invention, a decorative insert, such as string of electric lights, is provided between the two layers of ribbon fabric.
[0015] In accordance with a second aspect of the present invention there is provided an apparatus for making a decorative tubiform wired ribbon. The apparatus includes a stitching apparatus that has a work plate, a needle, a filament looper, and a needle plate disposed within and generally coplanar with the work plate. The needle plate is positioned above the filament looper and for the needle to pass therethrough. The needle plate has a tine that extends in a stitching direction. The apparatus also includes means for feeding a tubiform wired ribbon as set forth above through the stitching apparatus and means for drawing the tubiform wired ribbon through the stitching apparatus. A feed tube is mounted on the stitching apparatus adjacent to the tubiform wired ribbon feeding means so that a decorative insert can be inserted into the tubiform wired ribbon as it is drawn through the stitching apparatus.
[0016] In accordance with a further aspect of the present invention there is provided a method of making a decorative tubiform wired ribbon. The method includes the step of overlaying a first ply of a ribbon fabric having first and second edges and a second ply of a ribbon fabric having first and second edges such that the first and second edges of each ply are substantially aligned. The said first and second plies thus form a layered ribbon. A first wire filament is positioned along the first edge of the layered ribbon and is attached to the first edge of the layered ribbon in a continuous operation as follows. A first trim filament is looped around the first wire filament and the first edge of the layered ribbon and a first binding filament is passed through the layered ribbon to secure the first trim filament to the layered ribbon adjacent the first edge thereof. In this manner, the first wire filament is held in place along the first edge of the layered ribbon and the first edges of the first and second layers of ribbon fabric are bound together.
[0017] The invention and specific examples and embodiments thereof are further described in connection with the following drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The foregoing summary as well as the following detailed description of a preferred embodiment of the present invention will be better understood when read with the appended drawings, wherein:
[0019] [0019]FIG. 1 is a schematic view of a tubiform ribbon according to the present invention showing the arrangement of the wire filament, the trim filament, and the binding filament along one edge thereof;
[0020] [0020]FIG. 2A is a schematic diagram showing an arrangement for guiding the fabric as it is fed toward a stitching machine;
[0021] [0021]FIG. 2B is a side elevation view of the fabric guide shown in FIG. 2A;
[0022] [0022]FIG. 3 is a perspective view of a stitching apparatus according to the present invention;
[0023] [0023]FIG. 4 is a top plan view of a needle plate used in the stitching apparatus of FIG. 3;
[0024] [0024]FIG. 5 is a side elevation view of the needle plate shown in FIG. 4 with the wire filament adjacent thereto;
[0025] [0025]FIG. 6 is a bottom plan view of the needle plate shown in FIG. 4;
[0026] [0026]FIG. 7 is a perspective view of a tubiform ribbon according to the present invention that is assembled on one side only;
[0027] [0027]FIG. 8 is a perspective view of a stitching apparatus according to this invention showing the process of encapsulating a strand of lights within the tubiform ribbon; and
[0028] [0028]FIG. 9 is a plan view of a section of tubiform wired ribbon according to the invention including a string of electric lights inserted therein.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The tubiform ribbon of the invention is fabricated with two or panels pieces of fabric, a wire filament, at least one decorative or trim filament, and at least one binding filament. The trim and wire filament are firmly bound and affixed to the fabric by the binding filament. In a preferred embodiment, this is achieved in one simultaneous and continuous operation. Also, the binding filament is preferably chosen and the trim filament is applied in a size, quantity and manner such that the wire filament and binding filament are both substantially or even completely hidden by the trim filament. The tubiform ribbon may also include a decorative insert such as a string of electric lights encapsulated therein.
[0030] This arrangement provides a seamless stitched border that holds the wire filament in place without slippage, and without intermediate folding, gluing, embossing or laminating steps. The seamless stitched border can be formed in a single continuous operation.
[0031] The ribbon fabric can be any known fabric, either textile or plastic, and either flat or pleated.
[0032] Preferred finished ribbon sizes according to the invention are widths of 4″, 6″, 10″ up to 45″.
[0033] Pleated fabric can be obtained from flat fabric, for use in this invention, according to known means of pleating or texturing fabrics. Typically, a flat fabric is run through a pleating machine that is provides with knives. The fabric is scored with the knives, to produce the textured or pleated effect, which is preserved by heat treating the scored fabric to a temperature of about 250-300° F. The pleated fabric is sandwiched between holding paper and rolled for storage, so that the pleats retain their shape without damage.
[0034] The wire filament can be any flexible filament that will hold its shape without breaking when bent or twisted. The preferred wire filament of the invention is galvanized steel, which can range in gauge from about 20 to 32. The wire filament should be both strong and light, and the preferred size for ribbons ranging in width from 4 to 45 inches, is gauge 20 galvanized steel wire.
[0035] The trim filament of the invention can be any known decorative thread of a suitable strength and thickness, which can be wound around the wire filament and through the fabric on a needle, without breaking or snagging, and with enough weight and body to substantially or completely cover the wire filament. Metallic threads are particularly suitable, especially those comprising a metallic strand wrapped with one or two nylon strands. It has been found that a metallic strand that is {fraction (1/69)}th of an inch thick, or about 150 gauge, that is wrapped with one, or preferably two strands of 70 denier nylon strands is especially preferred. Non-metallic threads can also be used. According to the invention, threads ranging in thickness from {fraction (1/100)}th to {fraction (1/50)}th of an inch, and wrapped with one or two strands (or ends) of nylon ranging from 50 to 90 denier can be used.
[0036] The binding filament can be any filament chosen for strength and light weight, and preferably is one strand of monofilament ranging in thickness from 0.005 mil. to 0.009 mil. The preferred monofilament is 0.007 mil. in thickness.
[0037] The novel decorative ribbon of the invention is made by binding the wire filament and the trim filament to the fabric ribbon with the binding filament in one operation that both fixes the wire to the edge of the fabric, and hides the wire from view by covering it with turns of trim filament. This is done on a feed-driven stitching machine that is specially modified according to the invention, as further described below. Thus, the stitching machine supplies the fabric ribbon with a coextensive length of wire filament that is simultaneously bound to the fabric by the binding filament and covered over by the trim filament.
[0038] Referring now to the drawings, wherein like reference numerals refer to the same components across the several views, and in particular to FIG. 1, there is shown a portion of a tubiform ribbon including an edge wire secured according to the present invention. The ribbon 10 includes a first ply 10 a and a second ply 10 b having edges 11 a and 11 b respectively. An actual edge 11 of ribbon 10 is formed by the alignment of edges 11 a and 11 b . In this particular embodiment, a galvanized steel wire filament 12 is positioned along the actual edge 11 of the ribbon 10 . The wire filament 12 is secured to the ribbon 10 by a sewing stitch, such as the purl stitch shown. In this embodiment, the stitch includes two filaments, a decorative trim filament 18 and a binding filament 20 .
[0039] The purpose of the trim filament 18 is to substantially or entirely cover the wire filament 12 and the actual edge 11 , thereby providing a clean, continuous and decorative edging to the ribbon 10 . This can be achieved, as shown, by applying the trim filament 18 in a curved serpentine fashion over both the wire filament 12 and the actual edge 11 of the ribbon 10 . The serpentine shape of the trim filament includes loops 22 .
[0040] During the stitching process, the binding filament 20 pierces the ribbon 10 and inter-weaves through the serpentine loops 22 of the trim filament 18 to bind the trim filament 18 to the ribbon fabric. The binding filament 20 is kept taut during the stitching process, and the trim filament 18 and the interposed edge portion of the ribbon are pulled into engagement with the inner wire filament 12 . In this way, the decorative trim filament 18 becomes substantially wrapped around the otherwise exposed edge 11 and the ribbon 10 , all of which are securely bound together by the binding filament 20 . Thus, the tight stitch created by the binding and trim filaments, acting together, not only secures the wire filament 12 to the ribbon 10 , but also provides a decorative edging to the ribbon 10 . In a preferred embodiment, the binding filament is a natural monofilament, chosen for its strength and also to be effectively invisible. This allows the trim filament to be prominently seen, so that the ribbon is provided with a securely wired and decorative edge.
[0041] A similar arrangement of wire filament, decorative or trim filament and binding filament is applied in a similar manner to the opposite edge of ribbon 10 . In this way the resulting tubiform ribbon product has a tightly secured hidden wire filament 12 along each edge of the ribbon material to support the ribbon's shape, and a decoratively disguised stitch that provides an attractive edging on each side of the ribbon.
[0042] [0042]FIG. 7 shows a portion of a partially finished ribbon according to the invention having one edge wired, and stitched together.
[0043] Additionally, the present invention provides an improved adaptation to a conventional high speed stitching machine to create the secured wire ribbon-edge arrangement of the present invention. Two examples of conventional high speed stitching machines are the Merrow High Speed Trimming & Overseaming Machine manufactured by the Merrow Company of Hartford, Conn., and the Pegasus S32 manufactured by the Pegasus Sewing Machine Manufacturing Co., Ltd. of Osaka, Japan.
[0044] Referring now to FIG. 3, the stitching machine 30 which is adjacent to guide rollers 32 includes a work plate 34 for supporting the ribbon 10 . The machine 30 also includes a moveable sewing needle 36 , a feed carrier 38 for feeding the ribbon 10 , and a needle plate 40 , which is recessed into and generally coplanar with the work plate 34 .
[0045] The guide rollers 32 are preferably power driven using conventional methods so that the ribbon 10 is drawn from the work plate 34 of the stitching machine 30 in synchronization with the stitching operation. The purpose of the rollers 32 is to maintain tension and prevent buckling in the ribbon 10 during stitching and after it has been stitched. If the ribbon 10 is not pulled from the stitching machine 30 , the stitch can become distorted or otherwise uneven and unattractive and the various elements of the invention, such as the ribbon, wire and filaments, will not be secured in a satisfactory manner.
[0046] The drive speed of the rollers 32 is dictated by the feed rate established by the internal feed carrier 38 , typically protruding from within the needle plate 40 . The feed carrier 38 pulls one ply of ribbon material 10 a from an upper supply roll 61 and a second ply of ribbon material 10 b from a lower supply roll 62 as shown in FIGS. 2A and 2B. As the two-plies of ribbon material 10 a and 10 b are drawn into the stitching apparatus 30 , they are pulled through a pair of guide bars 65 and a pair of guiders 66 , to vertically and horizontally align the two-plies for stitching. It is conventionally known that the drive speed of the guide rollers 32 and the feedrate of the feed carrier 38 should be matched during high speed edge stitching so that the ribbon 10 can be drawn from the supply rolls, stitched, and drawn in a smooth flow. The ribbon may subsequently be drawn onto a collection roll, or some other means of storage.
[0047] A typical edge stitch comprises two filaments of thread. One thread is usually supplied to the fabric, which in this case is ribbon 10 , by “loopers” from below the needle plate 40 , while the other thread is fed to the needle 36 from above the needle plate 40 . In the process according to the present invention, the first thread below the needle plate 40 is preferably the trim filament 18 and the second thread, which is fed to the needle above the needle plate 40 , is preferably the binding filament 20 . The normal operation of the stitching machine 30 provides a conventional stitch by interweaving the binding filament 20 with the trim filament 18 , as further described below.
[0048] In accordance with another aspect of the present invention, a wire filament 12 is provided within the ribbon 10 , before the stitch is produced by the stitching machine 30 . An apparatus according to the present invention includes a needle plate 40 which has been modified such that a wire filament 12 can be guided and applied in a controlled manner onto the ribbon 10 during the stitching process. The needle plate 40 of the present invention is shown in FIGS. 4 - 6 . The needle plate 40 includes a top portion 42 having fabric engagement teeth 44 , a feed carrier access slot 46 , a fabric support tine 48 for supporting the fabric adjacent to the moving needle, and a needle stitching slot 49 . The needle plate 40 also includes a side portion 50 and a bottom portion 52 . The side portion 50 includes a side groove 54 along the side of the support tine 48 . The side groove 54 is of proper dimensions to effectively guide a sliding wire filament 12 of a chosen size from a wire filament source to the ribbon 10 , specifically along the ribbon's edge. A similarly shaped bottom groove 56 is disposed substantially inline with that of the side groove 54 . As shown in FIG. 5, the wire filament 12 is guided by both side and bottom grooves without stress or deformation. The wire filament 12 is first guided from its source, and under the work plate 34 by the bottom groove 56 along the bottom portion of the needle plate 40 and then, by the side groove 54 along the side of the support tine 48 adjacent to the top portion of the needle plate 40 where it is easily positioned on the ribbon's edge 11 and secured to the ribbon 10 during the stitching process.
[0049] In operation, a supply of an appropriate decorative trim filament 18 and a supply of binding filament 20 are loaded in a conventional manner into a standard stitching machine, like the preferred Merrow or Pegasus machine. The wire filament 12 is fed through the needle plate 40 , guided by both the side groove 54 and the bottom groove 56 and is ultimately drawn with the ribbon by the rollers 32 . The ribbon 10 is positioned in a conventional manner onto the work plate 34 of the stitching machine 30 . The previously described stitch is then produced around the edges and the enclosed wire 12 . The stitching process creates the necessary pull required to ensure tight engagement between the wire filament 12 and the ribbon 10 .
[0050] The tightness of the stitch can be regulated by adjusting the cams of the stitching machine. In a preferred embodiment, the cams are adjusted so that the trim filament is wrapped tightly, with each turn of the filament just touching or overlapping each adjacent turn, so that the wire and the edge of the ribbon are covered over. It will also be appreciated by skilled practitioners that more than one trim filament or binding filament can be used.
[0051] Preferably, one or two trim filaments is used and one binding filament is used.
[0052] An alternative method of binding the edges of the two-ply ribbon may be used. In the alternative technique a strip of fabric is folded over the edge of the decorative ribbon so as to straddle the wire filament and the edges of the fabric layers. The strip is drawn along with the ribbon by the stitching machine and stitched so that the wire filament is encapsulated and the edges of the ribbon fabric are bound together. The strand is stitched to the ribbon with a binding filament in a similar manner as previously described using a single needle stitch. If desired, one or more trim filaments may be stitched to the fabric along with the binding filament. The width of the fabric strand is preferably about ¼ inch, such that when folded it overlaps the edge of the decorative ribbon by approximately ⅛ inch. However, any width of strand may be used as would be desired depending on the particular application.
[0053] The above procedure is then duplicated, with modifications as described following, to stitch the opposite edge of the ribbon 10 and complete the tubiform wired ribbon. In this stage of the process, the decorative insert is encapsulated between the two plies of the ribbon fabric. Preferably, the decorative insert is a string of lights. However, other inserts could be used such as a string of LED's, confetti, glitter, or decorative shapes. If desired a decorative ribbon or yarn could be inserted. Of course, combinations of such decorative inserts could also be used.
[0054] Referring now to FIG. 8, the process for performing the closing and encapsulating steps utilizes the same sewing equipment described above. A tubular member 50 is disposed at the front of the sewing machine to allow a string of electric lights 52 to pass inside of the two-ply ribbon while the fabric or plastic surrounds the tubular member 50 leading it toward the sewing machine 30 . Tubular member 50 is mounted on a spring loaded holder 51 , which is pivotable so that tubular member 50 may be rotated out of the way for non-encapsulating stitching processes.
[0055] The stitching apparatus 30 closes the second edge of the ribbon 10 by the same procedure as described above, thereby encapsulating the light string 52 within the tubiform ribbon. A section of the completed ribbon is shown in FIG. 9.
[0056] The tubiform wired ribbon was created to form a new decorative ribbon product with electric lights or other decorative insert to create a dynamic and unique product electric wired ribbon. This product can be used indoors and outdoors when fabricated from plastic. All lights are and should be UL approved for indoor and outdoor applications. All plastic fabric utilized in the decorative ribbon according to this invention is preferably water-proof, mildew-proof, and fade resistant. Fabrics other than plastic should be specially treated for flame-retardancy and used in conjunction with UL approved lighting.
[0057] While the present invention has been described in terms of the foregoing exemplary embodiments, variations within the scope and spirit of the present invention as defined by the claims following will be apparent to those of ordinary skill in the art. | This invention relates to decorative tubiform wired ribbon and to a method and machine for making such ribbon. More specifically, a tubiform fabric or plastic ribbon is described that is edged with wire and trimmed with an overlay of decorative thread. The ribbon may also include a decorative insert such as a string of electric lights. According to the invention, the decorative ribbon is formed from two-plies of fabric that are edged with wire and tightly bound with a binding filament and a trim filament. The ribbon according to this invention is formed using a two-step process. The result is a unique tubiform construction, which has many desirable properties. The tubiform ribbon made in accordance with the invention is flexible, but will retain its shape when bent, twisted, or tied into a desired configuration. It is elegantly simple in design and provides a unique streamlined finished product with components that are firmly bound together. A method and an apparatus for making the tubiform wired ribbon are also described. | 3 |
RELATED APPLICATIONS
[0001] The present application is related to and claims priority from U.S. Provisional Patent Application Ser. No. 60/977,222 filed on Oct. 3, 2007.
FIELD OF THE INVENTION
[0002] The present invention relates generally to an incentive/awards program for a defined customer group. Specifically, the present invention relates to a method and system that monitors customer activity within a customer portfolio, preferably at regular intervals, to determine if predetermined criteria is met. The customers that have met the criteria are qualified to participate in an award giveaway, and the system then selects at least one award winner from among the qualified customers. The predetermined criteria is selected to provide incentives for customers to act responsibly and manage their affairs in a reasonable manner. By providing a recurring customer award program based on carefully selected criteria related to account activities, the present invention creates an incentive/awards program in a manner that generates customer enthusiasm and promotes responsible customer activity.
BACKGROUND OF THE INVENTION
[0003] To create loyalty and entice certain activities customer award programs are implemented by many different organizations. One example of such a customer awards program exists in the credit card industry where customers obtain points for card usage. The points are then redeemable through some means for specific products or awards of cash or credit. These programs provide an incentive for customers to continue using their cards and being active members of the account portfolio.
[0004] Other awards programs in the credit card field are based on either the individual customer's annual card usage—resulting in a year-end reimbursement—or a specific purchase made with the card—resulting in a free purchase. In other industries, products or services are awarded as prizes or rewards for loyalty or continued purchases. For instance, it is common for airlines to award “miles” to its customers as a reward for flying, such that the miles are redeemable for free or discounted travel services. Similarly, retail stores may award points to members of a loyalty program for their purchases, where the points may be used for products at the store.
[0005] All of these programs are based on the customers' personal transactions; i.e., the amount “awarded” is based on each individual customer's purchases. For instance, an individual's credit card may reimburse 0.5% of his or her purchases at the end of the year through cash/credit/points. Likewise, customers receive the points or miles as described above based on each customer's individual purchase activity.
[0006] Each of the above referenced programs provide effective programs to entice customers to continue utilizing their accounts. For the typical card customer, this provides options and opportunities for them to participate in a rewards program that is appealing. Once a member of a particular card portfolio, the continued use of the card provides the account holder with the desired award, or the potential for receiving the desired award.
[0007] For certain customers these awards/incentive programs are not effective because they do not have the opportunity to participate at a necessary level. Specifically, in the “sub-prime” market, cardholders typically have very low credit limits, and have limitations on card activity within a particular time period. Often, the customers in this market have poor credit, due to some mishap, or have not yet developed a credit history. For example, students and younger people often have not had the opportunity to hold credit accounts, thus making them higher risk customers. As another example, customers may have had financial difficulties resulting in bankruptcy or some other negative event. In these situations, the typical awards/incentive programs are not practical or feasible due to the limitations placed on the account. For example, a cash-back award of 0.5% of transactions, where the cardholder is limited to $300.00/month in charges would result in a potential payback of $1.50 per month, providing that the cardholder can repay the $300/month charges at the end of each month. This level of payback is not likely to provide an incentive to most customers.
[0008] There is therefore a need for a system and method which would reward customers in a manner that creates the potential for meaningful and substantial rewards. There is also a need for a system and method for rewarding customers that use their credit card responsibly. There is also a need for a system and method for rewarding customers that occurs at frequent, regular intervals, not just annual, seasonal, or ad hoc periods. In particular, there is a need for a system and method for administration of a rewards program that generates excitement and “buzz” by offering customers regular opportunities to win award values greater than a percentage of each individual customer's transactions. There is a further need to generate a rewards program that provides incentives for responsible use and management of a credit account. The present invention is directed toward meeting these needs.
SUMMARY OF THE INVENTION
[0009] For these reasons, one object of the present invention to provide an awards program that creates excitement, entertainment, and anticipation for customers while also providing incentives to act in a responsible manner. More specifically, a system and method is provided for rewarding customers by creating the possibility of winning significant awards, substantially greater than a percentage of each individual customer's transactions. It is a further object of the present invention to provide a system and method for rewarding customers at frequent, regular intervals, based upon the responsible actions of the customer. It is yet another goal of the present invention to provide a system and method for rewarding customers in a manner that generates enthusiasm and customer loyalty while providing incentives for the customer to act responsibly.
[0010] To meet these objectives and goals, the present invention provides a random entertaining incentive/reward program for those involved. In its most basic terms, this involves the periodic award of prizes to a defined customer group, based upon those customers meeting a defined criteria. In order to provide additional anticipation and excitement, the award itself is substantial when compared with existing account activity.
[0011] One method of practicing the present invention includes the initial step of acquiring or defining a customer group. As an example, the customer group may include the holders of a particular credit card, the holders of a retail loyalty card (clothing stores, gas stations, resorts, etc.), or members of travel groups, such as airline frequent travelers and hotel preferred customers. The process of defining the particular customer group depends on the sponsoring organization or the type of activity that is desirable for the sponsoring organization and thus worth rewarding. For instance, the sponsoring agency may be a credit card company that is issuing cards to high risk individuals, individuals who have had a “credit accident” or individuals who have not established a credit history (e.g. students and younger people). In that situation, the sponsoring agency is trying to promote good credit practices such as on-time payments and no charges over the customers credit limit. Given these goals, the account group can thus be appropriately defined.
[0012] Once the customer group is identified and defined, customer activity information for an interval of predetermined length is aggregated and stored. The customer activity information is then reviewed to determine which customers are eligible to participate in a monthly reward program. Based upon this analysis, a number of entries are given to each qualifying customer. The number of entries may be determined a number of ways, but are generally directed toward the responsible management of the customers account. For example, entries may be awarded for each on-time payment or for full payment on account. Further, the number of entries could be proportional to the amounts paid in each on-time payment. At the completion of a defined time period, a winner is selected from the eligible customers using a predetermined criteria. In one example, the award winner may be randomly selected from the group of qualified customers. Alternative selection methodology could be used, such as regional selection of multiple award winners, or any other criteria directed toward motivating the desired behavior. The reward is also defined prior to the selection of the winner and may be granted as either cash, credit, gift card, debit card or products/services. Cash and credit rewards may be presented in either a lump sum or installments at the discretion of the rewards program operator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic block diagram illustrating the information flow between parties according to one embodiment of the present invention;
[0014] FIG. 2 is a flow chart illustrating the steps used to implement one embodiment of the method of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0015] As described above, one feature of the present invention is the opportunity for customers to participate in a rewards program and potentially to receive a substantial award. Further, the opportunity is recurring, which creates continuous excitement for as long as the customers remain in good standing and involved with the program. The system and award program of the present invention is also capable of being tailored toward a specific customer base to ensure that the awards are appropriate to the targeted customer group. In addition, the rewards program provides incentives for customers to act in ways that are responsible and desirable to the sponsoring agency.
[0016] FIG. 1 illustrates the information flow between the relevant parties according to one embodiment of the present invention. A plurality of portfolios 10 each include a plurality of customers 14 . Each portfolio 10 includes a group of customers with some common interest or association. In this embodiment, the customer group will likely be high-risk credit customers potentially including those who have had some type of “credit accident” (e.g. bankruptcy, foreclosures, adverse judgments, etc.) Further, young people may be included in this program as they typically have not developed a credit history.
[0017] The activities of each customer 14 are monitored and stored by an awards program system 18 as described in more detail herein. In the credit card context, the customers 14 complete transactions with a plurality of merchants 12 via common point-of-sale terminals, which collect transaction data and transmit the data to a credit card issuer system 16 . The credit card issuer system 16 uses a transaction database 24 to store the transaction data and uses the transaction data to manage the customer accounts, which are stored in a credit card customer database 22 . The credit card issuer system 16 also communicates with customers 14 by issuing regular statements and other communication methods. In addition, credit card issuer system 16 monitors payment and credit actively from the customer 14 as a part of the transaction data that is monitored. This payment information is also stored in credit card customer database 22 and transaction database 24 .
[0018] Relevant portions of the customer information and transaction data are provided to the awards program system 18 for purposes of managing and administering the awards program. The awards program system 18 maintains account information for each customer 14 in an awards program participant database 28 . The information received from the credit card issuer system 16 may include customer 14 identification information, dollar amounts charged during a predetermined period, payments during the predetermined period and customer eligibility information. This information is utilized to determine which customers are eligible to participate in the award program, based upon established criteria. Those customers who meet the criteria are awarded entries, again governed by the criteria previously established. The account information and related entry information is stored by the awards program system 18 in an entries 26 database.
[0019] Processor 30 of the awards program 18 determines an award winner from the eligible customers 14 based on a predetermined award criteria. The awards program system 18 then provides award notification and/or payment information to the appropriate customer 14 . The awards program system 18 may also provide such information to the credit card issuer system 16 and sponsoring organization 20 where appropriate.
[0020] With the system architecture described above, the operation of the system is now explained. Referring now to FIG. 2 , one embodiment of the present invention first defines customer portfolios, step 100 . A sponsoring organization 20 may engage the awards program system 18 to administer an awards program. In conjunction with a credit card issuer system 16 , such as a banking institution, the awards program system 18 offers credit cards to potential customers, who then open credit card accounts with the credit card issuer 16 . The appropriate customer 14 personal information, credit information, and account information is stored in the credit card customer database 22 of the credit card issuer system 16 . Because the act of opening an awards program credit card potentially makes the customer 14 an awards program participant, the awards program system 18 will also store the necessary customer 14 information in the awards program participant database 28 .
[0021] The participating customers may be acquired through both traditional and non-traditional credit card acquisition channels, customer group enrollment, existing customer groups, in store sign-ups, etc. These channels may include, but are not limited to: direct mail, telemarketing, print advertisements (e.g. inserts, “take ones”), electronic advertisements (e.g., Internet, television), public relations, event marketing, call center transfer programs, branches, and agents. Additionally, targeted marketing toward predetermined groups or organizations (both existing and new) may be undertaken. As is well-known, potential customers may be rejected from an awards-program card based on a variety factors, such as bankruptcy score, risk score, demographic credit bureau information, and/or behavior screens. Given the particular features of the awards system, it is anticipated that fewer rejections will occur however, for reasons more fully outlined below.
[0022] At step 110 , customer activity is tracked. Customers 14 who sign up for the awards program conduct credit card transactions with merchants 12 via common point-of-sale terminals, which collect transaction data and transmit the data to the credit card issuer system 16 during a predetermined period. The customer transaction activity information is stored in the transaction database 24 as the information is received by the credit card issuer system 16 from the merchant 12 . Typically this information is transmitted electronically from the merchant 12 to the credit card issuer system 16 . The credit card issuer system 16 will also track payment and credit information as these activities occur.
[0023] Once the appropriate information is received and processed by the credit card issuer system 16 , a subset of that information is sent electronically from the credit card issuer system 16 to the awards program system 18 . The customer activity information that is transmitted from the credit card issuer system 16 to the awards program system 18 may include a customer's 14 individual activities immediately after completion, or each customer's 14 total activity amounts for the entire predetermined period. The predetermined period may be as long or short as desired, however, it is the regularly-occurring nature of the award that creates anticipation and loyalty by participating customers, thus a regular interval is desirable. Typically, this predetermined period will be consistent with the time period used for mailing account statements to participating customers. As is appreciated by credit card users, this is typically done monthly. The customer activity information received by the awards program system 18 is stored in the customer activity/entries database 26 and, if necessary, associated with the appropriate customer information in the awards program participant database 28 .
[0024] In step 120 , at the conclusion of the predetermined period, the awards program system 18 determines which customers 14 are eligible to win the award based on customer standing. The customers' eligibility may depend on a variety of factors involving responsible credit behavior. For instance, the group of eligible customers may include may include all customers except those who have a negative account status, are delinquent or in default, or have had no activity for the relevant period. Similarly, the group of eligible customers may include those who have made on-time payments in the last period and may include those who have not exceeded their credit limit. Further, the group of eligible customers may include those who have received a credit line increase due to responsible credit management. For example, a customer who receives a credit line increase from $300 to $500 resulting from good credit behavior, could receive 200 additional entries as a reward for that good behavior. The sponsoring organization may establish any criteria to determine customer eligibility, and eligibility requirements are easily designed and implemented depending on the desires of the sponsoring organization.
[0025] In step 130 , the processor 30 of the awards program system 18 selects a winning customer from among the eligible customers for the predetermined time period. In selecting a winning customer, several mechanisms may be implemented. For example, each eligible customer may be assigned an equal probability of being selected as the winner. Alternatively, each eligible customer may be assigned a weighted probability of being selected as the winner that is proportionally based on that customer's payment activity for the relevant period. For instance, each dollar paid, whereby payment lessens the customer's outstanding amount owed, may constitute an “entry” ($1=1 entry) such that each “entry” constitutes an opportunity to win. In that case, a customer who pays $200 during a period would have twice the probability of winning than a customer who paid $100 during that period and such an incentive to encourage payment results in good credit behavior. Alternatively, each customer may automatically receive one “entry” per period, with each dollar paid resulting in an additional entry.
[0026] In an embodiment where participating credit cards are implemented, the processor 30 determines the total number of eligible customers and identifies those customers (designated as C 1 , C 2 , C 3 . . . C n where n=total number of eligible customers). Next, the payment activities related to the participating credit cards are monitored for each customer. The net payments (NP) are then calculated for each eligible customer by combining payments (P) and returns (R):
[0000] NP =ΣP x +ΣR x (for customer C x , where C x is one of the customers C 1 . . . C n )
[0027] In the example where each customer is awarded an entry for each payment, the payments for customer C x is typically rounded to the nearest dollar. The process of calculating Net Payment is performed for each individual customer, C 1 . . . C n . Based on each calculated “Net Payments,” the customers are then assigned one entry (E) for each dollar calculated.
[0028] In order to determine the winning customer, each individual customer is assigned a set of unique entry numbers such that the total number of entry numbers assigned to a customer corresponds to the number of entries for that customer during the predetermined time period. For example, the unique entry numbers may be selected from the range: 0 . . . Total Entries-1. The winner is ultimately chosen using a standard random number generator which randomly generates a decimal number (RNDM) between zero (0) and one (1). The winning entry number is determined by:
[0000] Winning Number= INT ( RNDM *Total Entries)
[0029] As shown in the equation above, the winning number will be a randomly generated integer between 0 and the number of total entries less 1. With each eligible customer having a unique set of entry numbers, the above determined winning number will be previously associated with one customer. Thus, this allows for the identification of the winning customer.
[0030] In one embodiment, the reward may be a straight cash or credit award of that is a predetermined amount. Similarly, a gift card could easily be used. In an alternative embodiment, the award may be a product or service provided to the winning customer. For instance, the customer may be awarded products such as consumer electronics or household goods, or the customer may be awarded points in a larger rewards program.
[0031] Once the winner has been selected, step 130 , the award is granted to the winning customer 14 , in step 140 . If the award is a lump sum payment to the customer 14 , the amount is dispersed to the customer via cash or credit. This amount may be provided either directly from the awards program system 18 to the winning customer 14 , or, alternatively, the awards program system 18 may provide the necessary information to the sponsoring organization 20 or the credit card issuer system 16 and allow the winning amount be dispersed from the latter to the winning customer 14 . Other attendant actions may accompany the step of granting the award, step 140 . For instance, the winning customer or the specific award may be published via media statements.
[0032] Those skilled in the art will further appreciate that the present invention may be embodied in other specific forms without departing from the spirit or central attributes thereof. In that the foregoing description of the present invention discloses only exemplary embodiments thereof, it is to be understood that other variations are contemplated as being within the scope of the present invention. Accordingly, the present invention is not limited in the particular embodiments which have been described in detail therein. Rather, reference should be made to the appended claims as indicative of the scope and content of the present invention. | The present invention relates generally to a credit card holder awards system and method. The system and method is set up to “reward” responsible management of accounts and good credit practices. Specifically, the method and system monitors customer activity at defined intervals, selects an award winner from among the qualified customers based on a predetermined criteria and provides the predetermined award to the winning customer. The predetermined criteria used in the present invention relates to payments and good credit practices in order to allow users to develop a favorable credit history. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an air conditioner having a refrigerant heater.
2. Description of the Related Art
A conventional heat-pump air conditioner has the drawback that the heating capacity decreases as the outdoor temperature falls. An air conditioner having a refrigerant heater is known, which overcomes the drawback and in which a refrigerant heater such as a gas burner heats the refrigerant and cooperates with a heat pump to perform heating operation.
The air conditioner of the conventional type having a refrigerant heater will be described with reference to FIG. 1. As shown in FIG. 1, the air conditioner has a refrigeration circuit including compressor 1, four-way valve 2, outdoor heat exchanger 3, check valve 4, expansion valve 5, indoor heat exchanger 6, and check valve 7, all connected in this order by pipes. Electromagnetic valve 8 and refrigerant heater 9 are connected by pipes and arranged between the refrigerant suction pipe of compressor 1, on one side, and the node connecting check valve 4 and expansion valve 5, on the other side.
Refrigerant heater 9 has gas burner 10 for heating the refrigerant. Gas burner 10 is connected to the fuel source (not shown) by proportional control valve 11.
Outdoor fan 12 for circulating the outdoor air is arranged near outdoor heat exchanger 3, and indoor fan 13 for circulating the indoor air is arranged near indoor heat exchanger 6.
During cooling operation, compressor 1 is activated while electromagnetic valve 8 is closed. As a result, the refrigerant flows in the direction indicated by the solid-line arrows, outdoor heat exchanger 3 functioning as a condenser, and indoor heat exchanger 6 as an evaporator.
During heating operation, compressor 1 is activated and four-way valve 2 is switched while electromagnetic valve 8 is opened. In addition, refrigerant heater 9 is operated, i.e, gas burner 10 is turned on. As a result, the refrigerant flows in the direction indicated by the broken-line arrows, indoor heat exchanger 6 functioning as a condenser, and refrigerant heater 9 as an evaporator
In the air conditioner shown in FIG. 1, temperature Tc in indoor heat exchanger 6 is detected. FIG. 2 shows changes of temperature Tc. When the detected temperature Tc exceeds set temperature Ts1, the opening of proportional control valve 11 is narrowed, thereby reducing the degree of the combustion in gas burner 10. Thus, release control is performed so that refrigerant heater 9 generates less heat, preventing the pressure in the refrigeration circuit on the high pressure side from rising extraordinarily.
An air conditioner is also known, which can be set in a hot air blow-off mode. In the mode, indoor fan 13 rotates at a low rate, and hot air is blown off indoors, thereby increasing the indoor temperature satisfactorily.
If the above-mentioned air conditioner having the release control function is set in the hot air blow-off mode is set, hot air is blown off at first; however, as shown in FIG. 3, the temperature Tc of indoor heat exchanger 6 rises to a set temperature Ts1 instantaneously, and the release control is started. As a result, refrigerant heater 9 generates less heat, and warmth is not provided to the user. In addition, since the release control is executed and canceled alternately, the indoor temperature varies greatly, the user cannot have sufficient warm. Thus, it is difficult to perform a comfortable heating.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an air conditioner in which unnecessary release control is prevented when it is set in the hot air blow-off mode, so that the user can have sufficient warmth.
To achieve this object, the air conditioner of the present invention comprises: a heat-pump refrigeration circuit including a compressor, a four-way valve, an outdoor heat exchanger, a pressure reducer, an indoor heat exchanger, connected in this order; a refrigerant heater arranged in the refrigeration circuit, the heating capacity thereof being variable; an indoor fan for circulating indoor air through the indoor heat exchanger; temperature detecting means for detecting the temperature Tc in the indoor heat exchanger; heating operation means for causing the air conditioner to perform heating operation, in cooperation with the compressor, the four-way valve, and the refrigerant heater; release control means for reducing the heating capacity of the refrigerant heater when the detected temperature Tc exceeds a first set temperature Ts1; setting means for setting the air conditioner in a hot air blow-off mode in which the indoor fan rotates at a low rate; and rotation rate control means for controlling the rotation rate of the indoor fan so that the detected temperature Tc is lower than the first set temperature Ts1, while the air conditioner is set in the hot air blow-off mode.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 shows the structure of the refrigeration circuit of a conventional air conditioner;
FIG. 2 is a graph showing operation of a conventional release control means;
FIG. 3 is a graph showing an operation of the conventional air conditioner;
FIG. 4 shows the air conditioner having a refrigerant heater according to a first embodiment of the present invention;
FIG. 5 shows the structure of the refrigeration circuit and the control circuit of the first embodiment;
FIG. 6 is a flow chart showing operation of the air conditioner according to the first embodiment;
FIG. 7 is a graph showing changes of the temperature in the indoor heat exchanger according to the first embodiment;
FIG. 8 is a flow chart showing operation of the air conditioner of a second embodiment; and
FIG. 9 is a graph showing changes of the temperature in the indoor heat exchanger according to the second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An air conditioner having a refrigerant heater according to a first embodiment of the present invention will be described with reference to the accompanying drawings.
As shown in FIG. 4, the air conditioner is constituted by indoor unit 21 and outdoor unit 22 connected to each other. Indoor unit 21 has case 23, which houses indoor heat exchanger 24 and indoor fan 25. Indoor temperature sensor 27 for detecting the indoor temperature is provided near suction ports 26 of case 23. Indoor control section 28, including a microcomputer and its peripheral circuits, is also housed in case 23. It controls the entire air conditioner in response to commands sent from an operation panel (not shown) or remote controller 29. Remote controller 29 includes mode switch 291 for setting the air conditioner in a hot air blowoff mode.
Indoor heat exchanger temperature sensor 30 is provided near indoor heat exchanger 24. It detects the temperature of the refrigerant flowing from or into heat exchanger 24. In accordance with the temperature of the refrigerant detected by sensor 30, the flow rate of air which indoor fan 25 allows to flow is controlled, the pressure on the high pressure side is prevented from rising extraordinarily during the heating operation, and heat exchanger 24 is prevented from freezing.
Outdoor unit 22 has housing 31, in which compressor 32, refrigerant heater 33, and outdoor heat exchanger 34 are arranged. Outdoor heat exchanger 34 is used only during cooling operation of the air conditioner. Compressor 32, refrigerant heater 33, outdoor heat exchanger 34, and indoor heat exchanger 24 are connected by refrigerant tube 35, constituting a refrigerant circuit.
Heat exchangers 24 and 34, and heater 33 are connected in parallel to compressor 32 by four-way valve 36. During heating operation, the refrigerant is discharged from compressor 32 and flows through four-way valve 36, indoor heat exchanger 24, and refrigerant heater 33. During cooling operation, the refrigerant is discharged from compressor 32 and flows through four-way valve 36, outdoor heat exchanger 34, and indoor heat exchanger 24
Refrigerant heater 33 includes heat exchanger section 37, in which the refrigerant flows, connected to refrigerant tube 35. Gas burner 38 and guide duct 39 for guiding combustion gas generated by the combustion of gas burner 38, constitute a combustion chamber. Heat exchanger section 37 is arranged in guide duct 39. The refrigerant flowing through heat exchanger section 37 is heated by the combustion gas flowing through guide duct 39. Combustion fan 40 for supplying air necessary for combustion to gas burner 38 is arranged near the entrance of gas burner 38. Exhaust top 41 is provided on the exit of guide duct 39.
Gas burner 38 is connected by gas supplying tube 42 to fuel gas source 43. In the middle portion of gas supplying tube 42, gas proportional control valve 44 and a pair of electromagnetic valves 45 and 46 are provided for controlling the amount of gas supplied to gas burner 38. These valves 44 to 46 are controlled by controller 47 arranged in housing 31.
Outdoor unit 22 also has entrance heat sensor 48 for detecting the temperature of the refrigerant flowing into refrigerant heater 33, and exit heat sensor 49 for detecting the temperature of the refrigerant discharged from refrigerant heater 33. On the basis of the difference between the temperatures detected by entrance heat sensor 48 and exit heat sensor 49, expansion valve 50 is controlled. In addition, discharge sensor 51 is provided near the discharging port of compressor 32 and detects the temperature of the refrigerant discharged form compressor 32. If the temperature detected by discharge sensor 51 is equal to a set value or higher, the refrigeration circuit is turned off.
Accumulator 52 is interposed in refrigerant tube 35, between the suction port of compressor 32 and refrigerant heater 33.
Out door unit 22 further includes electromagnetic valve 53, check valve 54, and outdoor fan 55.
FIG. 5 shows the refrigeration circuit and the control circuit of the air conditioner shown in FIG. 4. In FIG. 5, to make the explanations simple, indoor control section 28 and controller 47 shown in FIG. 4 are substituted by controller 281. Indoor fan 25 is rotated by motor 25m, the rotation rate of which is continuously controlled by controller 281.
An operation of the first embodiment as mentioned above will now be described. When cooling operation is started in response to the command from remote controller 29, controller 281 activates compressor 32 and causes electromagnetic valve 53 to close. As a result, the refrigerant flows in the direction indicated by the solid-line arrows in FIG. 5, thereby forming a cooling circuit. In other words, outdoor heat exchanger 35 functions as a condenser, and indoor heat exchanger 24 as an evaporator, thus operating indoor fan 25 so that cold air is blown off in the room.
In contrast, when heating operation is started in response to the command from remote controller 29, controller 281 activates compressor 32 and causes electromagnetic valve 53 to open. In addition, four-way valve 36 is operated and refrigerant heater 33 is driven, i.e., gas burner 38 is turned on. As a result, the refrigerant flows in the direction indicated by the broken-line arrows in FIG. 5, thereby forming a heating circuit. In other words, indoor heat exchanger 24 functions as a condenser, and refrigerant heater 33 as an evaporator, thus operating indoor fan so that hot air is blown off in the room.
In the heating operation, controller 281 executes processes shown in the flow chart of FIG. 6. First, it is determined whether a heating operation is performed (step S11). If it is determined that heating operation is performed, the temperature Tc detected by indoor heat exchanger temperature sensor 30 is compared with a first set temperature Ts1 (step S12). If "Tc≧Ts1" is determined in step S12, the amount of fuel supplied to gas burner 38 is reduced by narrowing down the opening of gas proportional valve 44, i.e., the heater 33 generates less heat. As a result, the pressure on the high pressure side of compressor 32 is prevented from extremely rising.
If "Tc<Ts1" is determined in step 12, control section 28 determines whether the hot air blow-off mode is set by mode switch 291 of remote controller 29 (step S14). If it is determined that the hot air blow-off mode is set in step 14, the rotation rate N of indoor fan 25 is continuously controlled so that the detected temperature Tc is equal to a second set temperature Ts2 (Ts2<Ts1) (step S15).
Thus, when the hot air blow-off mode is set by remote controller 29, the rotation rate N of indoor fan 25 is continuously controlled by, e.g. the PID action (proportional plus integral plus derivative action), so that the detected temperature Tc approaches the second set temperature Ts2. By virtue of this control, the detected temperature Tc is kept around the second set temperature Ts2, as shown in FIG. 7. Thus, since the detected temperature Tc is prevented from increasing above the set temperature Ts1, release control is performed only if absolutely necessary. Moreover, since the execution and cancellation of the release control are not repeated, change in the indoor temperature is kept small, thereby enabling comfortable heating.
A second embodiment of the present invention will be described below with reference to FIGS. 8 and 9. The second embodiment has the same structure as that of the first embodiment, except that the rotation rate of motor 25m for driving indoor fan 25 is controlled step by step, by means of controller 281. Hence, descriptions of the structure will be omitted here.
An operation of the second embodiment will now be described. In heating operation, when the air conditioner is set in the hot air blow-off mode by remote controller 29, indoor fan 25 rotates at the low rate initially set (step S21). As a result, hot air is blown off in the room. Then, the temperature Tc detected by indoor heat exchanger temperature sensor 30 is compared with a second set temperature Ts2 (steps S22, S23). First to fourth set temperatures Ts1 to Ts4 has the relationship Ts1>Ts2>Ts3>Ts4, as shown in FIG. 9. While "Tc<Ts2" is determined in step S23, process of steps S22 and S23 are repeated.
As the detected temperature Tc gradually increases as indicated by curve A in FIG. 9, and exceeds the second set temperature Ts2, the controller determines "Tc≧Ts2" in step S23, and the rotation rate N of motor 25m for driving indoor fan 25 is increased by a predetermined rate ΔN each time a predetermined period of time Δt1 elapses (step S24). Then, the detected temperature Tc is compared with the first set temperature Ts1 (step S25). If "Ts≧Ts1" is determined in step S25, the opening of gas proportional valve 44 is narrowed down, thus executing release control in which refrigerant heater 33 generates less heat (step S26). If "Tc<Ts1" is determined in step S25, the detected temperature Tc is compared with the third set temperature Ts3 (step S27). If "Tc>Ts3" is determined in step S27, the process returns to step S24 and the subsequent process is repeated. Thus, When the detected temperature is equal to or higher than the second set temperature Ts2, the control subsequent to step S24 is continued unless the detected temperature decreases to the third set temperature Ts3 or lower.
As the detected temperature decreases by the release control, if "Tc≧Ts3" is determined in step S27, the rotation rate N of motor 25m for driving indoor fan 25 is maintained at a value set when the detected temperature Tc is equal to the third set temperature Ts3 (step S28).
Then, the detected temperature Tc is compared with the fourth set temperature Ts4 (step S29). If "Tc≧Ts4" is determined in step S29, the rotation rate N of motor 25m is decreased by a predetermined rate ΔN each time a predetermined period of time Δt2 elapses (step S30). Thereafter, the processes of step S22 and the subsequent steps are repeated.
If "Tc>Ts4" is determined in step S29, the process returns to step S22. Thus, the processes of step 22 and the subsequent steps are performed after the detected temperature Tc decreases to the third set temperature Ts3 or lower. If the detected temperature is equal to the second set temperature Ts2 or higher, the rotation rate N of motor 25m is increased by ΔN each time when a predetermined period of time Δt1 elapses (step S24).
As described above, in the second embodiment, when the detected temperature Tc rises to the second set temperature Ts2 or higher, the rotation rate N of motor 25m is increased. However, the rotation rate N does not decrease immediately after the detected temperature T becomes lower than the second set temperature Ts2. It decreases when the detected temperature becomes lower than the fourth set temperature Ts4.
In the second embodiment also, as in the first embodiment, since the detected temperature Tc is prevented from rising above the set temperature Ts1, release control is performed only if absolutely necessary. Moreover, since the execution and cancellation of the release control are not repeated, change in the indoor temperature is kept small, thereby enabling comfortable heating.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices, shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | An air conditioner comprising a heat-pump refrigeration circuit including a compressor, a four-way valve, an outdoor heat exchanger, a pressure reducer, an indoor heat exchanger, connected in this order, a refrigerant heater arranged in the refrigeration circuit, the heating capacity thereof being variable, release control for reducing the heating capacity of the refrigerant heater when a detected temperature Tc exceeds a first set temperature Tsl, mode switch for setting the air conditioner in a hot air blow-off mode in which the indoor fan rotates at a low rate during a heating operation. When the mode switch sets the hot air blow-off mode, the rotation rate of the indoor fan is controlled so that the detected temperature Tc is kept lower than the first set temperature Tsl, thereby preventing release control in the hot air blow-off mode. | 5 |
The invention relates to oversampled analog-to-digital converters of the delta-sigma type and, more particularly, to correcting systematic errors arising therein.
BACKGROUND OF THE INVENTION
In a single-ended delta-sigma analog-to-digital converter an error signal is integrated over time to generate an integrator response voltage that is then compared to the reference voltage, which comparison is performed with single-bit resolution at oversampling rate. The oversampled digital response of the converter is supplied to a digital decimation filter, such as afforded by a regularly read and then reset digital counter, to generate the analog-to-digital converter response at normal sampling rate. The oversampled digital response of the converter is also converted to an analog feedback signal voltage, which is differentially combined with the analog input signal voltage in generating the error signal. A commonplace practice is to obtain the analog feedback signal voltage from the output port of a data flip-flop receiving the oversampled digital response at its data input port.
A systematic error in a signed analog-to-digital conversion response occurs when the voltage at the output port of the the data flip-flop switches between two operating supply voltages that do not exactly average to the direct reference voltage. This can occur because the circuitry to develop a reference voltage midway between the two operating supply voltages is kept very simple to keep hardware costs very low. In such case the reference voltage is likely to depart from exactly the average of the data flip-flop output voltage range, which departure will appear as a systematic error in the conversion result.
In digital electronic circuit breakers or in digital electronic power meters, for example, twelve-bit accuracies are sought on the oversampled analog-to-digital converters included therein. These accuracies cannot be achieved when reference voltages are obtained by simple potential dividing circuits.
SUMMARY OF THE INVENTION
The objective of the invention is to permit the source of reference voltage in a signed, single-ended over-sampled analog-to-digital converter to supply reference voltage that departs from optimum value without incurring a systematic error caused by such departure. A method for performing oversampled analog-to-digital conversion of an input signal to generate a conversion result signal essentially free of systematic errors in accordance with the invention includes the steps of: performing oversampled analog-to-digital conversion of the input signal to generate a preliminary conversion result signal accompanied by systematic error, performing oversampled analog-to-digital conversion of a zero-valued signal to generate a correction signal essentially consisting of a corresponding systematic error, and differentially combining the correction signal and the preliminary conversion result signal to generate the conversion result essentially free of systematic errors. In a structural embodiment of the invention the systematic error in an oversampled analog-to-digital converter is suppressed by subtracting from the conversion response the response of a similar oversampled analog-to-digital converter that has the reference voltage as its analog input signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an oversampled analog-to-digital converter embodying the invention.
FIG. 2 is a schematic diagram of a digital electronic circuit breaker and power meter for three-phase power, which embodies the invention.
DETAILED DESCRIPTION
In FIG. 1 a first delta-sigma analog-to-digital converter ΔΣ1 is used to provide digital responses at a normal sampling rate to an analog input signal voltage V IN supplied from a voltage source VS as in a prior-art oversampled analog-to-digital converter. Rather than using these digital responses without correcting for any error in a reference voltage V REF supplied to the converter ΔΣ1 from a potential divider PD, as is done in the prior-art converter, these digital responses are supplied to the minuend input port of a subtracter SUB, the difference output port of which provides the ultimate digital responses for the analog-to-digital conversion. The subtrahend input port of subtracter SUB receives a correction term that corrects for systematic errors.
A usual source of these systematic errors is the potential divider PD. Potential divider PD generates a reference voltage V REF that is nominally the average of the relatively negative and relatively positive operating supply voltages applied to a data flip-flop DFF1 used in the delta-sigma converter ΔΣ1, but which may actually depart somewhat from being the exact average of those two operating supply voltages. For example, if the relatively negative and relatively positive operating supply voltages are 0 and +5 volts respectively, the reference voltage V REF may depart slightly from the +2.5 volt value it nominally should have. This departure, δ, gives rise to a systematic error in the digital responses that converter ΔΣ1 supplies to the minuend input port of subtracter SUB.
The delta-sigma converter ΔΣ1 includes an operational amplifier OA1 connected to function as a Miller integrator, with an integrating capacitor IC1 between its output port and its inverting input port. The Miller integrator voltage response is supplied from the output port of operational amplifier OA1 to the inverting input port of a digital comparator CMP1, to be compared to the reference voltage applied to the non-inverting input port of the comparator. If the Miller integrator voltage response is larger than reference voltage, digital comparator CMP1 output voltage is a logic ONE; if smaller, a logic ZERO.
A data flip-flop DFF1 responds to a regularly recurrent ΔΣclock signal to latch the comparator output signal, with the Q output signal of data flip-flop being set to the relatively positive operating supply voltage if comparator CMP1 output signal is a ONE and being reset to the relatively negative operating supply voltage if comparator CMP1 output signal is a ZERO. The Q output signal of data flip-flop DFF1 is complementary to its Q output signal. Data flip-flop DFF1 may be considered as being a digital-to-analog converter insofar as a degenerative feedback connection from comparator CMP1 output port to the inverting input port of operational amplifier OA1 is concerned. Data flip-flop DFF1 may be considered as a source of latched, single-bit-resolution, digital results insofar as a subsequent digital decimation filter DDF1 is concerned. Filter DDF1 responds to the oversampled output signal from data flip-flop DDF1 to provide digital response with multiple-bit-resolution at a normal sampling rate.
An input resistor IR1 connects in series with voltage source VS between the non-inverting and inverting input ports of operational amplifier OA1, and a feedback resistor FR1 connects between output port Q of the data flip-flop DFF1 and the inverting input port of operational amplifier OA1. The degenerative feedback that integrating capacitor IC1 provides maintains the inverting input connection of operational amplifier OA1 close to V REF , so voltage source VS voltage V IN appears across input resistor IR1 to cause a current flow V IN /R to that inverting input connection, assuming the resistance of resistor IR1 to have the value R. If resistor FR1 has a similar resistance of value R, the average value of Q output of data flip-flop DFF1 being V REF - V IN will cause current flow V IN /R from that inverting input connection of operational amplifier OA1, so there is no direct component of current flow to or from the Miller integrator connection of elements OA1 and IC1 to alter its voltage response as applied to voltage comparator CMP1.
When the average value of Q output of data flip-flop DFF1 is V REF - V IN , the average value of Q output of data flip-flop DFF1 has to be +5.0 volts positive operating supply voltage minus (V REF - V IN ), since Q and Q output voltages always sum to that +5.0 positive operating supply voltage. That is, the average value of Q output of data flip-flop DFF1 will be V IN +(+5.Ov -V REF ). These average values are short term averages of oversampling taken over time periods such as those between digital decimation filter DDF1 output samples supplied at normal sampling rate.
If V REF is exactly +2.5 volts -- that is, exactly midway between the +5-volt and 0-volt operating supply voltages, Q output voltage from data flip-flop DFF1 has an average value V IN +(5.0v-2.5v)=V IN+ 2.5v. That is, the offset voltage added to V IN in the conversion result supplied from digital decimation filter DDF1 output port is exactly V REF =2.5 volts, as desired.
If V REF is +2.5 volts plus a departure -δ, however, Q output voltage from data flip-flop DFF1 has an average value V IN+ [+5.0v-(2.5v-δ)]=V IN+ 2.5v+δ. The offset voltage added to V IN in the conversion result supplied from digital decimation filter DDF1 output port errs by a departure δ. This departure δ is the systematic error in the conversion results which the invention seeks to eliminate.
Another delta-sigma modulator ΔΣ0 has elements IR0, OA0, IC0, CMP0, DDF0, FR0 and DFF0 respectively very much similar to elements IR1, OA1, IC1, CMP1, DFF1, FR1 and DDF1 of the first delta-sigma modulator ΔΣ1 in operating characteristics, and in similar connection with each other. The other delta-sigma modulator ΔΣ0 has a short circuit SC, rather than a voltage source corresponding to VS, connected across its input port. Accordingly, the other delta-sigma modulator ΔΣ0 responds to the reference voltage V REF itself as input signal to generate a digital output signal at normal sampling rate, which digital output signal is descriptive of the systematic error δ and is supplied as the subtrahend signal to subtracter SUB. The difference signal supplied from the output port of subtracter SUB is free of the systematic error δ applied to each of its input ports, accomplishing the objective of the invention.
FIG. 2 shows a digital electronic circuit breaker and power meter for three-phase operation which embodies the invention thus far described. In FIG. 2 potential divider PD supplies reference voltage V REF to delta-sigma analog-to-digital converters ΔΣ2, ΔΣ3, ΔΣ4, ΔΣ5, ΔΣ6 and ΔΣ7 as well as to analog-to-digital converters ΔΣ0 and ΔΣ1. The conductors CA, CB and CC conduct respective phase of three-phase power unless selectively interrupted by a normally conducting three-pole-single-throw switch 3PST responding to an electromechanical actuator ACT energized by an electric trip signal.
Voltage transformers VTA, VTB and VTC have respective primary windings in star connection to the three-phase power conductors CA, CB and CC. The voltage transformers VTA, VTB and VTC have respective secondary windings connected at first ends thereof to supply analog voltages responsive to phase voltages to delta-sigma analog-to-digital converters ΔΣ1, ΔΣ3 and ΔΣ5, respectively, and connected at second ends thereof to receive reference voltage V REF from potential divider PD. Current transformers CTA, CTB and CTC have respective primary windings provided by segments of the three-phase power conductors CA, CB and CC, respectively. The current transformers CTA, CTB and CTC have respective secondary windings connected at first ends thereof to apply analog voltages responsive to phase currents to delta-sigma analog-to-digital converters ΔΣ2, ΔΣ4 and ΔΣ6, respectively, and connected at second ends thereof to receive reference voltage V REF from potential divider PD. Neutral current flowing from the center of the star connection of the primary windings of the voltage transformers VTA, VTB and VTC to ground is sensed in the primary winding of current transformer CTN to provide at a secondary winding of transformer CTN an analog voltage that is added to V REF and applied as an input signal to delta-sigma analog-to-digital converter ΔΣ7.
Delta-sigma analog-to-digital converter ΔΣ0 digitizes V REF to generate a correction signal for V REF not being exactly the average of the B+and ground voltages between which the digital-to-analog converter portions of the converter ΔΣ1, ΔΣ2, ΔΣ3, ΔΣ4, ΔΣ5, ΔΣ6 and ΔΣ7 operate. This correction signal could be individually subtracted from the digital response of each of the converters ΔΣ1, ΔΣ2, ΔΣ3, ΔΣ4, ΔΣ5, ΔΣ6 and ΔΣ7. However, in FIG. 2, the digital responses of these converters are time-division multiplexed by a multiplexer TDM to the minuend input part of subtracter SUB.
The time-division-multiplexed difference signals from subtracter SUB output port are shown applied to power monitoring circuitry PMC. In circuitry PMC the digitized voltage and current for each phase are latched at suitable times. Digital multiplication procedures are followed to develop indications of mean power in that phase. These indications of power in the three phases P A , P B and P c may also be summed together to generate an indication P 7 of the total mean power in the three phases.
Certain of the time-division-multiplexed signals from subtracter SUB output port may be selected as input signal to trip generating circuitry TGC, notably the digitized response to phase currents and neutral current as provided by analog-to-digital converters ΔΣ2, ΔΣ4, ΔΣ6 and ΔΣ7. The absolute values of these responses over given periods of time are compared to threshold values in the trip generating circuitry TGC in order to generate trip signals responsive to overcurrent conditions.
An error that is observed in the FIG. 2 circuitry when correction signal is not applied as subtrahend signal to subtracter SUB from converter ΔΣ0 is attributable to the secondary current of the transformers VTA, VTB, VTC, CTA, CTB, CTC and CTN causing voltage drop variations in V REF because the source impedance of potential divider PD is not zero-valued. This error appears as crosstalk between the digitized responses of converters ΔΣ1, ΔΣ2, ΔΣ3, ΔΣ4, ΔΣ5, ΔΣ6 and ΔΣ7. Applying correction signal from converter ΔΣ0 to the subtrahend input port of the subtractor SUB suppresses this crosstalk. This is in addition to the suppression of V REF errors originally appearing or arising with temperature change or passage of time.
Signed, single-ended, delta-sigma converters are known that differ from those shown in FIG. 1 in that Q output connection of data flip-flop DFF1 connects back to the non-inverting input connection of operational amplifier OA1 via a feedback resistor and in that voltage source VS is relocated to apply V REF +V IN to the non-inverting input connection of operational amplifier OA1. The systematic error evidenced in such a variant of delta-sigma converter ΔΣ1 can be compensated for using an appropriate variant of delta-sigma converter ΔΣ0, it should be evident from the foregoing disclosure. Signed, single ended, delta-sigma converters similar to ΔΣ1 and ΔΣ0 converters in FIG. 1, except for reversal of the + and - input connections to each of comparators CMP1 and CMP0, and except for reversal of the Q and Q output connections from each of data flip flops DFF1 and DFF0 as well, can be used in practicing the invention. One skilled in the art and acquainted with the foregoing disclosure is accordingly enabled to design other embodiments of the invention, and this should be borne in mind when construing the scope of the claims which follow. | A method for performing oversampled analog-to-digital conversion of an input signal to generate a conversion result signal essentially free of systematic errors in accordance with the invention includes the steps of: performing oversampled analog-to-digital conversion of the input signal to generate a preliminary conversion result signal accompanied by systematic error, performing oversampled analog-to-digital conversion of a zero-valued signal to generate a correction signal essentially consisting of a corresponding systematic error, and differentially combining the correction signal and the preliminary conversion result signal to generate the conversion result essentially free of systematic errors. In a structural embodiment of the invention the systematic error in an oversampled analog-to-digital converter is suppressed by subtracting from the conversion response the response of a similar oversampled analog-to-digital converter to the reference voltage as its analog input signal. | 7 |
RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 10/737,683 filed Dec. 16, 2003 now U.S. Pat. No. 11/184,481.
FIELD OF THE INVENTION
The invention relates to a new and improved Chum bait system and process for making the system and its uniquely blended composition.
BACKGROUND OF THE INVENTION
One of the problems with chum that is commercially available today is there is a lot of waste and once the chum is purchased, it cannot be stored without refrigeration. Thus, it is easier to dispose of it than to try to keep it for re-use. Refrigeration with its required source of electricity, is needed just to store the chum. Existing chum can be purchased in a frozen block form, but should be maintained in this frozen state until ready for use; otherwise, the thawed chum begins to spoil.
The present invention is based on this underlying recognition of a need for an effective all-inclusive fish chum system, where the chum does not require electricity for refrigeration or ice and that can be stored for long periods of time anywhere. The result was the development of a fish chum incorporated in a packaging system for facilitating its storage and eventual dispersion in the water. Further, the chum product developed is not messy and does not smell.
The present invention can be used on fresh or salt-water fish. The novel fish chum system gives the fisherman freedom and choice to use or not to use. The fisherman can keep the fish chum system close by his hook. In one embodiment, the packaging components allows for the fish chum system to be refilled easily any time anywhere with no mess. However, once used, the fisherman will have to re-seal the fish chum system, or at least place it in a sealable/closable poly-bag. The invention is effectively an all-inclusive fish chum system in a kit ready to drop in the water. The mesh bag incorporated in the invention allows for the self-regulating dispersion of the chum so as not to waste fish chum.
SUMMARY OF THE INVENTION
The present invention includes a method of or process for combining dry fish food with fish oil and crustacean oils. The end product is a complete fish chum kit that is self-regulating and that gives a fisherman total control of fish chumming results, without the need of additional steps such as adding fish oil, water for mixing, or the need to put the chum in a bag suitable for chumming, as is necessary with other chums.
A special chum dispersion self-regulating slotted mesh bag obtains this controlled release. The fish chum system is preferably vacuumed packed so that it doesn't need electricity for refrigeration or ice to store it. That is, the novel chum system can be stored anywhere, anytime and plenty can be kept on hand without spoiling.
A self-regulating slotted mesh bag can be refilled with the different chum types available. The chum system can be used on boats, docks, piers, and bridges and can even be used for trolling or drifting. It is great for freshwater or saltwater and fish and crab traps. This all-inclusive fish chum system, with its special blends, is ready to use, versatile and economical, whereas other products fall short of all of these options.
The important novel packaging components includes a special polyethylene slotted mesh bag with drawstring. The bag has self-regulating slots that are vertical top to bottom of the bag. When the fish chum bag is put in the water, the pulsation of the water action opens and closes these slots thus letting out small amounts of fish chum. Manually pumping the chum bag lets out a larger amount as needed thus giving the fisherman total control of the chumming results. When the water currents are strong or trolling the weight of the chum in the bag pulls the bag straight causing the slots to close, smaller amount of chum is let out. This action means that the chum bags last just as long in strong currents as it does bobbing up and down next to an anchored boat. The fisherman therefore maintains total control of these actions.
Further, a heavy-duty vacuum pouch (preferably about 5 mil) contains the novel special fish chum blend, which is in turn contained in the slotted mesh bag. The slotted mesh bag further includes a plastic snap clip. The chum, bag and clip are vacuumed-sealed for freshness and an extended shelf-life. This special fish chum system is an all-inclusive kit and ready for use. Again the fisherman has total control of his chumming needs with the availability of this chum kit.
Where this system not only eliminates the need for electricity, refrigeration, or ice, it can be stored in any tackle box. The mixture ratio is varied to achieve desired floating or sinking characteristics of the resultant blend. The resultant blended fish chum is added to the self regulating mesh bag with its clip and draw string, which allows the chum to disperse at different rates depending on the water conditions. This handy all-inclusive unit gives the fisherman total control of his chumming without the need to add any additional ingredients. The chum bag is vacuum sealed to ensure freshness and long term dry, non-refrigerated storage.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a schematic representation of the invention;
FIG. 2 is a schematic representation of an example of a typical process for making the chum; and
FIG. 3 is an exploded partial view of the mesh bag depicting the filament configuration between the circumferential cords of the bag.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1 discloses the present invention, the chum system, depicted generally as 10 , and an example of making the system 10 , as depicted in the process chart schematically depicted in FIG. 2 . FIG. 3 is an exploded partial view of the mesh bag 14 depicting the filament 24 configuration between the circumferential cords 22 of the bag 14 .
Before describing a typical example of the process, it should be understood what certain components referred in the process are typically comprised of. For example, dry fish food is used in the process. Although the ingredients of dry fish food can vary, depending on the manufacturing source, the dry fish food used by the inventor herein is consistent with a product commercially available from as the F-R-M® Clover Brand from Flint River Mills, Inc. of Tallahassee, Fla.
According to the ingredients listing for this brand, this dry fish food has crude protein—minimum 32.000%, crude fat—minimum 2.505%, crude fiber—minimum 6.000%, and crude fiber—maximum 12.000%. It includes soybean meal, corn meal, wheat middling, fish meal, meat and bone meal, alfalfa meal, salt, dicalcium phosphate, vitamin A, vitamin D-3, vitamin E, L-ascobyl-2 polyphosphate, ascorbic acid, riboflavin, pantothenic acid, niacin, vitamin B-12, choline chloride, menadione, sodium bisulfate, thiamin, mononiticate, pyridoxine hydrochloride, folic acid, manganous oxide, calcium iodate, copper oxide, cobalt carbonate, zinc oxide, ferrous carbonate, sodium selenite, fish oil, and ethoxyquin. Certainly, one can recognize that not all these ingredients are really necessary to provide an adequate fish food. They are only provided as an example of the listed contents on the packaging for one satisfactory fish food commercially available to date.
References to “sinking” fish food and “floating” fish food are made herein below in the description and in the claims. Flint River Mills, Inc., makes available both types of dried fish food, which are typically available in bulk in 50 pound bags. The dried fish food with floating characteristics is essentially packed not as dense as the sinking version. That is, it is “airy” or light so as to be able to float, that is, provide some measure of buoyancy. The sinking version is more densely packed as a solid and hard form. This characteristic allows it to sink. Otherwise, the ingredients are essentially similar to those typical ingredients described above for the commercially available dried fish food available from the Flint River Mills company.
Although there are several fish oils that would work well with the inventive process and invention, a preferred fish oil is 100% pure Manhaden fish oil. Similarly, crustacean oils are also common and readily available on the commercial market.
The following is an example only for making a typical batch of the chum 12 , for shallow water and deep water use. Different percentages and ingredients may be used to provide for certain performance features such as depth; however, the following process is an example of a very satisfactory process, where the performance of the invention 10 was deem very effective.
Example of Chum Blending Process
Referring to FIG. 2 , dry fish foods of two types are used for the base, to facilitate achieving either the desired floating or sinking characteristics. A substantial amount of time was used in testing and blending these two types to achieve the desired blends for the desired performance. The blending is typically done in a rotating hopper, not shown in the figures.
For batch no. 1, about 50 lbs of floating dry fish food was used. The floating fish food was added to a rotating hopper. About 78 oz of pure 100% Menhaden fish oil was added by spraying the fish oil over the dry fish food. Batch no. 1 was removed from hopper and allowed to air dry to achieve a specified or desired hardness.
For batch no. 2, about 50 lbs of sinking dry fish food was placed in the rotating hopper. About 50 oz of 100% pure Menhaden fish oil was added by spraying the fish oil over the dry fish food. Before this batch was removed, about 3.2 lbs of fish chum starter was added. Batch no. 2 was then removed and allowed to air dry to achieve a specified or desired hardness.
The fish chum starter was made by grinding dry sinking fish food in any type of grinder to a rough mash. To the rough mash, crustacean oil was added by spraying the crustacean oil at a rate of about 1 to 1.5 oz per pound of mash, and the oil/mash combination was then allowed to air dry. The chum starter is important as it releases chum right away when put in water while the larger chum blends soak up water in about 20 minutes until the chum is soft enough to start releasing chum.
One pound of this unique blend of chum expands in water to about 4 lbs and two to three times its dry size. The two batches were blended together for a desired blend, as described below.
The shallow water fish chum blend is recommended for water depths up to 20 feet. The preferred blend for this shallow water performance characteristic was achieved by mixing 2 parts floating mix and 1 part sinking/chum starter mix per pound of total mixture.
The deep water fish chum blend is recommended for a water depth of 20 feet or more. The preferred blend for this deep water performance characteristic was achieved by mixing 2 parts sinking/chum starter mix and 1 part of floating mix per pound of total mixture.
For each blend selection made, the selected blend is placed into a self-regulating slotted mesh bag 14 with a pull cord or draw string 16 and snap clip 18 . These components will be further described below.
The chum kit is installed in pouch 20 , which is vacuum-sealed. The kit or invention 10 is vacuum-sealed for freshness and longevity. This resultant vacuumed sealed kit 10 gives the fisherman the freedom to choose when to use the chum, anytime, anywhere, without the need to add any additional ingredients. No worries like frozen chums that need ice or refrigeration to keep the chum fresh. This kit can be stored anywhere with out the use electricity. This is also an economical money saving factor for the retailer.
Below is another example of recipes for 100 lbs of chum (per blend) using a process similar to that described above:
Shallow Water Blend (Floating):
63 lbs floating fish food
31 lbs sinking fish food
1 gallon fish oil
6 lbs chum starter (a crushed fish food with 6 oz of shrimp or crustacean oil)
Deep Water Blend (Sinking):
63 lbs sinking fish food
31 lbs floating fish food
1 gallon fish oil
6 lbs chum starter (a crushed fish food with 6 oz of shrimp or crustacean oil)
Referring back to FIG. 1 , FIG. 1 depicts the clip 18 that is attached to the pull cord or draw string 16 of the chum bag 14 . This clip 18 is also used to attach the chum bag to a fixed object or lanyard, generally a rope or cable or other similar type of lanyard typically used in the marine fishing industry. This allows the fisherman to decide how to use the bag 14 containing the chum 12 . He can keep the bag 14 close by or let it out on a rope. Although clip 18 can be made from a variety of materials, it preferable that it be made from a polymeric or plastic material and that it be a snap type for easy attachment to the draw string 16 and/or rope. Draw string 18 serves as means for closing and securing off the open end of the bag 14 after it has been filled with chum 12 . The draw string 18 can also be loosened and opened to add more chum 12 to an existing bag 14 .
Bag 14 is a mesh bag designed when in use to self-regulate the dispersion or distribution of the chum 12 . As shown in FIG. 3 , the essentially parallel intermediate circumferential cords 22 are spaced-apart a desired distance, typically about ½ inch apart. Between each cord 22 , a filament 24 is cyclically woven in a generally continuous and cyclical V-shape pattern or M-shape pattern, or what can also be described as a zig-zag pattern. Each filament, as a practical matter, is about 1/64 inch to about 1/32 inch in thickness or width.
The weave of the filament 24 between each pair of cords 22 effectively forms slots 26 in the bag 14 that are vertical top to bottom to the bag 14 . This is one of the important features contributing to the performance success of the invention by self-regulating the amount of fish chum 12 released. This controlled release is done by the weight of the chum 12 pulling on the bag 14 . With the bag 14 full of chum 12 and lowered in the water with a heavy current, the weight of the fish chum 12 pulls on the bag 14 closing off the slots 26 thus slowing down the release of fish chum 12 . That is, when the bag 14 is stretched, the slots 26 close off as the filaments 24 pull close together. Stated another way, when the bag 14 containing the fish chum 12 is put in the water the pulsation of the water action opens and closes these slots 26 , thus letting out small amounts of fish chum 12 . This action means that a full chum bag 14 will last just as long hanging on the side of an anchored boat or pier as it would be trolled by a boat or dropped in heavy current. The chum bag 14 is also reusable and can be refilled. On the other hand, when the bag 14 is not exposed to any kind of current force or tension, the bag does not stretch and the woven slots 26 are in a more open state, thereby allowing the release of more chum 12 . Further, manually pumping the bag 14 containing the chum 12 lets out a larger amount as needed thus giving the fisherman total control of the chumming results. If the water currents are strong or trolling the weight of the chum 12 in the bag pulls the bag straight causing the slots to close thus letting out a smaller amount of chum. This action means that the chum bags last just as long in strong currents as it does bobbing up and down next to an anchored boat. The fisherman therefore has total control of these actions.
Although the bag 14 can be made from a variety of materials, where it is anticipated that chum 12 will be used in a salt water marine environment, it is preferred that the bag 14 be made from a polymeric base material such as polyethelene material or fiberglass.
The vacuum pouch 20 is typically a polymeric laminate material and should be heavy duty. For example, a heavy-duty 5-mil vacuum pouch can be used. After the desired blended chum 12 is placed in the mesh bag 14 , the draw string 16 with its attached clip 18 is used to tie off the bag 14 . The filled bag 14 is then vacuum sealed using the laminate material or pouch 20 . This vacuum sealing operation provides for extended freshness and an extended shelf life of the chum 12 . This special fish chum system 10 is therefore an all-inclusive kit and ready for use. Again the fisherman has total control of his chumming needs with the availability of this chum kit 10 . This kit 10 eliminates the need for electricity, refrigeration, ice and can be stored in any tackle box.
It should be understood that the preceding is merely a detailed description of one or more embodiments of this invention and that numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit and scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention. | A blended fish chum system using dry fish food modified for buoyancy to either provide for a desired floating characteristic or a desired sinking characteristic. Fish oil is added to the fish food used for floating characteristics and fish oil is added to the fish food used for sinking characteristics. A starter fish chum comprising sinking fish food to which crustacean oil is added, is mixed with the combination of sinking fish food and fish oil. The floating fish food mixture, which has been dried, is blended with the sinking fish food mixture, which has also been dried, to form the blended fish chum. The mixture ratio is varied to achieve desired floating or sinking characteristics of the resultant blend. The resultant blended fish chum is added to a self regulating mesh bag with its clip/draw string, which is vacuum sealed to ensure freshness and long term dry, non-refrigerated storage. | 0 |
BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
The present invention relates to an airbag for protecting an occupant as a result of expanding during an emergency in a vehicle.
In order to protect an occupant during a collision in a vehicle, a driver airbag device, a passenger airbag device, a back-seat airbag device, and a side airbag device are used. Of these various types of airbag devices, the passenger airbag device is accommodated inside an instrument panel disposed at the front side of the vehicle. Of the different types of passenger airbag devices, the type of passenger airbag device which is disposed at a windshield-opposing location of the top portion of the instrument panel is called a top-dash-mount-type passenger airbag device.
Hereunder, a description of an airbag device will be given taking a top-dash-mount-type passenger airbag device as an example.
FIG. 14 (A) is a schematic side view used to illustrate the form of a conventional passenger airbag device when it has finished spreading. FIG. 14 (B) is a front view thereof.
FIG. 15 (A) is a schematic side view used to illustrate the form of the conventional passenger airbag device when a load acts thereupon (that is, when an occupant moves forward). FIG. 15 (B) is a front view thereof.
FIG. 16 (A) is a perspective view showing the conventional airbag in an expanded state. FIG. 16 (B) is a perspective view showing the airbag in a squashed state when a load acts thereupon. FIGS. 16 (C) and 16 (D) are schematic views used to illustrate the characteristics of the squashed state of the airbag when a load acts thereupon.
The passenger airbag device shown in FIGS. 14 (A) and 15 (A) comprises a retainer R disposed at a windshield-F-opposing location of the top portion of an instrument panel P of a vehicle. Inside the retainer R are disposed an airbag 103 and an inflator I for supplying spread gas into the interior of the airbag 103 . As simply shown in FIG. 16 (A), the airbag 103 is a three-piece bag in which two pieces of side cloths 103 b are sewed, one at each side of one piece of strip-like central cloth 103 a interposed therebetween. The airbag 103 has an open end (that is, a gas-circulation hole) 103 c which is narrowed down thinly at the base of the airbag 103 . The open end 103 c merges with a space in the inflator I. The airbag 103 is accommodated in a folded state inside the retainer R.
A description of the operation of the passenger airbag device will now be given.
At the time of a collision of a vehicle, spread gas is supplied into the airbag 103 from the inflator I. This causes the airbag 103 to expand in front of an occupant H, as shown in FIGS. 14 (A) and 14 (B). When the spreading of the airbag 103 is completed, the side cloths 103 b extend in smooth curved forms or substantially straight lines from top to bottom portions thereof, as shown in FIG. 14 (B). Here, the internal pressure or resistance inside the airbag 103 is substantially uniform at the top and bottom portions thereof.
After the airbag 103 has spread, as shown in FIG. 15 (A), the occupant H that moves forward due to inertial force hits the airbag 103 . This causes the airbag 103 to be pushed and squashed as a result of being sandwiched between the instrument panel P and the windshield F and the occupant H. At this time, as shown in FIG. 15 (B), the upper portion of the airbag 103 spreads horizontally by a greater amount than the lower portion thereof. The following factors (1) to (3) cause the airbag 103 to be in a squashed state.
(1) As simply shown in FIG. 15 (B), regarding the areas of the portions of the upper part of the body (from the waist upward) of the occupant H that hits the airbag 103 , the area of the upper portion of the upper body (from the neck upwards) is smaller than the area of the lower portion of the upper body (from the shoulders downward).
(2) Regarding the masses of the portions of the upper body of the occupant H, the mass of the upper portion of the upper body is smaller than that of the lower portion of the upper body.
(3) While the lower portion of the airbag 103 is pushed upward by the knees of the occupant H, the upper portion of the airbag 103 is relatively not pushed.
When an attempt is made to correct the characteristics of the squashed state of the airbag 103 , the output of the inflator I must be set relatively high.
A description of the resistance on the airbag 103 when a load is exerted thereupon will now be given with reference to FIG. 16 .
When the occupant hits the airbag 103 shown in FIG. 16 (A) from the front surface of the airbag 103 , an external force a shown in FIG. 16 (B) acts upon the airbag 103 . As shown in the same figure, this causes the airbag 103 to become squashed while spreading flatly. Here, as shown schematically in FIGS. 16 (C) and 16 (D), the airbag 103 escapes towards a region of lower resistance (that is, in the directions of empty arrows inside the bag 103 ), so that the resistance against a load body f becomes smaller, thereby making it easier to squash the bag.
In view of the above-described problems, it is an object of the present invention to provide an airbag which has a more preferable spread form without increasing the output of an inflator.
SUMMARY OF THE INVENTION
To overcome the above-described problems, according to the present invention, there is provided an airbag for protecting an occupant as a result of expanding during an emergency in a vehicle, wherein, in a front form of the airbag at the time of expansion thereof as viewed from the occupant, an inwardly extending depression is formed in a middle portion of a side surface of the airbag as viewed in a vertical direction.
When the occupant collides against the airbag, the depression at the middle portion of the airbag makes it difficult for the gas in the bottom portion of the bag to move upward. Consequently, the resistance at the bottom portion of the bag effectively acts upon the occupant. Therefore, it is possible to provide an airbag which has a more preferable spread form without increasing the output of the inflator.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 (A) is a schematic side view showing the form of a passenger airbag device of an embodiment of the present invention when it has finished spreading;
FIG. 1 (B) is a front view thereof;
FIG. 2 (A) is a schematic side view showing the form of the passenger airbag device of the embodiment of the present invention when a load acts thereupon (that is, when an occupant moves forward);
FIG. 2 (B) is a front view thereof;
FIG. 3 (A) is a perspective view showing the state of the airbag of the present invention when it is expanded;
FIG. 3 (B) is a perspective view showing the squashed state of the airbag when a load acts thereupon;
FIGS. 3 (C) and 3 (D) are schematic views used to illustrate the characteristics of the squashed state of the airbag when a load acts thereupon;
FIG. 4 (A) is a perspective view showing a structural example (that is, a partition-type structure) of the airbag of the present invention;
FIG. 4 (B) is a vertical sectional view of FIG. 4 (A);
FIG. 4 (C) is a vertical sectional view of another example of the airbag;
FIGS. 5 (A) to 5 (E) are schematic plan views of the forms of the front surface of the air bag when it has finished spreading;
FIG. 6 (A) is an exploded perspective view of a structural example of an airbag using one tether strap;
FIG. 6 (B) is a side view of the airbag shown in FIG. 6 (A);
FIG. 6 (C) is a front view of the airbag shown in FIG. 6 (B);
FIG. 7 (A) is a schematic side view of a top-dash-mount-type passenger airbag device using two tether straps;
FIG. 7 (B) is a front view of the airbag shown in FIG. 7 (A);
FIG. 7 (C) is a sectional view taken along line 7 (C)— 7 (C) of FIG. 7 (A);
FIG. 7 (D) is a sectional view taken along line 7 (D)— 7 (D) of FIG. 7 (A);
FIG. 8 (A) is a schematic side view of a top-dash-mount-type passenger airbag device using a tucked seam;
FIG. 8 (B) is a front view of the airbag shown in FIG. 8 (A);
FIG. 8 (C) is a sectional view taken along line 8 (C)— 8 (C) of FIG. 8 (A);
FIG. 9 (A) is a perspective view of an example of an airbag having a two-piece structure;
FIG. 9 (B) is an exploded perspective view of the airbag shown in FIG. 9 (A);
FIG. 9 (C) is an exploded plan view of the airbag shown in FIG. 9 (A);
FIGS. 9 (D) and 9 (E) are perspective views used to illustrate the procedure of assembling the airbag shown in FIG. 9 (A);
FIG. 10 (A) is an exploded plan view of another example of the airbag having a two-piece structure;
FIG. 10 (B) is a perspective view used to illustrate the procedure of assembling the airbag shown in FIG. 10 (A);
FIGS. 11 (A)- 11 (H) are used to illustrate the procedure or assembling the airbag having a two-piece structure;
FIG. 12 (A) is a plan view of an example of an airbag having a one-piece structure;
FIG. 12 (B) is a perspective view of the airbag formed from the one-piece structure;
FIG. 12 (C) is a front view (in the direction of arrow 12 (C) in FIG. 12 (B)) when the airbag has finished spreading;
FIG. 13 (A) is a plan view of another example of the airbag having a one-piece structure;
FIG. 13 (B) is a perspective view of the airbag shown in FIG. 13 (A);
FIG. 13 (C) is a front view (in the direction of arrow 13 (C) in FIG. 13 (B)) when the airbag has finished spreading;
FIG. 14 (A) is a schematic side view used to illustrate the form of a conventional passenger airbag device when it has finished spreading;
FIG. 14 (B) is a front view thereof;
FIG. 15 (A) is a schematic side view used to illustrate the form of the conventional passenger airbag device when a load acts thereupon (that is, when an occupant moves forward);
FIG. 15 (B) is a front view thereof;
FIG. 16 (A) is a perspective view showing the conventional airbag in an expanded state;
FIG. 16 (B) is a perspective view showing the airbag in a squashed state when a load acts thereupon;
FIGS. 16 (C) and 16 (D) are schematic views used to illustrate the characteristics of the squashed state of the airbag when a load acts thereupon;
FIG. 17 (A) is a perspective view of another example of the partition-type airbag of the invention;
FIG. 17 (B) is a plan view of a partition of the airbag shown in FIG. 17 (A);
FIG. 17 (C) is a vertical sectional view of FIG. 17 (A);
FIG. 17 (D) is a plan view of another example of the partition wall; and
FIG. 17 (E) is a vertical sectional view of the airbag using the partition shown in FIG. 17 (D).
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Hereunder, a description will be given with reference to the drawings.
In the description of the following embodiments, an airbag of the present invention is described as being a top-dash-mount-type passenger airbag device.
FIG. 1 (A) is a schematic side view showing the form of a passenger airbag device of an embodiment of the present invention when it has finished spreading. FIG. 1 (B) is a front view thereof.
FIG. 2 (A) is a schematic side view showing the form of the passenger airbag device of the embodiment of the present invention when a load acts thereupon (that is, when an occupant moves forward). FIG. 2 (B) is a front view thereof.
FIG. 3 (A) is a perspective view showing the state of the airbag of the present invention when it is expanded. FIG. 3 (B) is a perspective view showing the squashed state of the airbag when a load acts thereupon. FIGS. 3 (C) and 3 (D) are schematic views used to illustrate the characteristics of the squashed state of the airbag when a load acts thereupon.
FIG. 4 (A) is a perspective view showing a structural example (that is, a partition-type structure) of the airbag of the present invention. FIG. 4 (B) is a vertical sectional view of FIG. 4 (A). FIG. 4 (C) is a vertical sectional view of another example of the airbag.
The airbag device shown in FIGS. 1 (A) and 2 (A) comprises a retainer R disposed at a windshield-F-opposing location of the top portion of an instrument panel P of a vehicle. Inside the retainer R are disposed an airbag 11 made of cloth, and an inflator I for supplying spread gas into the airbag 11 . Ordinarily, the airbag 11 is accommodated in a folded state inside the retainer R.
As simply shown in FIG. 4 (A), the airbag 11 is a three-piece bag which is formed by sewing together one piece of strip-like central cloth 12 and two side cloths 13 ( 13 a and 13 b ) one at each side of the central cloth 12 . The airbag 11 has an open end (that is, a gas circulation hole) 14 which is narrowed down thinly at the base thereof. The gas circulation hole 14 merges with a space of the inflator I.
A partition 15 is mounted inside the airbag 11 . The partition 15 is disposed at the middle portion of the airbag 11 as viewed in the vertical direction, and divides the interior of the airbag 11 into an upper portion 11 A and a lower portion 11 B. The partition 15 is formed of cloth or is a knitted product, and the material or the form thereof is such as to allow passage of gas between the two divided chambers (that is, the upper portion 11 A and the lower portion 11 B). For example, as shown in FIG. 4 (A), the partition 15 is formed by making the portion thereof disposed towards the open end 14 of the airbag 11 short. In this case, as simply shown in FIG. 4 (B), a gas flow path S which connects the upper portion 11 A and the lower portion 11 B is formed inside the airbag 11 . In another example, the partition 15 is formed by also making the portion thereof towards the front side of the airbag 11 short, in which case, as shown in FIG. 4 (C), two gas flow paths S and S′ can be formed. Cutaway portions 15 a are formed, one in each edge of the partition 15 . The outer peripheral edges of the partition 15 are attached to the inside surface of the airbag 11 by, for example, sewing or welding. The cutaway portions 15 a of the partition 15 allow the substantially middle locations of both side cloths 13 of the airbag 11 (portions where the cutaway portions 15 a of the partition wall 15 are attached) to be brought towards each other, thereby forming inwardly extending depressions d.
A description of a modification of the partition 15 will be given later.
A description of the operation of the airbag device having the above-described structure will be given.
In the usual state of a vehicle, the airbag 11 is accommodated in a folded state in the retainer R. When the vehicle collides, a sensor (not shown) detects the collision, and sends an ignition signal to an initiator of the inflator I. The initiator is ignited, and a propellant is ignited, thereby producing spread gas from the inflator I. There is also a type of airbag device which is spread using accumulated pressure of inactive gas.
The spread gas that has been produced flows inside the airbag 11 after passing through the gas circulation hole 14 . As shown in FIGS. 1 (A) and 1 (B), the airbag 11 expands and spreads in front of the occupant H. As shown in FIG. 1 (B), at the time of completion of the spreading of the airbag 11 , the depressions d, disposed at substantially the central portions of the side cloths 13 a and 13 b , are depressed inward, so that the front surface of the airbag 11 is shaped like a package.
As shown in FIGS. 2 (A) and 2 (B), the occupant H moves forward due to inertial force and hits the spread airbag 11 . This causes the airbag 11 to be pushed and squashed as a result of being sandwiched among the instrument panel P and the windshield F and the occupant H. At this time, the depressions d make it difficult for the gas at the lower portion inside the airbag 11 to escape towards the upper portion, so that the resistance of the lower portion 11 B of the bag acts uniformly upon the lower portion of the upper body (from the waist to the chest) of the occupant H. As shown in FIG. 2 (B), the upper portion 11 A and the lower portion 11 B of the airbag 11 are substantially equally horizontally spread.
The resistance acting in the airbag a load is applied will be described in more detail with reference to FIGS. 3 to 16 .
An external force α equivalent to the force produced by the body of the occupant acts upon the airbag 11 shown in FIG. 3 (B) from the front surface thereof. Here, as long as the portions where the depressions d of the airbag 11 are formed are not spread to the sizes of other portions, the depressions d limit the movement of the gas inside the bag. As described above and as shown schematically in FIGS. 16 (C) and 16 (D), in the conventional airbag, the airbag 103 escapes towards a region of lower resistance in the directions of empty arrows inside the bag 103 , so that the resistance with respect to the load body f becomes small, thereby making it easy for the bag to become squashed. On the other hand, as shown schematically in FIGS. 3 (C) and 3 (D), air in the airbag 11 of the present invention cannot easily escape in the direction of the upper portion 11 A of the bag, thereby making it possible to produce a large resistance with respect to a load body f at the lower portion 11 B. This causes the lower portion of the airbag 11 to have sufficient resistance.
Although the embodiment has been described by taking as an example the case where the depressions d are formed in substantially the central portions of the airbag 11 by placing one partition inside the bag, various modifications may be made as described below.
Hereunder, modifications will be given in terms of the front surface shapes of the airbag during expansion thereof with reference to FIG. 5 .
FIGS. 5 (A) to 5 (E) are schematic plan views of the forms of the front surface of the air bag when it has finished spreading.
The form shown in FIG. 5 (A) is the same as that shown in FIGS. 1 (B) and 2 (B). More specifically, in this case, the depressions d are formed in substantially the central portions of the side surfaces of the airbag, and a maximum width B 1 of the upper portion of the bag and a maximum width B 2 of the lower portion thereof are substantially equal to each other.
In the form shown in FIG. 5 (B), the depressions d are formed closer to the bottom portion of the airbag, and a maximum width B 1 of the upper portion of the bag is greater than a maximum width B 2 of the lower portion of the bag.
In the form shown in FIG. 5 (C), which is the reverse form of that shown in FIG. 5 (B), the depressions d are formed closer to the top portion of the airbag, and a width B 1 of the upper portion of the bag is less than a width B 2 of the lower portion of the bag.
In the form shown in FIG. 5 (D), depressions d 1 and depressions d 2 are formed in two levels in the bag.
In the form shown in FIG. 5 (E), three levels of depressions d 1 , depressions d 2 , and depressions d 3 are formed in the bag. More than three levels of such depressions may also be formed.
Modifications of the structure of the airbag will be given.
Specific Examples of Airbags Having Three-Piece Structures Using a Tether Strap or Tether Straps
Specific examples of airbags using tether straps will be described with reference to FIGS. 6 (A)- 7 (D). The characteristic of this type of airbag is that a tether strap or tether straps are used instead of the partition used in the above-described airbag 11 .
FIG. 6 (A) is an exploded perspective view of a structural example of an airbag using one tether strap. FIG. 6 (B) is a side view of the airbag. FIG. 6 (C) is a front view of the airbag.
FIG. 7 (A) is a schematic side view of a top-dash-mount-type passenger airbag device using two tether straps. FIG. 7 (B) is a front view of the airbag shown in FIG. 7 (A). FIG. 7 (C) is a sectional view taken along line 7 (C)— 7 (C) of FIG. 7 (A). FIG. 7 (D) is a sectional view taken along line 7 (D)— 7 (D) of FIG. 7 (A).
In an airbag 21 shown in FIGS. 6 (A)- 6 (C), a tether strap 22 is provided in a tensioned state between both side surface cloths 13 a and 13 b of the airbag having a three-piece structure. The tether strap 22 is a string-like or strip-like member which is formed of cloth or which is a knitted product. The ends of the tether strap 22 are sewed to the corresponding side surface cloths 13 a and 13 b through corresponding reinforcing cloths 23 . The side surface cloths 13 a and 13 b are brought inwardly towards each other by the tether strap 22 , and depressions d (see FIG. 6 (C)) are formed where the ends of the tether strap 22 are sewed.
In an airbag 25 shown in FIGS. 7 (A)- 7 (D), two tether straps 22 of the same type as that used in the airbag 21 shown in FIGS. 6 (A)- 6 (C) are sewed in two levels. In this case, two levels of depressions d 1 and d 2 are formed in the side surfaces of the airbag 25 in correspondence with the two tether straps 22 . The form of the front surface of the airbag 22 at the time of expansion thereof is that shown in FIG. 7 (B). It is the same as the form of the front surface of the airbag shown in FIG. 5 (D).
Specific Example of Airbag Having a Three-Piece Structure Using a Tucked Seam
A specific example of an airbag using a tucked seam will be described with reference to FIGS. 8 (A)- 8 (C). The characteristic of this type of airbag is that depressions are formed by a tucked seam without using a tether strap or tether straps or the partition used in the above-described airbag 11 .
FIG. 8 (A) is a schematic side view or a top-dash-mount-type passenger airbag device using a tucked seam. FIG. 8 (B) is a front view of the airbag shown in FIG. 8 (A). FIG. 8 (C) is a sectional view taken along line 8 (C)— 8 (C) of FIG. 8 (A).
In an airbag 28 shown in FIGS. 8 (A)- 8 (C), a tucked seam 29 is formed at portions of both side surface cloths 13 a and 13 b of the airbag having a three-piece structure. The side surface cloths 13 a and 13 b are brought towards each other and joined at the tucked seam 29 , and a depression d is formed at the sewed portion thereof. The locations and number of depressions can be increased by forming tucked seams 29 at a plurality of locations.
Specific Examples of Airbags Having Two-Piece Structures
Hereunder, a description of specific examples of airbags having two-piece structures will be given.
FIG. 9 (A) is a perspective view of an example of an airbag having a two-piece structure. FIG. 9 (B) is an exploded perspective view of the airbag. FIG. 9 (C) is an exploded plan view of the airbag. FIGS. 9 (D) and 9 (E) are perspective views used to illustrate the procedure of assembling the airbag.
FIG. 10 (A) is an exploded plan view of another example of the airbag having a two-piece structure. FIG. 10 (B) is a perspective view used to illustrate the procedure of assembling the airbag.
FIGS. 11 (A)- 11 (H) are used to illustrate the procedure of assembling the airbag having a two-piece structure.
In an airbag 31 shown in FIGS. 9 (A)- 9 (E), a cloth front panel 31 (at the side of an occupant) and a back panel 33 (at the side of an instrument panel) are integrally sewed together into the shape of a bag. As simply shown in FIG. 9 (C), both of the panels 32 and 33 are elliptical. As most simply shown in FIGS. 9 (B) and 9 (C), protruding ears 32 a are formed, one on each of the two sides of the front panel 32 . A tether strap 34 is provided in a tensioned state between both ears 32 a.
In an airbag 31 shown in FIG. 9, a cloth front panel 31 (at the side of an occupant) and a back panel 33 (at the side of an instrument panel) are integrally sewed together into the shape of a bag. As simply shown in FIG. 9 (C), both of the panels 32 and 33 are elliptical. As most simply shown in FIGS. 9 (B) and 9 (C), protruding ears 32 a are formed, one on each of the two sides of the front panel 32 . A tether strap 34 is provided in a tensioned state between both ears 32 a.
As most simply shown in FIGS. 9 (B) and 9 (C), a rectangular gas circulation hole 33 a is formed in the center of the back panel 33 . In addition, two circular vent holes 33 b are formed in the back panel 33 . A reinforcing cloth 33 c is sewed along the periphery of the gas circulation hole 33 a of the back panel 33 and reinforcing cloths 33 d are sewed along the peripheries of the corresponding vent holes 33 b . Holes 33 e are formed in the reinforcing cloth 33 c , sewed along the periphery of the gas circulation hole 33 a.
The ears 32 a used for mounting the tether strap 34 may be formed at the back panel 33 .
In an airbag 35 shown in FIGS. 10 (A) and 10 (B), tether straps of the type used in the airbag 31 shown in FIGS. 9 (A)- 9 (E) are integrally provided at a front panel. More specifically, as shown in FIG. 10 (A), the airbag 35 comprises tether straps 34 A and 34 B, one extending from each side of a front panel 32 .
In this case, the tether straps 34 A and 34 B maybe provided at a back panel 33 .
An airbag 38 shown in FIGS. 11 (A)- 11 (H) comprises a package-shaped front panel 32 ′ and a package-shaped back panel 33 ′, each of which has a cutaway portion 39 , and has a two-piece structure without a tether strap. In the airbag 38 , depressions are formed where the cutaway portions 39 are formed.
The airbags 31 , 35 , and 38 are assembled using the following procedure.
(1) The reinforcing cloth 33 c and the reinforcing cloths 33 d are aligned with positioning holes that are previously formed in the back panel 33 ( 33 ′), and are sewed to the back panel 33 ( 33 ′). Then, the gas circulation hole 33 a and the vent holes 33 b are formed by cutting operations. (See FIGS. 11 (A) to 11 (C).)
(2) Outer surfaces (as viewed in the state shown in FIG. 9 (A)) of the front panel 32 ( 32 ′) and the back panel 33 ( 33 ′) are positioned so as to oppose each other, and are placed upon each other in order to sew them together along their outer peripheries. (See FIGS. 11 (D) and 11 (E).)
( 3 ) (For the airbag 31 shown in FIG. 9 (A))
As shown in FIG. 9 (D), the tether strap 34 is sewed to both ears 32 a of the front panel 32 .
( 3 ′) (For the airbag 35 shown in FIG. 10 (A))
As shown in FIG. 10 (B), the ends of the tether straps 34 A and 34 B that protrude from the front panel 32 are placed upon each other and are sewed to ether.
These steps are not required for the airbag 38 shown in FIGS. 11 (A)- 11 (H).
(4) As shown in FIGS. 9 (D) and 11 (E), the front panel 32 ( 32 ′) is pulled out from the gas circulation hole of the back panel 33 ( 33 ′), and the inside and outside surfaces of both panels 32 and 33 ( 32 ′ and 33 ′) that have been sewed together are reversed.
In the airbags 31 , 35 , and 38 , depressions are formed where the tether strap 34 , the tether straps 34 A and 34 B, and the cutaway portions 39 are formed, respectively. The shapes of the front surfaces of the airbags 31 , 35 , and 38 when they have finished spreading are as shown in FIG. 5 (A). By moving the tether strap or tether straps or the cutaway portions vertically in the upward direction or the downward direction, the airbags 31 , 35 , and 38 can take the form shown in FIGS. 5 (B) or 5 (C). In addition, by providing the tether straps or the cutaway portions in two or three levels, they can take the form shown in FIGS. 5 (D) or 5 (E).
Specific Examples of Airbags Having One-Piece Structures
Hereunder, a description of specific examples of cases where the present invention is applied to airbags having one-piece structures will be given.
FIG. 12 (A) is a plan view of an example of an airbag having a one-piece structure. FIG. 12 (B) is a perspective view of the airbag. FIG. 12 (C) is a front view (in the direction of arrow 12 (C) in FIG. 12 (B)) when the airbag has finished spreading.
FIG. 13 (A) is a plan view of another example of the airbag having a one-piece structure. FIG. 13 (B) is a perspective view of the airbag. FIG. 13 (C) is a front view (in the direction of arrow 13 (C) in FIG. 13 (B)) when the airbag has finished spreading.
An airbag 41 shown in FIGS. 12 (A)- 12 (C) is previously formed into the shape of a bag. Triangular protruding portions 41 A to 41 F are formed, three on each side of the airbag 41 . The center protruding portions 41 B and 41 E have ears 42 . A tether strap 45 is provided in a tensioned state between both ears 42 .
As shown in FIG. 12 (A), a gas circulation hole 43 is formed in the illustrated right end of the airbag 41 , and two vent holes 44 are formed towards the left end thereof. A reinforcing cloth 43 a and reinforcing cloths 44 a are sewed along the periphery of the gas circulation hole 43 and the peripheries of the vent holes 44 , respectively. Holes 43 b are formed in the reinforcing cloth 43 a formed along the periphery of the gas circulation hole 43 .
As shown in FIG. 12 (B), the airbag 41 is formed into a three-dimensional form by sewing together, as shown in FIG. 12 (B), sewing lines, formed along the outer periphery thereof, having the same reference numerals (X 1 , X 2 , Y 1 , Y 2 , Z 1 , Z 2 , and W), and by accommodating a tether strap 45 inside the airbag 41 . Reference numeral T denotes edge lines. In this case, the front surface has the shape of a package as shown in FIG. 12 (C).
In an airbag 48 shown in FIGS. 13 (A)— 13 (C), protruding portions 41 B′ and 41 E′ such as those used in the airbag 41 shown in FIGS. 12 (A)- 12 (C) are formed smaller than the other protruding portions 41 A, 41 C, 41 D, and 41 F, and no tether straps are used. By forming the protruding portions 41 B′ and 41 E′ smaller, arcuate edge lines L are formed in the state shown in FIG. 13 (B) after the sewing operation. In the airbag 48 , the front surface also has the shape of a package as shown in FIG. 13 (C).
Modification of Partition-Type Airbag
Hereunder, a description of a modification of a partition-type airbag will be given.
FIG. 17 (A) is a perspective view of another example of the partition-type airbag. FIG. 17 (B) is a plan view of a partition of the airbag shown in FIG. 17 (A). FIG. 17 (C) is a vertical sectional view of FIG. 17 (A). FIG. 17 (D) is a plan view of another example of the partition wall. FIG. 17 (E) is a vertical sectional view of the airbag using the partition shown in FIG. 17 (D).
A partition 55 is mounted inside an airbag 50 shown in FIG. 17 (A). The partition 55 is disposed at the middle portion of the airbag 50 as viewed in the vertical direction, and divides the inside of the airbag 50 into an upper portion 50 A and a lower portion 50 B. As simply shown in FIG. 17 (B), the partition 55 has two holes 55 x and 55 y formed therein. As shown in FIG. 17 ( 0 ), these holes 55 x and 55 y make it possible to connect the upper portion 50 A and the lower portion 50 B inside the airbag. Cutaway portions 55 a are formed, one at each side edge of the partition 15 . The outer peripheral edges of the partition 55 are attached to the inside surface of the airbag 50 by, for example, sewing or welding. As in the airbag 11 shown in FIGS. 4 (A)- 4 (C), the cutaway portions 55 a of the partition 55 form inwardly extending depressions d at substantially the middle portions thereof as viewed in the vertical direction.
The external shape of a partition 65 shown in FIG. 17 (D) is the same as that of the partition 55 shown in FIG. 17 (B) and does not have holes. The partition 65 is made of cloth or is a knitted product having high air permeability. In this case, as shown in FIG. 17 (E), gas circulates almost uniformly over the entire surface of the partition 65 .
As is clear from the foregoing description, according to the present invention, it is possible to provide an airbag having a more preferable spread form without increasing the output of an inflator. | An inflatable airbag for installation in front of a passenger compartment of a vehicle for protecting an occupant during an emergency includes a rearwardly directed surface positioned to be contacted by the occupant when expanded, an end located at a side opposite to the rearwardly directed surface and having a hole for receiving an inflation gas, and laterally spaced side surfaces extending between the rearwardly directed surface and the end and being oriented substantially vertically in the passenger compartment. Inwardly extending depressions are formed in a middle portion of each side surface of the airbag as viewed in a vertical direction. The depressions are located away from the rearwardly directed surface to restrict movement of the inflation gas inside the airbag when the occupant hits the inflated airbag. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to an improved compact transmission mechanism for driving a pair of output shafts by a reversible motor in a coin dispensing apparatus and more particularly to a simplified and economical switching gear mechanism that automatically responds to the output of a reversible electric motor.
2. Description of the Related Art
The present invention is directed to improvements in vending machine equipment wherein maintenance and costs are important factors. Vending machine equipment has been required to become more compact while still being required to handle the dispensing of coins and tokens for change or jackpots in gaming machines.
Generally, a coin hopper has components driven by a motor through a gear transmission system so that the motor can rotate in a clockwise direction and a counter-clockwise direction. Coin hopper equipment is usually driven to output coins from a bulk hopper. In a large capacity hopper equipment that is suitable, for example, in gambling and gaming machines, a large number of medallions or coins are stored and dispensed. As used in this application, the terminology “coin” includes not only coins of a monetary currency, but also can include medallions, disc-like medals, tokens, etc.
An example of a large capacity coin hopper can be found in the laid open Japanese Patent Application No. 11-251,652. Referring to FIG. 9, a perspective view of the hopper equipment is disclosed. A cross-sectional view of the motor drive transmission assembly is shown in FIG. 9. A rectangular support or baseboard 4 extends in a vertical installation position and is supported by a pair of support frames 3 . On one surface of the baseboard 4 , a primary tank 1 for coin storage having a cylindrical shape is disclosed. Attached to this primary tank 1 is a larger capacity slanted or angled barrel case 10 with a secondary tank of a large pot like configuration having an opening 5 for receiving bulk coins. As can be readily determined, the primary tank 1 , the intermediate case member 10 and the secondary tank 2 can store a large number of coins in bulk quantity. Within the primary tank 1 , a deep plate-like dispensing disc 50 as shown in FIG. 10 is capable of contacting and releasing coins in a controlled manner. The deep plate-like disc is mounted for free rotation.
Mounted within the intermediate case member 10 is a flexible belt 14 with teeth or projections 15 that can be utilized for elevating the coins from the secondary storage tank 2 and dropping the coins into the deep plate-like disc 50 . Thus, rotation of the belt 14 can distribute the coins to the primary tank I and as is conventionally known, the disc 50 or other structure can interact with the coins and selectively dispense the coins one by one.
To provide the rotational movement, a gear case 41 is fixed on the back surface of the baseboard 4 as can be seen in FIG. 10 . An electric motor 40 can be appended from the gear case 41 so that the electric motor 40 can drive a small pinion gear 44 which is fixed to a shaft of the electric motor 40 . The cross-section view of this gear arrangement is seen in FIG. 10 . The pinion gear 44 can in turn mesh with a larger gear 45 . The gear 45 is freely mounted within bearings to rotate. An output gear 46 further meshes with the large gear 45 and is also mounted for free rotation. Attached to this output gear 46 is a primary clutch member 47 and a secondary clutch member 48 . The primary clutch member 47 can rotate the primary output shaft 42 when the electric motor 40 is rotated in a first positive direction. In this rotation, the primary output shaft 42 is coupled to a disc 50 for sending out the coins in the primary tank 1 . The secondary clutch member 48 rotates a secondary output shaft 43 when the electric motor 40 is driven in a reverse direction. The secondary output shaft 43 is in turn coupled to a belt 31 , see FIG. 9, by an intervening driving of the pulley 38 , the belt 37 , the pulley 36 shown in FIG. 9, and the shaft 34 . This belt 31 , while not shown, is coupled to the belt 14 for driving the coins in the case 10 .
In summary, the disc 50 , for picking up and sending the coins in a controlled manner, is rotated by the action of the primary clutch 47 when the electric motor 40 is rotated in a positive direction. At this time, the belt 14 for coin carrying is stopped by the action of the second clutch 48 . When, however, the electric motor 40 is reversed, the second output shaft 43 is rotated by the action of the second clutch 48 . As a result of this drive, the belt 31 is activated. During this activation, the disc 50 is not rotated by the action of the primary clutch 47 . Thus, in this disclosure, either the disc 50 is rotated or the belt 14 is rotated in a selective manner, depending upon the direction of rotation of the electric motor 40 .
As can be seen from FIG. 10, this arrangement requires a number of components and increases the size requirements of the coin dispenser. Additionally, since a pair of one-way clutches are utilized, there is always the possibility that inertia forces may jar and cause wear and vibration when the motor is reversed.
SUMMARY OF THE INVENTION
The present invention was developed in order to simplify transmission switching gear arrangement for dealing with a reversible motor. The present invention was also designed to decrease the number of parts and to simplify the transmission switching gear equipment. Additionally, the present invention was designed to absorb any reaction forces by a sudden stopping or reversing of the motor. The present invention was also designed to provide a relatively uncomplicated activation of one of two output shafts that can be automatically determined by a positive-reverse switching cycle relating to the direction of rotation of the motor.
The present invention provides a transmission assembly in a coin handling apparatus that can automatically activate one of two output shafts. A primarily stepped gear, which is freely mounted on a fixed shaft, includes a helical gear meshing with an output pinion of an electric motor. A spur gear is coaxially mounted on the shaft. A link unit comprising a pair of elongated movable boards or link members sandwich the primary step gear and are rotatable about the fixed shaft. Radially outward from the fixed shaft is a transfer shaft that extends between the respective link members and a second step gear is freely rotatably mounted on the transfer shaft and includes a switching gear that meshes with a coaxial spur gear. The spur gear can mesh with respective output shaft gears to respectively drive the desired output shafts. Positioned between the movable boards or link members and the primary step gear are elastic members such as spring like ring members to provide a frictional force between the primary step gear and the respective link members. Depending upon the rotation of the output shaft of the electric motor, the pinion gear will drive the helical gear to move upward or downward axially relative to the fixed shaft 23 . When driven upward, it will cause a frictional engagement through an elastic spring member to drive the upper link member to rotate in a specific direction, thereby bringing the switching gear into engagement with a gear train to drive one of the output shafts. Conversely, a reverse driving of the pinion gear will drive the helical gear shaft downward to engage the lower elastic spring member to frictionally move the lower link member and rotate the large switching gear in the other direction to engage a transmission gear assembly to drive the other output shaft. As can be appreciated, the spring mounting can absorb some of the thrust forces that can occur upon a reversing of the electric motor.
As can be further determined, the number of parts and components utilized are substantially less than the conventional transmission mechanisms that have heretofore been used.
In summary, the present invention can be utilized in a coin storage and dispensing apparatus for storing coins in bulk wherein a reversible electrical motor can provide a driving force for transporting coins and also dispensing coins from a dispensing member. The present invention includes a transmission assembly of a compact configuration connected to the rotational output of the reversible electrical motor. A first supporting member or fixed shaft can rotatably mount a link unit. The link unit can include a first link member and a second link member that are rotatably mounted about the first support member. A first gear unit is mounted adjacent to the link unit and is operatively connected to the rotational output of the reversible motor. The first gear unit can be a stepped helical gear that can mesh with a helical pinion gear connected to an output shaft of the reversible electrical motor. A mounting unit is positioned to operatively contact the first gear unit and to rotate the link unit about the first support member depending upon the direction and rotation of the reversible electrical motor. The mounting unit can comprise a pair of spring plates or flexible bearing members that are mounted on either side of the first gear unit adjacent the first and second link members, respectively. The first gear unit can be driven to axially move along the support member and apply a thrust force to the mounting unit. Depending upon the direction of rotation of the reversible electrical motor, the link unit can rotate about the first support member in a clockwise or counter-clockwise direction. Radially offset from the first support member is a switching gear unit that can be mounted on a transfer support member extending between the first and second link members. The switching gear unit can be a stepped gear unit and it can be operatively connected to the first gear unit so that it provides a driving force at two separate positions about the first support member depending upon the direction of rotation of the reversible motor. The switching gear unit can include a spur gear that can intermesh with one of two output gears that are connected respectively to output shafts.
BRIEF DESCRIPTION OF THE DRAWINGS
The exact nature of this invention will be readily apparent from consideration of the following detailed description in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of the electric motor and compact transmission mechanism for providing a pair of output shafts;
FIG. 2 is a side elevational view of FIG. 1 disclosing an output shaft on either side of the housing of the transmission mechanism;
FIGS. 3 a and 3 b are partial cross-sectional views of a switching gear mechanism contained within the transmission assembly;
FIGS. 4 a and 4 b are respectively a schematic bottom view and a partial cross-sectional view of the transmission assembly;
FIGS. 5 a and 5 b are respectively cross-sectionals views with certain elements missing on FIG. 4 for explanatory purposes;
FIGS. 6 a and 6 b are respectively bottom views of FIG. 2 with certain elements removed for explanatory purposes;
FIGS. 7 a and 7 b are respectively cross-sectional views of a portion of FIG. 6 with certain elements omitted for explanatory purposes;
FIGS. 8 a and 8 b are explanatory views for disclosing the switching operation of the transmission mechanism;
FIG. 9 is a perspective view of a conventional coin hopper equipment; and
FIG. 10 is a cross-sectional view of a portion of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the general principles of the present invention have been defined herein to specifically provide a compact transmission of power that is automatically switchable to a coin dispenser.
The drawings disclosing the features of the present invention are illustrative only and not necessarily drawn to scale. Referring to FIG. 1, a perspective view of a compact gear box or transmission assembly including a housing that is split to have an upper casing member 1 and a lower casing member 2 is disclosed. The gear box, and more particularly the lower casing member 2 is mounted on a flange 9 attached to one end of the electric motor 10 . As can be seen in FIG. 1, the transmission assembly is relatively compact and provides an upper output shaft 20 and a lower output shaft 30 . The electric motor 10 that extends downward from the flange 9 can be of a direct current type and is reversible so that there is a positive rotation, for example, in a clockwise direction and a reverse rotation in a counter clockwise direction. As can be appreciated, as with a conventional hopper arrangement, the electric motor and transmission assembly can be appropriately mounted and suspended from the frame of a coin hopper for appropriately driving the coin hopper and components therein. Referring to FIG. 2, a side elevated view of the perspective view of FIG. 1 is disclosed.
Referring to FIGS. 3 a and 3 b , the driving shaft of the electric motor 10 is connected to a small helical pinion gear 11 that is mounted between the upper case member 1 and the lower case member 2 within the gear box. See for example, FIGS. 5 a and 5 b . Referring again to FIG. 1, the cylindrical output shaft 20 , which is shown at the right-hand portion of FIG. 1, is the primary output shaft of the gear transmission assembly. This primary output shaft 20 can rotate an internal disc (not shown) for selectively sending out coins in the hopper equipment. The disclosure of U.S. Pat. No. 5,984,771 is incorporated herein by reference to supplement the present disclosure. Fixed at the inner end of the primary output shaft 20 is a large output gear 21 as shown in FIG. 4 . Also shown in FIG. 1 at the left-hand side is a second output shaft 30 . This second output shaft 30 can drive a belt (not shown) for picking up and agitating coins within the hopper equipment so that coins could be translated from the open hopper through an intermediate casing member to the coin selecting disc. As shown in FIGS. 4 a and 4 b , a large output gear 31 is fixed to an inner end of the second output shaft 30 within the transmission casings 1 and 2 .
Referring to FIGS. 3 a and 3 b , a switching gear mechanism is positioned within the transmission assembly between the primary output shaft 20 and the secondary output shaft 30 .
The switching gear mechanism has a fixed shaft or first support member 23 that extends between the top and bottom case members 1 and 2 . Freely rotated at either end of this fixed shaft member is a link unit comprising in one embodiment a pair of elongated movable board members or link members 25 and 27 . Also journaled for free rotation about the fixed shaft 23 between the movable boards 25 and 27 is a large helical gear 33 that can move along the axial direction of the shaft 23 . Additionally, a smaller spur gear 35 is coaxially mounted on the upper side of the gear 33 and with the gear 33 forms a primary stepped gear arrangement. A set of resilient bearing members such as plate springs 37 , having a relatively strong elastic or spring force are positioned between respectively the movable board or link member 25 and the spur gear and helical gear 33 and act as switch members to form a mounting unit.
As also can be seen, the plate springs 37 are arranged between the lower movable board or link member 27 and the helical gear 33 . Radially outward from the fixed shaft 23 is a transfer shaft 51 that is fixed adjacent to the end of each of the movable board members 25 and 27 . Mounted about the transfer shaft 51 between the movable boards or link members 25 and 27 is a large switching gear 53 that can be freely rotated and is movable in the axial line of direction of the transfer shaft 51 . This switching gear 53 further engages with a small spur gear 35 that is mounted on the fixed shaft 23 . Thus, when the pinion gear 11 drives the helical gear 33 , the spur gear 35 will drive the switching gear 53 . In addition, a small spur gear 55 is formed at one side of the switching gear 53 so that the large switching gear 53 and the small spur gear 55 provide a second step gear arrangement. The plate springs 57 which are mounted between the lower movable board of link member 27 and the spur gear 55 have a relatively weak elastic or resilient force. Likewise, the upper plate spring 57 that is mounted between a flange on the transfer shaft 51 and the switching gear 53 or spur gear 55 also has a relatively weak elastic or resilient force.
Referring to FIGS. 5 a and 5 b , and FIGS. 7 a and 7 b , the relative rotation of the transfer gear 53 in a clockwise and counter-clockwise direction is disclosed.
Referring to FIG. 8, a pivotable stop member or link arm 61 rotates about a hinge or support post 63 on the top case member 1 . This roughly U-shaped link 61 can act as a stopper or brake for the primary output shaft 20 . A spring 65 is arranged so that a portion of the stopper 61 may engage with a primary output gear 21 as shown in FIG. 6 . Additionally, the tip of the stopper 61 can freely contact the movable board or link member 25 .
In operation, the helical gear 33 can be rotated for example in a counter-clockwise direction when the electric motor 10 is rotated in the manner disclosed in FIG. 5 a . When the helical gear 33 is rotated by the pinion 11 in the counter-clockwise direction, the gear 33 will receive a force along its axial line direction, that is, the helical gear 33 which is rotated by the pinion 11 will receive the thrust so that the helical gear 33 will press the movable board 27 against the plate springs 37 . As a result, the movable board 27 will be moved in the counter-clockwise direction receiving a turning force of the helical gear 33 as can be seen in FIG. 4 b . Thus, when the helical gear 33 is rotated in this manner, the movable boards or link members 25 and 27 are moved in the counter-clockwise direction as a result of the compression of the appropriate set of plate springs 37 . The radially outboard transfer shaft 51 is then moved in the counter-clockwise direction so that the spur gear 55 will engage with the primary output gear 21 as can be seen in FIG. 5 a . In this condition, the counter-clockwise turning force of the helical gear 33 is transmitted to the switching gear 53 as shown in FIG. 5 b . Then, the turning force of the helical gear 33 is transmitted to the primary output gear 21 through the existing contact with the switching gear 53 and the spur gear 55 as shown in FIG. 5 a . At this time, the primary output gear 21 can be placed into a free or nondriven condition as the movable board 27 and movable board 25 are moved in the counter-clockwise direction as shown in FIG. 8 a . That is to say, the stopper 61 can separate from the primary output gear 21 .
When the electric motor 10 is reversed, the helical gear 33 is rotated in the clockwise direction, for example, as shown in FIG. 7 a . When the helical gear 33 is rotated in a clockwise direction by the pinion gear 11 , the gear 33 will receive a thrust force along the axial line direction. As a result of this thrust force, the helical gear 33 will press the movable board 25 , for example, against the force of the plate spring 37 . Upon receiving the thrust or turning force of the helical gear 33 , the movable board or link 25 will be moved in the clockwise direction as shown in FIG. 8 b . Thus, when helical gear 33 is rotated in a clockwise direction, the respective movable boards or link members 25 and 27 are also moved in the clockwise direction against the force of the plate spring 37 . As a result, the transfer shaft 51 is also moved in a clockwise direction and the spur gear 55 will engage the second output gear 31 as shown in FIG. 7 a.
In this condition, the clockwise rotation of the helical gear 33 is transmitted to the switching gear 53 and the existing gear 35 as shown in FIG. 7 b when the rotation of the helical gear 33 is transmitted to the second output gear 31 through the switching gear 53 and the spur gear 55 as shown in FIG. 7 a . Additionally, at this time, the stopper 61 becomes in a free condition since the movable board or link member 25 is moved in the clockwise direction as can be seen in FIG. 8 b . Therefore, as a result of the action of the spring 65 , a part of the stopper 61 will mesh with the primary output gear 21 and thereby will act as a braking member to prevent gear 21 from being rotated. See, for example, FIG. 6 .
While not shown, a second similar stopper can also mesh freely with the second output gear 31 . In this case, the second output gear 31 becomes in a free condition when the movable board or link member 25 is moved in the clockwise direction. Thus, the second stopper can be placed in a free condition when the movable board or link member 25 is moved in the counter-clockwise direction. As a result of a spring (not shown), a part of the second stopper can mesh with the second output gear 31 and thus brake or hold the gear 31 from rotating.
It should be understood that each of the plate springs 37 can also be alternatively provided with a friction material to transmit the thrust of the helical gear 33 to each of the movable board or link members 25 and 27 . In the preferred embodiment, each of the plate springs 37 may be of a ring shaped spring and washer member and each of the plate springs 57 between the second step gear and the movable board or link members 25 and 27 can be expressed as a load member which is arranged properly. When the load member such as plate springs 57 are arranged, the thrust of the primary step gear is smoothly transmitted to each of the respective movable boards or link members 25 and 27 .
Thus, wherein a load is applied to the second step gear, the thrust of the primary step gear can be smoothly transmitted to the movable boards 25 and 27 . As can be appreciated, it is an advantage to permit the plate springs 27 to be made in a ring-type configuration such as a spring and washer or file plate.
In the preferred embodiment, the pinion gear 11 and the gear 33 were designed to be helical. However, it is possible that the pinion gear 11 and the gear 33 may be gears which generate thrust when they are rotated.
In the present invention, the large gear 33 with a helical tooth engaging the small pinion gear 11 with a helical tooth arrangement can be utilized as a driving force. Therefore, the repeated operations of positive rotation, stop and reverse operations and subsequent stopping of the electric motor can be surely transmitted to the output gears 21 and 31 while absorbing any inertia forces that would be imposed on the output gears 21 and 31 as a result of the axial movement and the elastic spring members.
As can be readily appreciated, this relatively simple construction permits an improved performance with a minimum of parts to thereby permit a relatively compact transmission gear assembly for use with a reversible electrical motor. The relative selection or choice of the output shafts can be easily performed by the automatic swing mechanism that is simply activated by the appropriate rotation of the electric motor. The present invention therefore can simply switch the rotating shafts from a hopper disc to a handler belt by a simple switching of the rotational direction of the electric motor.
In each of the above embodiments, the different positions and structures of the present invention are described separately in each of the embodiments. However, it is the full intention of the inventor of the present invention that the separate aspects of each embodiment described herein may be combined with the other embodiments described herein. Those skilled in the art will appreciate that adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein. | The present invention provides a compact transmission assembly for use in a coin storage and dispensing apparatus. The transmission assembly can connect the rotational output of a reversible electrical motor to a link unit that supports a switching gear unit. A helical gear unit can be mounted adjacent to the link unit and can be driven axially along a shaft to contact a mounting unit to receive a thrust force and to drive the link unit in a clockwise or counter-clockwise direction depending upon the rotation of the reversible motor. The switching gear unit is radially mounted at an offset position on the link unit and can appropriately contact output gears connected to output shafts for providing a selective dual power output. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Applications and patents 09/924,392, 10/666,897, 10/746,957, 10/799,549, 10/825,912, 10/825,974, 11/022,078, 11/025,363, 11/025,680, 11/025,681, 11/025,692, 11/025,693, 11/084,486, 11/121,737, 11/187,213, U.S. 20050166834, U.S. 20050161773, U.S. 20050163692, 11/053,775, 11/053,785, 11/054,573, 11/054,579, 11/054,627, 11/068,222, 11/188,081, 11/253,525, 11/254,031, 11/257,517, 11/257,597, 11/393,629, 11/398,910, 11/472,087, 11/788,153, 11/858,838, 11/960,418, 12/119,387, 60/820,438, 60/811,311, 61/089,786, 12/171,200, 12/119,387, 12/408,297, 12/510,977, 12/619,621, 12/619,549, 12/619,637, 60/847,767, 60/944,369, 60/949,753, 61/312,061, 61/301,597, 61/298,896, U.S. Pat. No. 7,018,484, U.S. Pat. No. 7,037,806, U.S. Pat. No. 7,135,699, U.S. Pat. No. 7,199,015, U.S. Pat. No. 7,586,177, and U.S. Pat. No. 7,807,917, all held by the same assignee, contain information relevant to the instant invention and are incorporated herein in their entirety by reference. U.S. Pat. No. 7,589,003, U.S. Pat. No. 7,598,513, U.S. application Ser. No. 12/133,225 and PCT/US2009/057213, published as WO2010/044978 contain information relevant to the instant invention, are licensed by the assignee and are incorporated herein in their entirety by reference. References noted in the specification and Information Disclosure Statement are incorporated herein in their entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to photovoltaic device structures of more than one layer comprising rare earth compounds and Group IV materials enabling spectral harvesting outside the conventional absorption limits for silicon.
[0004] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98.
[0005] As an alternative approach to multiple junction solar cells where specific materials are matched to discrete portions of the solar spectrum, spectral harvesting works on the principle of moving parts of the spectrum to the wavelength band of a single junction cell. For example it is widely accepted that a single junction, single crystal silicon solar cell has an optimum performance in the wavelength range 500 to 1,100 nm, whilst the solar spectrum extends from 400 nm to in excess of 2,500 nm.
[0006] Rare earths, the lanthanide series, have long been known for the unique optical properties in which the incomplete, 4f shells exhibit multiple optical transitions many of which lie within the solar spectrum. Examples of some of these optical transitions are: Er: 410 nm, 519 nm, 650 nm, 810 nm, 972 nm, 1,529 nm; Yb: 980 nm; Tb: 485 nm.
[0007] Certain rare earths and combinations of rare earths, optionally, with one or more transition metals and/or one or more Group IV elements, can absorb light at one wavelength (energy) and re-emit at another wavelength (energy). This is the essence of spectral harvesting; when the incident, adsorbed, radiation energy per photon is less than the emission, emitted, energy per photon the process is referred to as “up-conversion”. “Down-conversion” is the process in which the incident energy per photon is higher than the emission energy per photon. An example of up conversion is Er absorbing at 1,480 nm and exhibiting photoluminescence at 972 nm.
[0008] Sensitization of RE materials with transition metals Cr and V is taught in the prior art; in particular the use of Cr 5+ within an Er doped YVO 4 powder for up-conversion of infrared light to visible light. In this invention we disclose films deposited on semiconductor devices, optionally photovoltaic devices. A. C. Pan, et al. in “Characterization of up-converter layers on bifacial silicon solar cells”; Matls. Sci. & Engin., 159-160 (2009), 212; describe rare earth-doped zinc/cadmium sulphides or selenides phosphor films applied to a solar cell as a spin-on oxide or with silicone gel. A. C. Pan has also published on rare earths in combination with PbS quantum dots as up-converters. A. Polman, et al., disclose up conversion a film of Si nanocrystals in a SiO 2 matrix doped with Er 3+ ions in “Broadband sensitizers for erbium-doped planar optical amplifiers”; J. Opt. Soc. Am. B, 21, No. 5, May 2004. Other references cited in the Information Disclosure Statement include, Gong, 20010; Chang, 2006; Choi, 2007; Isshiki, 2005, 2006, 2008, etc.; Zhao, 2007; Kimura, 2006; Liu, 2007; Qi, 2000; Sands, 1990; Schaevitz, 2008; Sh, 2006; Goldschmidt, 2009; AC Pan, 2009; Michael, 2008; Polman, 2004; Presting, 2002; all incorporated herein in their entirety by reference.
[0009] Silicon quantum dots have been demonstrated in Gd 2 O 3 layers grown on silicon wafers for use as optical absorber materials, where the Gd 2 O 3 acts as an inert matrix for the Si nano dots. In the discussion, it is implied that electrons would be extracted directly from the Si nano dots, and that the REO layer does not have an electrical or optical function in the device. The present invention discloses Group IV nano dots in a fundamentally different way in that energy is absorbed by a Group IV nano dot and then transferred via resonant energy transfer into an optically active REO matrix containing at least one optically active RE ion diluted in an inert REO matrix. The present invention also discloses the use of carbon as a nano dot and mixtures of Group IV elements as an optical absorber material.
[0010] U.S. Pat. No. 6,613,974 discloses a tandem Si—Ge solar cell with improved efficiency; the disclosed structure is a silicon substrate onto which a Si—Ge epitaxial layer is deposited and then a silicon cap layer is grown over the Si—Ge layer; no mention of rare earths is made. U.S. Pat. No. 7,364,989 discloses a silicon substrate, forming a silicon alloy layer of either Si—Ge or Si—C and the depositing a single crystal rare earth oxide, binary or ternary; the alloy content of the alloy layer is adjusted to select a type of strain desired; the preferred type of strain is “relaxed”; the preferred deposition method for the rare earth oxide is atomic layer deposition at temperatures below 300° C. While the Si—Ge film is “relaxed”, its primary function is to impart no strain, tensile strain or compressive strain to the rare earth oxide layer; the goal being to improve colossal magnetoresistive, CMR, properties of the rare earth oxide. A preferred method disclosed requires a manganese film be deposited on a silicon alloy first. Recent work on rare earth films deposited by an ALD process indicate the films are typically polycrystalline or amorphous.
[0011] U.S. Pat. No. 7,432,550 discloses a method of forming a semiconductor structure including a rare earth oxide on silicon; use of La x Y 1-x ) 2 O 3 as an intermediate layer on freshly grown silicon or SiO 2 is disclosed; strain engineering is not employed. U.S. Pat. No. 72,48,226, by the same inventors, discloses depositing amorphous silicon on a rare earth oxide and the recrystallizing it at an elevated temperature. U.S. Pat. No. 6,670,544 discloses a Si—Ge thin film solar cell having a quantum well structure; rare earth oxides are not disclosed. U.S. Pat. No. 7,599,593 discloses Si—Ge quantum wells comprising two buffer layers; rare earths are not disclosed.
[0012] U.S. Pat. No. 7,589,003, U.S. Pat. No. 7,598,513, WO2010/044978 and U.S. application Ser. No. 12/133,225 disclose methods and structures for depositing Ge 1-x Sn x layer on a silicon substrate wherein the Ge 1-x Sn x layer has a direct band gap between about 0.72 and about 0.041 eV. Also disclosed are Si x Ge 1-x Sn y Ge 1-x-y layers grown on Si substrates wherein x≦0.25 and y≦0.11 and the band gap is between about 0.80 and about 1.40 eV; in some embodiments a high-k dielectric layer, optionally comprising a Lanthanum based oxide, is part of a semiconductor structure consisting of a second Si-based layer comprising elemental silicon.
[0013] Liu, J., et al. in “Tensile-strained, n-type Ge as a gain medium for monolithic laser integration on Si”; Optics Express, 3 Sep. 2007/Vol. 15, No. 18, 11272, analyze the optical gain of tensile-strained n-type Ge material for Si-compatible laser applications. Michael, et al., in “Growth, processing and optical properties of epitaxial Er 2 O 3 on silicon”; Optics Express, 24 Nov. 2008/Vol. 16, No. 24, 19649 discloses erbium-doped materials for generating and amplifying light in low-power chip-scale optical networks on silicon. Laha, et al. in “Encapsulated solid phase epitaxy of a Ge quantum well embedded in an epitaxial rare earth oxide”; 2009 Nanotechnology 20, 475604 disclose a method to integrate an epitaxial Ge quantum well into a single crystalline rare earth oxide comprising Gd 2 O 3 —Ge—Gd 2 O 3 grown on a silicon substrate. The prior art does not disclose a semiconductor structure incorporating rare earth and Si—Ge—Sn based layers for spectral harvesting in a photovoltaic device configuration.
BRIEF SUMMARY OF THE INVENTION
[0014] In some embodiments the instant invention discloses materials as thin films operable with a solar cell or photovoltaic device(s). One advantage of thin films is the control provided over a process both in tuning a material to a particular wavelength and in reproducing the process in a manufacturing environment. In some embodiments, rare earth oxides, nitrides, and phosphides, transition metals and Group IV materials and various combinations thereof are employed. The instant invention discloses a device structure enabling increased conversion efficiency by harvesting a larger portion of the solar spectrum than conventional technology by coupling a Group IV based broadband absorber to a rare earth based photoluminescent layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIGS. 1 a, b, c are schematic illustrations of embodiments of the invention.
[0016] FIGS. 2 a and b are schematic illustrations of different embodiments.
[0017] FIGS. 3 a, b and c are schematic illustrations of a REO emitter and Group IV absorber.
[0018] FIG. 4 a is a schematic illustration of an embodiment; FIG. 4 b shows RE absorption vs. Ge mole fraction and band gap.
[0019] FIGS. 5 a and b are schematic illustrations of one embodiment and an optional repeating structure.
[0020] FIG. 6 is schematic illustration of an embodiment with multiple repeating layers, optionally of different compositions.
[0021] FIG. 7 is a schematic illustration of an embodiment with multiple layers and predetermined thickness and strain in each layer.
[0022] FIG. 8 a is a schematic illustration of an embodiment with a discrete quantum dot inclusions; FIG. 8 b is a schematic illustration of an embodiment with discrete quantum dot inclusions in a single layer.
[0023] FIG. 9 shows photoluminescence data from a REO layer comprising Group IV sensitizers.
[0024] FIG. 10 is an exemplary REO layer with Ge sensitizer.
[0025] FIG. 11 shows absorption and emission location for various REOn compositions.
DEFINITIONS
[0026] As used herein a rare earth, [REa, REb, . . . RE q ], is chosen from the lanthanide series of rare earths from the periodic table of elements { 57 La, 58 Ce, 59 Pr, 60 Nd, 61 Pm, 62 Sm, 63 Eu, 64 Gd, 65 Tb, 66 Dy, 67 Ho, 68 Er, 69 Tm, 70 Yb and 71 Lu} plus yttrium, 39 Y, and scandium, 21 Sc, are included as well for the invention disclosed. As used herein a “REO” layer contains two or more elements, at least one chosen from a rare earth and at least one chosen from oxygen and/or nitrogen and/or phosphorous and/or mixtures thereof; structures are not limited to specific rare-earth elements cited in examples. REO[N], or [REO]n, is used to mean a compound of the form (RE a , RE b , . . . RE q ) w O x N y P z , wherein there is at least one rare earth, at least one of a, b, . . . q is greater than zero, and w>0 and at least one of x, y, z is >0. In some embodiments, in addition to REO an alloy may include one or more Group IV elements such as Si and/or Ge and/or C and/or Sn and mixtures thereof. As used herein, S1, S2, S3, . . . Sm are mixtures of Group IV elements wherein S1 is C v Si x Ge y Sn z and S2 is C a Si b Ge c Sn d and so on and at least one of (a, b, c, d) and one of (v, x, y, z) are greater than zero. In this context, S1:REO[1], alternatively REO 1 , refers to a specific Group IV based composition in combination with a specific REO composition; in general S1 is different than S2 and REO[1] different than REO[2]; however there may be embodiments when 1, 2, 3, etc. are the same. In some embodiments a layer of a disclosed structure may consist of only Group IV elements, as in S1, C v Si x Ge y Sn z .
[0027] As used herein a transition metal, [TM1, TM2 . . . TM n ], is chosen from the transition metal elements consisting of { 22 Ti, 23 V, 24 Cr, 25 Mn, 26 Fe, 27 Co, 28 Ni, 29 Cu, 30 Zn, 40 Zr, 41 Nb, 42 Mo, 43 Tc, 44 Ru, 45 Rh, 46 Pd, 47 Ag, 48 Cd, 71 Lu, 72 Hf, 73 Ta, 74 W, 75 Re, 76 Os, 77 Ir, 78 Pt, 77 Au, 80 Hg}. Group IV materials include Carbon, Silicon, Germanium, Tin and Lead and mixtures thereof; Groups III, V and Groups II, VI elements have the conventional meaning and include II-V mixtures and II-VI mixtures. As used herein all materials and/or layers may be present in a single crystalline, polycrystalline, nanocrystalline, nc, nanodot or quantum dot and amorphous form and/or mixture thereof; in some cases a Group IV layer may be hydrogenated, for example, as in Si:H or nanocrystalline hydrogenated, nc-Si:H.
[0028] It should be understood that when a layer is referred to as being “on” or “over” another layer or substrate, it can be directly on the layer or substrate, or an intervening layer may also be present. It should also be understood that when a layer is referred to as being “on” or “over” another layer or substrate, it may cover the entire layer or substrate or a portion of the layer or substrate.
[0029] It should be further understood that when a layer is referred to as being “directly on” or “directly over” another layer or substrate, the two layers are in direct contact with one another with no intervening layer. It should also be understood that when a layer is referred to as being “directly on” or “directly over” another layer or substrate, it may cover the entire layer or substrate, or a portion of the layer or substrate.
[0030] The terms “region” and “block” as used herein, mean a single-layer or a multi-layer structure. The term “active block” as used herein, means an active single layer or multilayer, such as a heterostructure, p-n junction, p-i-n junction, or single quantum well (QW) or multiple QW, single or multiple quantum dots, that can provide a photocurrent under incident radiation.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Examples of device structures utilizing layers of single crystal rare earth oxides to perform the tasks of up conversion, and/or down conversion along with, optionally, designing in required optical and/or anti reflective properties are now given. In embodiments of the instant invention, v, x, y and z range from 0 up to and including 1. A substrate may be silicon, poly or multi-crystalline silicon, silicon dioxide, glass or alumina; as used herein multi-crystalline includes poly, micro and nano crystalline. The number of REO/Si(1-y)Ge(y) bilayers may range from one to more than one hundred. “A layer” also comprises multiple layers, optionally. REO, Si(1-x)Ge(x), Si(1-y)Ge(y), and Si(1-z)Ge(z) layers are, optionally, single crystal, multi-crystalline or amorphous layers and are, optionally, optically active dielectrics compatible with semiconductor processing techniques. In some embodiments a low cost substrate such as soda glass or polycrystalline alumina is used in combination with a rare-earth based structure comprising a diffusion barrier layer, a buffer layer, an active region, up and/or down layer(s), one or more reflectors, one or more Bragg layers, texturing is optional; one or more layers may comprise a rare-earth. The exact sequence of the layers is application dependent; in some cases sunlight may enter a transparent substrate initially; in other cases a transparent substrate may be interior of multiple layers.
[0032] FIGS. 1 a - c illustrate several embodiments; structure 101 has rare earth layer 110 between semiconductor layers S1, 105 , and S2, 115 with radiation impinging on S1 initially; structure 102 in FIG. 1 b has REO[2] layer between incoming radiation and layer S2; similarly structure 103 in FIG. 1 c has S1 layer between incoming radiation and REO[3] layer; in all cases the REO layer is re-emitting radiation at one or more preselected wavelengths based upon its composition and construct of one or more layers; in all cases the Group IV, Sm, layers are functioning as broadband absorbers and the REO layer has spectral up-converting and/or down-converting capabilities. In some embodiments semiconductor structures comprising Ge 1-x-y Si x Sn y alloys are disclosed that have tunable band gaps ranging between about 0.80 eV to about 1.40 eV.
[0033] In general the Group IV layer, nanocrystal, quantum dot or inclusion absorbs a photon and generates an exciton; the exciton may be bound to a Group IV site; alternatively an exciton may recombine radiatively, emitting a photon with energy based on the Group IV site size, such the nanocrystal or quantum dot size. With rare earth present an exciton can recombine non-radiatively by bringing a rare earth ion into one of its excited states. Alternatively, other energy transfer processes may be operable; energy transfer from a Group IV material to a rare earth material may be based on phonon transfer, resonant energy transfer and/or emission of a localized, non-radiative photon. The instant invention discloses the use Group IV materials as broad band absorbers and narrow band emitters coupled to localized, narrow band, rare earth absorbers operable as emitters at predetermined frequencies. A detailed explanation of energy transfer processes is found in Chapter Five of “Novel Solar Cell Concepts” by J. C. Goldschmidt, Ph.D. Dissertation, September 2009; incorporated herein in its entirety by reference. FIG. 11 shows various absorption wavelengths for various REO[N] combinations with associated emission energies after up-conversion.
[0034] FIG. 2 a is an alternative embodiment; structure 204 comprises REO[4] layer 215 comprising a Group IV mixture, S3, located between solar cell 210 and reflective layer 220 . FIG. 2 b is an alternative embodiment; structure 205 comprises REO[5] layer 216 and layer 217 comprising Group IV composition S4, located between solar cell 211 and reflective layer 221 . Solar cells 210 and 211 may be a single cell or multiple cells; layers 215 and 216 / 217 are designed to absorb in a spectral range not absorbed by the solar cell and re-emit radiation in a range capable of absorption by the solar cell, thus increasing its efficiency. The term “spectral harvesting” is used to define the process of wavelength shifting by an REO layer, such as 215 and 216 , optionally with Group IV additives or sensitizers, as in layer 215 ; broadband absorption by a layer such as 217 is also occurring with subsequent energy transfer to rare earth layer REO[4], 216. In all cases the compositions REO[4, 5], S3 and S4 are selected based upon the overall device, 204 or 205 , construction; optionally one or more layers of device 204 or 205 is in a state of strain to enhance its functionality. FIG. 3 a is REO[4]:S3 layer 215 , showing the growth direction in a vertical fashion wherein a REO emitter is combined with a Group IV absorber, S3, in a single layer; FIG. 3 b shows an example of S3 nano-crystals being randomly distributed throughout the layer; FIG. 3 c shows S3 nano-crystals being distributed in a discrete manner, also termed “delta doping”. In this embodiment S3 is, optionally, a quantum dot or nano-crystal in a REO matrix; quantum dot compositions are quantized in both the z (growth) direction and in the x, y plane, as shown in FIG. 8 .
[0035] FIG. 4 a illustrates an REO[5] 416 emitter and Group IV 417 absorber as a bulk double layer, as 416 and 417 . In this case the properties and composition of S5 is matched to a desired transition; such as, up conversion by Er absorbing at 1,480 nm and exhibiting photoluminescence at 980 nm. A Group IV absorber is tuned with a Ge mole fraction of about 0.7 to transfer energy at 1480 nm to an Er based rare earth for up conversion to 980 nm and absorption by an adjacent solar cell such as 210 or 211 .
[0036] FIGS. 5 a and b show alternative embodiments 501 and 502 wherein there are single, 501 , or multiple layers, 502 , of an REO emitter matched to a Group IV absorber Sm, optionally, REO1/S1, REO2/S2, . . . REOn/Sm. In some embodiments compositions REOn 516 and Sm are chosen to impart a strain in the Group IV layer and/or REO layer. Alternatively, S6, 518 , and S7, 519 , may repeat one or more times for N pairs; optionally reflective layers 222 and 223 are mirrors or Distributed Bragg Reflectors or other means for reflecting radiation back through structures 501 and 502 . In this manner strain between S5, 417 , and REO[5] of layer 416 can be constructed from S6, 518 , and S7, 519 ; for example S6 may be Si 0.4 Ge 0.6 and S7 may be Si 0.6 Ge 0.4 . By using multiple layers of predetermined composition the lattice parameter of a given layer is decoupled from a given band gap constraint. In this way a rare-earth, REO/Group IV spectral conversion structure is fabricated on, underneath, or within solar cell device structures for the purpose of modifying the spectral distribution of the incident radiation and harvesting radiation previously not converted.
[0037] FIG. 6 illustrates an embodiment 601 wherein the Group IV layer, Sm, and REOn layers repeat at least once to m pairs. FIG. 7 illustrates an example of strain engineering wherein a Group IV layer, S7, is between [REO] 7 and [REO] 8 layers, of thickness t 7 and t 8 . The structure 701 is designed such that the strain in each layer is predetermined to optimize absorption and energy transfer by the S7 layer. In some embodiments there are multiple layers of Sm and [REO]n, as noted in FIGS. 5 and 6 . FIGS. 8 a and b illustrate embodiments wherein a Group IV material, Sm, is, optionally, a quantum dot or nano-crystal or inclusion in a REO matrix; quantum dot compositions are quantized in both the z (growth), FIG. 8 a , direction and in the x, y plane, FIG. 8 b.
[0038] FIG. 9 shows up-conversion photoluminescence data from a REO layer comprising Group IV sensitizers with REO up-conversion emission about 650 nm and 980 nm. FIG. 10 is an exemplary REO layer with germanium sensitizer wherein 0.25≦Ge≦3 at. % and the REO matrix is (Gd 1-x Er x ) 2 O 3 with Er between about 5 and 20 at. %.; optionally, layers may repeat in a fashion as described in FIGS. 5 , 6 and 7 .
[0039] A growth or deposition process may be any one, or combination, of those known to one knowledgeable in the art; exemplary processes include CVD, MOCVD, PECVD, MBE, ALE, PVD, electron beam evaporation, multiple source PVD. In some embodiments a rare-earth layer(s) functions as a transition region between similar or dissimilar semiconducting layers and also functions as an up and/or down converting region for converting a portion of incident radiation to higher or lower energy. An exemplary structure may be a multiple-junction solar cell wherein one region comprises a silicon p-n junction cell, a second region is a rare-earth transition region functioning as a defect sink and an up converter and a third region is a germanium p-n junction cell; optionally, a first or second region may be alternative Group IV, Group III-V or Group II-VI semiconductors.
[0040] In some embodiments a rare-earth layer(s) transition region may comprise sensitizers to enhance up conversion. In some embodiments a sensitizer may be a discrete layer in a transition region; alternatively a rare-earth layer(s) transition region may comprise a sensitizer as part of its overall composition; alternatively a rare-earth layer(s) transition region may comprise a sensitizer in the form of quantum dots in a rare-earth based matrix; alternatively, a sensitizer may take more than one form in a rare-earth layer(s) transition region such as quantum dots and part of an overall composition of a rare-earth matrix.
[0041] In some embodiments a rare-earth layer transition region comprises a first rare-earth portion of first composition adjacent to a first semiconductor region, a second rare-earth portion of second composition adjacent to a second semiconductor region and a third rare-earth portion of third composition separating the first and second rare-earth portion; in some embodiments the third rare earth composition varies from the first rare-earth composition to the second rare-earth composition in a linear fashion; alternatively the third rare earth composition may vary in a step-wise fashion; alternatively, the third rare earth region may comprise multiple layers, each with a distinct composition determined by a desired stress profile to facilitate the capture and/or annihilation of lattice defects as may be generated by the transition from the first and second semiconductor regions during a growth process and subsequent process steps. In some embodiments a third rare earth region may transition from a compressive stress to a tensile stress based upon the beginning and ending compositions.
[0042] Substantially single crystal multilayer structures allow for the formation of low dislocation density material with low structure defects. Electronic propagation parallel and perpendicular to the plane of the layers is therefore improved compared to polycrystalline material. Alternatively, in some embodiments, a first semiconductor layer may be polycrystalline, large grained crystalline or micro/nano crystalline; subsequent layers may also be polycrystalline, large grained crystalline or micro/nano crystalline. As used herein, large grained is defined as a grain of lateral dimension much larger than the dimension in the growth direction.
[0043] Rare earth oxide materials for spectral conversion have previously been disclosed in U.S. application Ser. No. 12/408,297; various spectral conversion layers relative to the solar cell are disclosed. To improve the conversion efficiency of these materials, and/or reduce the thickness of spectral conversion material required, a “sensitizer” component may be added to the spectral conversion material. The instant invention discloses a sensitizer component, a transition metal, TM, such as chrome or vanadium, incorporated into or distinctly adjacent to a rare-earth containing material; a sensitizer may be incorporated into a layer comprising rare earths, a distinct transition metal layer or in the form of nanodots embedded within or adjacent to the rare-earth containing layer; alternatively silicon, germanium, tin or other Group IV elements or mixtures thereof with dimensions less than about 100 nm within a rare earth based matrix may function as a sensitizer. The function of the sensitization material is to absorb radiation for spectral conversion. In the case of an up converter photovoltaic device, long wavelength radiation beyond the spectral range of the ‘host’ device is absorbed by the sensitizer material. Through a resonant energy transfer process, the absorbed energy is transferred to the rare-earth ions contained in the up conversion material, or in an adjacent layer of up conversion material. The purpose of using a sensitizer component in the up conversion material is to widen the spectral absorption band of the up converter and also increase the absorbance. The effect of this is to absorb a greater amount of radiation in a thinner device.
[0044] Sensitized spectral conversion layers for photovoltaic devices are disclosed in this invention, including types represented by the formula [RE1] a [RE2] b [RE3] c [TM1] d [TM2] e [TM3] f [O] g [P] h [N] i , where 0<a, d, at least one of g, h, i≧0, and 0≦b, c, e, f; optionally, at least two of g, h, i≧0, with RE1,2,3 and TM1, 2, 3 chosen from the groups defined previously; 0, N, P are the symbols for oxygen, nitrogen, phosphorus. Alternatively, in some embodiments, sensitized spectral conversion layers for photovoltaic devices are disclosed with formulas being [RE1] a [RE2] b [RE3] c [TM1] d [TM2] e [TM3] f [O] g [P] h [N] i :[Si j Ge k ], where: [IV j IV k ] represents a distinct layer of a Group IV material or a mixture of at least two; alternatively, in some embodiments Group IV materials, optionally, Si and/or Ge, are present as nanocrystals with dimensions less than about 100 nm within a [RE1] a [RE2] b [RE3] c [TM1] d [TM2] e [TM3] f [O] g [P] h [N] i , matrix wherein an overall composition of [RE1] a [RE2] b [RE3] c [TM1] d [TM2] e [TM3] f [O] g [P] h [N] i :[IV j IV k ], is described by [0<a, (one of g, h, i) and at least one of (j or k)≧0], and [0≦b, c, d, e, f, (two of g, h, i) and one of (j or k)≧0]; optionally [IV j IV k ] may be C, Si, Ge, Sn and/or mixtures thereof.
[0045] In some embodiments a solid state device for converting incident radiation into electrical energy comprises a structure comprising; a first region of first rare earth composition [REO]n; a second region of second composition, Sm, consisting of Group IV elements in contact with the first region wherein the first region is in a first state of strain and the second region is in a second state of strain such that the second region is operable as a direct band gap semiconductor; optionally, the device composition of the second region is operable to absorb a portion of the incident radiation and transfer a portion of the absorbed incident radiation to the first region; optionally, the device has a second region of a composition described by C v Si x Ge y Sn z , S 1 , and at least one of (v, x, y, z) is greater than zero; optionally, the device has a second region comprising a first layer and a second layer wherein the first layer is a first composition described by C v Si x Ge y Sn z and the second layer is a second composition described by C a Si b Ge c Sn d , S 2 , and at least one of (v, x, y, z) and at least one of (a, b, c, d) is greater than zero; optionally, the device composition of the first region is described by [RE1] v [RE2] w [RE3] x [J1] y [J2] z , [REO]p, wherein [RE] is chosen from a rare earth; [J1] and [J2] are chosen from a group consisting of Oxygen (O), Nitrogen (N), and Phosphorus (P), and 0≦v, w, z≦5, and 0<x, y≦5; optionally, the device has a second region operable to convert a portion of the incident radiation from a first energy to a second energy.
[0046] In some embodiments a solid state device for converting incident radiation into electrical energy comprises a first region comprising rare earth ions of first composition and quantum dots of second composition described by C v Si x Ge y Sn z wherein at least one of (v, x, y, z) is greater than zero such that the quantum dots are operable to convert a portion of the incident radiation from a first energy to a second energy and transfer the second energy to the rare earth ions; optionally, the device first region is operable to photoluminesce at a predetermined wavelength as determined by the first composition.
[0047] In some embodiments a solid state device for converting incident radiation into electrical energy comprises a photovoltaic cell, a first region comprising rare earth ions of composition [REO] 1 adjacent the photovoltaic cell; and a second region comprising a Group IV semiconductor in contact with the first region wherein the Group IV semiconductor is operable to convert a portion of the incident radiation from a first energy to a second energy and place a portion of the rare earth ions in an excited state by transfer of the second energy to the rare earth ions such that the excited rare earth ions are operable to photoluminesce at predetermined wavelengths; optionally, the device first region has a composition described by (Gd 1-x Er x ) 2 O 3 with Er between about 5 and 20 atom percent; optionally, the device second region has a composition described by C v Si x Ge y Sn z wherein at least one of (v, x, y, z) is greater than zero; optionally, the device second region has a composition described by Ge 1-x-y Si x Sn y wherein the band gap is between about 0.70 eV and about 1.50 eV; optionally, the device second region is a plurality of quantum dots or nano-crystals distributed in a predetermined fashion within the first region; optionally, the device second region is a layer of Group IV semiconductor material, Sm, in contact with the first region; optionally, the device first region comprises a first portion of first composition, [REO] 1 , and first thickness adjacent the photovoltaic cell and a second portion of second composition, [REO] 2 , and second thickness separated from the first portion by the second region wherein the first portion and the second portion exert a strain on the second region such that the second region is operable to convert a portion of the incident radiation from a first energy to a second energy.
[0048] The foregoing described embodiments of the invention are provided as illustrations and descriptions. They are not intended to limit the invention to a precise form as described. In particular, it is contemplated that functional implementation of invention described herein may be implemented equivalently in various combinations or other functional components or building blocks. Other variations and embodiments are possible in light of above teachings to one knowledgeable in the art of semiconductors, thin film deposition techniques, and materials; it is thus intended that the scope of invention not be limited by this Detailed Description, but rather by Claims following. All patents, patent applications, and other documents referenced herein are incorporated by reference in their entirety for all purposes, unless otherwise indicated. | The invention relates to photovoltaic device structures of more than one layer comprising rare earth compounds and Group IV materials enabling spectral harvesting outside the conventional absorption limits for silicon. | 8 |
FIELD OF THE INVENTION
The present invention relates to a hinge, particularly but not exclusively relates to a hinge for a glass door.
BACKGROUND OF THE INVENTION
A glass door can be mounted in a doorframe universally by using hinges to provide a light-admitting and waterproof circumstance in public or at home. There are a variety of structures of glass door hinges.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a hinge suitable for a glass door, having a roller actuating by a spring member and cooperating with a cylindrical surface and slots on the cylindrical surface to hold the glass door in the opened and closed positions, and to make the fluent opening and closing movement of the glass door.
To accomplish this object, the present invention is characterized by a hinge for a glass door comprising: a first clamp member having a first recess, a spring slot in the inside surface of the first clamp member, and a roller receiving hole in the side surface of the spring slot communicating with the first recess; a second clamp member fastened to the first clamp member to provide a glass pane receiving space and having a second recess corresponding to the first recess; a leaf spring received in the spring slot of the first clamp member; a positioning member received in the roller receiving hole and connected to the leaf spring, the end of which pass through the roller receiving hole into the first recess by urging of the leaf spring; a pivot bracket mounted on a doorframe and received in the first recess and the second recess and having a cylindrical out surface corresponding to the positioning member and pressed against the positioning member and having a plurality of positioning slot on the cylindrical out surface corresponding to the positioning member; and a pivot pin by which the first clamp member is hinged to the pivot bracket.
It is particularly preferred that a gear is defined on one end of the pivot pin, the first clamp member having a pair of pivot holes in the two side surface of the recess and a gear ring in the pivot hole, the gear going into mesh with the gear ring when the first clamp member is hinged to the pivot bracket by the pivot pin extending therethrough.
It is particularly preferred that the first clamp member has a notch and a fastening panel covering the open side of the notch to form the spring slot.
It is particularly preferred that a roller-mounting hole is defined in the leaf spring and a spring-mounting hole is defined in the positioning member corresponding to the roller-mounting hole, the leaf spring and the positioning member being interconnected by a bolt screwing respectively into the roller-mounting hole and the spring-mounting hole.
It is particularly preferred that a through hole is defined in the side surface of the spring slot corresponding to the roller receiving hole.
It is particularly preferred that the positioning member is pressed and urged by the leaf spring.
It is particularly preferred that the positioning member comprises: a connecting post; a roller bracket extending from the connecting post; and a roller, hinged to the roller bracket, the end of which passes through the roller receiving hole into the first recess by urging of the leaf spring.
It is particularly preferred that the pivot bracket has three the positioning slots at intervals of 90 degrees on the cylindrical out surface.
It is particularly preferred that the hinge further comprises a mounting base fastened on the pivot bracket and mounted securely on the doorframe.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1A is a perspective view of a hinge for a glass door of a first example according to the present invention.
FIG. 1B is a perspective view, looking from another perspective, of the hinge for the glass door of the first example according to the present invention.
FIG. 1C is a perspective view, partly broken away, of the hinge for the glass door of the first example according to the present invention.
FIG. 1D is an exploded perspective view of the hinge for the glass door of the first example according to the present invention.
FIG. 2A is a perspective view, partly broken away, of a hinge for a glass door of a second example according to the present invention.
FIG. 2B is an exploded perspective view of the hinge for the glass door of the second example according to the present invention.
FIG. 3A is a perspective view, partly broken away, of a hinge for a glass door of a third example according to the present invention.
FIG. 3B is an exploded perspective view of the hinge for the glass door of the third example according to the present invention.
FIG. 4A is a perspective view, partly broken away, of a hinge for a glass door of a fourth example according to the present invention.
FIG. 4B is an exploded perspective view of the hinge for the glass door of the fourth example according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner.
Example 1
As shown in the FIGS. 1A-1D , a first preferred embodiment is described as below.
A hinge for a glass door comprises a first clamp member 1 , a second clamp member 2 , two gasket 3 , a leaf spring 4 , a positioning member 5 , a pivot bracket 6 , a pivot pin 7 and a mounting base 8 .
The first clamp member 1 has a clamp plate 11 and a connecting block 12 interconnected. The clamp plate 11 has a platelike structure. The connecting block 12 is smaller in diameter than the clamp plate 11 and is extending backwards from the back surface of the clamp plate 11 . A first recess 13 is defined in the bottom end of the clamp plate 11 and the connecting block 12 . The first recess 13 has a pair of pivot hole 123 in the two side surfaces thereof respectively. Two threaded clamp holes 121 are defined in the back surface of the top portion of the connecting block 12 . A “T”-shaped spring slot 124 is defined between the threaded clamp holes 121 in the back surface of the top portion of the connecting block 12 . A mounting hole 127 and a pressing hole 128 are defined in the top surface of the connecting block 12 corresponding to the two ends of the spring slot 124 and communicating with the spring slot 124 . The mounting hole 127 passes through the top and bottom wall of the spring slot 124 . The pressing hole 128 only passes through only the top wall of the spring slot 124 . A roller receiving hole 125 is defined in the middle of the bottom surface of the spring slot 124 , passing through the portion of the connecting block 12 below the spring slot 124 , communicating with the recess 122 . A rectangular hole 122 is defined in the back surface of the connecting block 12 , below the two ends of the spring slot 124 and above the first recess 13 , which is provide the economy of manufacture material.
The second clamp member 2 is a clamp plate which has the same size of the first clamp member 1 . A second recess 22 is defined in the bottom of the second clamp member 2 corresponding to and communicating with the first recess 13 of the first clamp member 1 . A through hole 21 is defined in the second clamp member 2 corresponding to the threaded clamp hole 121 of the connecting block 12 . The second clamp member 2 is fattened on the connecting block 12 of the first clamp member 1 by a bolt 91 passing through the through hole 21 and screwing into the threaded clamp hole 121 . The bolt 91 use an allen countersunk head screws.
The gaskets 3 are made of nylon. The gasket 3 has the similar shape and size with the clamp plate 11 of the first clamp member 1 and second clamp member 2 . The gasket 3 has a notch 31 corresponding to the connecting block 12 of the first clamp member 1 . The gaskets 3 are mounted around the connecting block 12 respectively adjacent to the clamp plate 11 and the second clamp member 2 .
A glass pane (not shown) can be clamped between the clamp plate 11 of the first clamp member 1 and the second clamp member 2 of the hinge after being notched out to receive the connecting block 12 of the first clamp member 1 . Two gaskets 3 are mounted between the glass pane and the clamp plate 11 , the second clamp member 2 respectively. Thus, the hinge is mounted on the glass pane.
The leaf spring 4 is received in the spring slot 124 of the connecting block 12 of the first clamp member 1 . A spring-mounting hole 42 is defined in one end of the leaf spring 4 corresponding to the mounting hole 127 of the connecting block 12 . By a bolt 92 screwing into the mounting hole 127 and the spring-mounting hole 42 , one end of the leaf spring 4 is mounted in the spring slot 124 securely. A bolt 93 screws into the pressing hole 128 and presses the other end of the leaf spring 4 . The bolt 92 use an allen sunk screw, and the bolt 93 use a holding screws.
The positioning member 5 has a connecting post 51 , a roller bracket 52 and a roller 53 . The connecting post 51 corresponds with the roller receiving hole 125 of the connecting block 12 . The roller bracket 52 extends downwards from the connecting post 51 . The roller 53 is hinged to the roller bracket 52 . The bottom of the roller 53 passes through the roller receiving hole 125 into the first recess 13 by the press of the leaf spring 4 .
The pivot bracket 6 has a half-cylindrical top portion and a cuboid bottom portion. The pivot bracket 6 is received in the first recess 13 of the first clamp member 1 and the second recess 22 of the second clamp member 2 . The cylindrical surface of the pivot bracket 6 is pressed against the roller 53 . The pivot bracket 6 has a bore 61 . Two bushings 63 are mounted respectively in the two ends of the bore 61 . The pivot bracket 6 has three positioning slot 62 at intervals of 90 degrees, i.e in the 9, 12, 3 o'clock position, on the cylindrical surface. The pivot bracket 6 has two bracket mounting holes 64 on the bottom thereof.
A gear 71 is defined on one end of the pivot pin 7 . The connecting block 12 has a pair of pivot holes 123 on two side surface of the recess 13 and a gear ring (not shown) on the side surface of each of the pivot holes 123 respectively. When the first clamp member 1 is hinged to the pivot bracket 6 by the pivot pin 7 extending through the pivot holes 123 and the bore 61 , the gear 71 goes into mesh with the gear ring to prevent the rotation of the pivot pin 7 relative to the first clamp member 1 and the glass door, i.e. the second clamp member 2 , the first clamp member 1 and the glass door pane move at the same time. When the first clamp member 1 and the glass door pane turned relative to the pivot bracket 6 , the cylindrical out surface of the pivot bracket 6 is urged by the roller 53 . During the turning of the glass door, the roller 53 will inserted into the three positioning slots 62 in the proper order, i.e locate at the inwards opened position, the closed position and the outwards opened position.
Two through holes 81 are defined in the mounting base 8 corresponding to the bracket mounting holes 64 in the pivot bracket 6 . The pivot bracket 6 is fastened to the mounting base 8 by a plurality of bolts screwing into the through holes 81 and the bracket mounting holes 64 . The mounting base 8 is also fastened to the doorframe by four bolts screwing into four through holes 82 in the corners of the base 8 and the holes in the doorframe.
Example 2
As shown in FIGS. 2A-2B , a second preferred embodiment of the hinge for the glass door of the present invention is schematically depicted. The components thereof same as or similar to those of the first preferred embodiment in FIGS. 1A-1D use the same numerals.
The second preferred embodiment differs from the first preferred embodiment only as follows:
The leaf spring 4 has a through roller-mounting hole 41 in the middle thereof corresponding to the roller receiving hole 125 of the connecting block 12 . A spring-mounting hole 54 is defined in the top surface of the connecting post 51 of the positioning member 5 corresponding to the roller-mounting hole 41 . The leaf spring 4 is connected to the positioning member 5 by a bolt 94 screwing into the roller-mounting hole 41 and the spring-mounting hole 54 respectively. The bolt 94 uses a cross recessed countersunk head screw. For the convenience of the installation of the leaf spring 4 and the positioning member 5 , a through hole 126 is defined in the top surface of the connecting block 12 corresponding to the roller receiving hole 125 and communicating with the spring slot 124 to provide a passage for the bolt 94 .
Two pressing holes 128 are defined in the top surface of the connecting block 12 communicating with the spring slot 124 . Two ends of leaf spring 4 do not have the spring-mounting hole 42 . The leaf spring 4 is mounted in the spring slot 124 by the bolts 93 screwing into the pressing holes 128 and pressing the two ends of the leaf spring 4 securely. The bolts 93 use holding screws.
Example 3
As shown in FIGS. 3A-3B , a third preferred embodiment of the hinge for the glass door of the present invention is schematically depicted. The components thereof same as or similar to those of the first preferred embodiment use the same numerals.
The third preferred embodiment differs from the first preferred embodiment only as follows:
The connecting block 12 has a notch in the top thereof and a fastening panel 14 covering the open side of the notch to form the spring slot 124 . Two threaded holes 127 are defined in the bottom surface of the spring slot 124 of the connecting block 12 . The fastening panel 14 has two through holes 141 corresponding to the holes 127 respectively. Each end of the leaf spring 4 has a spring-mounting hole 42 respectively corresponding to the holes 127 . By bolts 92 screwing into the holes 141 , the spring-mounting holes 42 and the holes 127 , the fastening panel 14 is fastened on the connecting block 12 , and the leaf spring 4 is mounted in the spring slot 124 at the same time. The bolt 92 uses a cross recessed countersunk head screw.
Example 4
As shown in FIGS. 4A-4B , a fourth preferred embodiment of the hinge for the glass door of the present invention is schematically depicted. The components thereof same as or similar to those of the first preferred embodiment use the same numerals.
The fourth preferred embodiment differs from the third preferred embodiment only as follows:
A roller-mounting hole 41 is defined in the middle portion of the leaf spring 4 corresponding to the roller receiving hole 125 of the connecting block 12 . A spring-mounting hole 54 is defined in the top surface of the connecting post 51 of the positioning member 5 corresponding to the roller-mounting hole 41 . The leaf spring 4 is connected to the positioning member 5 by a bolt 94 screwing into the roller-mounting hole 41 and the spring-mounting hole 54 . The bolt 94 use a cross recessed countersunk head screw.
Example embodiments being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the present invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | The present invention is to provide a hinge suitable for a glass door, having a roller actuating by a spring member and cooperating with a cylindrical surface and slots on the cylindrical surface to hold the glass door in the opened and closed positions, and to make the fluent opening and closing movement of the glass door. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 13/446,510, filed Apr. 13, 2012, which claims priority to U.S. Provisional Application No. 61/619,124, filed Apr. 2, 2012, and is a continuation-in-part of U.S. patent application Ser. No. 13/363,154, filed on Jan. 31, 2012 and entitled “Gas Turbine Engine With High Speed Low Pressure Turbine Section.”
BACKGROUND
[0002] This application relates to a gas turbine engine wherein the low pressure turbine section is rotating at a higher speed and centrifugal pull stress relative to the high pressure turbine section speed and centrifugal pull stress than prior art engines.
[0003] Gas turbine engines are known, and typically include a fan delivering air into a low pressure compressor section. The air is compressed in the low pressure compressor section, and passed into a high pressure compressor section. From the high pressure compressor section the air is introduced into a combustion section where it is mixed with fuel and ignited. Products of this combustion pass downstream over a high pressure turbine section, and then a low pressure turbine section.
[0004] Traditionally, on many prior art engines the low pressure turbine section has driven both the low pressure compressor section and a fan directly. As fuel consumption improves with larger fan diameters relative to core diameters it has been the trend in the industry to increase fan diameters. However, as the fan diameter is increased, high fan blade tip speeds may result in a decrease in efficiency due to compressibility effects. Accordingly, the fan speed, and thus the speed of the low pressure compressor section and low pressure turbine section (both of which historically have been coupled to the fan via the low pressure spool), have been a design constraint. More recently, gear reductions have been proposed between the low pressure spool (low pressure compressor section and low pressure turbine section) and the fan.
SUMMARY
[0005] A turbine section of a gas turbine engine according to an example of the present disclosure includes a fan drive turbine section and a second turbine section. The fan drive turbine section has a first exit area at a first exit point and is configured to rotate at a first speed. The second turbine section has a second exit area at a second exit point and is configured to rotate at a second speed, which is faster than the first speed. A first performance quantity is defined as the product of the first speed squared and the first area. A second performance quantity is defined as the product of the second speed squared and the second area. A ratio of the first performance quantity to the second performance quantity is between about 0.5 and about 1.5. The second turbine section is configured to drive a first shaft supported by a first bearing. The fan drive turbine is configured to drive a second shaft supported by a second bearing, and the first and second bearings are situated between the first exit area and the second exit area.
[0006] A further embodiment of any of the foregoing embodiments includes a mid-turbine frame positioned intermediate the fan drive and second turbine sections. The first and second bearings are situated at the mid-turbine frame.
[0007] In a further embodiment of any of the forgoing embodiments, the first bearing is configured to support an outer periphery of the first shaft, and the second bearing is configured to support an intermediate portion of the second shaft along an outer periphery of the second shaft.
[0008] In a further embodiment of any of the forgoing embodiments, the mid-turbine frame includes a guide vane positioned intermediate the fan drive and second turbine sections.
[0009] In a further embodiment of any of the forgoing embodiments, the fan drive and second turbine sections are configured to rotate in opposed directions, and the guide vane is a turning guide vane.
[0010] In a further embodiment of any of the forgoing embodiments, each of the fan drive turbine section and the second turbine section is configured to rotate in a first direction.
[0011] In a further embodiment of any of the forgoing embodiments, the ratio is above or equal to about 0.8.
[0012] In a further embodiment of any of the forgoing embodiments, the fan drive turbine section has between three and six stages. The second turbine section has two or fewer stages, and a pressure ratio across the fan drive turbine section is greater than about 5:1.
[0013] A gas turbine engine according to an example of the present disclosure includes a compressor section including a first compressor section and a second compressor section, a gear arrangement configured to drive a fan, and a turbine section including a fan drive turbine section and a second turbine section. The fan drive turbine is configured to drive the gear arrangement. The fan drive turbine section has a first exit area at a first exit point and is configured to rotate at a first speed. The second turbine section has a second exit area at a second exit point and is configured to rotate at a second speed, which is faster than the first speed. A first performance quantity is defined as the product of the first speed squared and the first area. A second performance quantity is defined as the product of the second speed squared and the second area. A ratio of the first performance quantity to the second performance quantity is less than or equal to about 1.5. The second turbine section is supported by a first bearing. The fan drive turbine is supported by a second bearing, and the first and second bearings are situated between the first exit area and the second exit area.
[0014] A further embodiment of any of the foregoing embodiments includes a mid-turbine frame positioned intermediate the fan drive and second turbine sections. The first and second bearings are situated in the mid-turbine frame.
[0015] In a further embodiment of any of the forgoing embodiments, the second turbine section and the second compressor section are straddle-mounted by the first bearing and a third bearing. The first and third bearings support an outer periphery of a first shaft. The first shaft is configured to rotate with the second compressor section and the second turbine section.
[0016] In a further embodiment of any of the forgoing embodiments, the second bearing is configured to support an intermediate portion of a second shaft along an outer periphery of the second shaft, and the second shaft is configured to rotate with the fan drive turbine section and the first compressor section.
[0017] In a further embodiment of any of the forgoing embodiments, the ratio is above or equal to about 0.5. The fan defines a pressure ratio less than about 1.45.
[0018] In a further embodiment of any of the forgoing embodiments, the first compressor section includes fewer stages than the second compressor section.
[0019] In a further embodiment of any of the forgoing embodiments, the fan drive turbine section and the first compressor section are configured to rotate in a first direction, and the second turbine section and the second compressor section are configured to rotate in a second opposed direction.
[0020] In a further embodiment of any of the forgoing embodiments, each of the fan drive turbine section and the second turbine sections is configured to rotate in a first direction.
[0021] A method of designing a gas turbine engine according to an example of the present disclosure includes providing a fan, providing a compressor section in fluid communication with the fan, and providing a turbine section, including both a fan drive turbine section and a second turbine section. The second turbine section is supported by a first bearing in a mid-turbine frame. The first bearing is positioned intermediate the fan drive and second turbine sections. The fan drive turbine section has a first exit area at a first exit point and is configured to rotate at a first speed. The second turbine section has a second exit area at a second exit point and is configured to rotate at a second speed, which is faster than the first speed. A first performance quantity is defined as the product of the first speed squared and the first area at a predetermined design target. A second performance quantity is defined as the product of the second speed squared and the second area at the predetermined design target. A ratio of the first performance quantity to the second performance quantity is between about 0.5 and about 1.5.
[0022] In a further embodiment of any of the forgoing embodiments, the predetermined design target corresponds to a takeoff condition.
[0023] In a further embodiment of any of the forgoing embodiments, the compressor section includes a first compressor section and a second compressor section. An overall pressure ratio is provided by the combination of a pressure ratio across the first compressor and a pressure ratio across the second compressor at the predetermined design target, and the overall pressure ratio is greater than or equal to about 35.
[0024] In a further embodiment of any of the forgoing embodiments, the first compressor section includes fewer stages than the second compressor section. The fan drive turbine section includes between three (3) and six (6) stages. The second turbine section includes two or fewer stages.
[0025] These and other features of this disclosure will be better understood upon reading the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 shows a gas turbine engine.
[0027] FIG. 2 schematically shows the arrangement of the low and high spool, along with the fan drive.
[0028] FIG. 3 shows a schematic view of a mount arrangement for an engine such as shown in FIGS. 1 and 2 .
DETAILED DESCRIPTION
[0029] FIG. 1 schematically illustrates a gas turbine engine 20 . The gas turbine engine 20 is disclosed herein as a two-turbine turbofan that generally incorporates a fan section 22 , a compressor section 24 , a combustor section 26 and a turbine section 28 . Alternative engines might include an augmentor section (not shown) among other systems or features. The fan section 22 drives air along a bypass flow path B while the compressor section 24 drives air along a core flow path C for compression and communication into the combustor section 26 then expansion through the turbine section 28 . Although depicted as a turbofan gas turbine engine in the disclosed non-limiting embodiment, it should be understood that the concepts described herein are not limited to use with turbofans as the teachings may be applied to other types of turbine engines including three-turbine architectures.
[0030] The engine 20 generally includes a low speed spool 30 and a high speed spool 32 mounted for rotation about an engine central longitudinal axis A relative to an engine static structure 36 via several bearing systems 38 . It should be understood that various bearing systems 38 at various locations may alternatively or additionally be provided.
[0031] The low speed spool 30 generally includes an innermost shaft 40 that interconnects a fan 42 , a low pressure (or first) compressor section 44 and a low pressure (or first) turbine section 46 . Note, turbine section 46 will also be called a fan drive turbine section. The inner shaft 40 is connected to the fan 42 through a geared architecture 48 to drive the fan 42 at a lower speed than the fan drive turbine 46 . The high speed spool 32 includes a more outer shaft 50 that interconnects a high pressure (or second) compressor section 52 and high pressure (or second) turbine section 54 . A combustor 56 is arranged between the high pressure compressor section 52 and the high pressure turbine section 54 . A mid-turbine frame 57 of the engine static structure 36 is arranged generally between the high pressure turbine section 54 and the low pressure turbine section 46 . The mid-turbine frame 57 further supports bearing systems 38 in the turbine section 28 . As used herein, the high pressure turbine section experiences higher pressures than the low pressure turbine section. A low pressure turbine section is a section that powers a fan 42 .
[0032] In the illustrated example, the low pressure compressor 44 includes fewer stages than the high pressure compressor 52 , and more narrowly, the low pressure compressor 44 includes three (3) stages and the high (or second) pressure compressor 52 includes eight (8) stages ( FIG. 1 ). In another example, the low pressure compressor 44 includes four (4) stages and the high (or second) pressure compressor 52 includes four (4) stages ( FIG. 3 ). In the illustrated example, the high pressure turbine 54 includes fewer stages than the low pressure turbine 46 , and more narrowly, the low pressure turbine 46 includes five (5) stages, and the high pressure turbine 54 includes two (2) stages. In one example, the low pressure turbine 46 includes three (3) stages, and the high pressure turbine 54 includes two (2) stages ( FIG. 3 ).
[0033] The inner shaft 40 and the outer shaft 50 are concentric and rotate via bearing systems 38 about the engine central longitudinal axis A which is collinear with their longitudinal axes. The high and low spools can be either co-rotating or counter-rotating.
[0034] The core airflow C is compressed by the low pressure compressor section 44 then the high pressure compressor section 52 , mixed and burned with fuel in the combustor 56 , then expanded over the high pressure turbine section 54 and low pressure turbine section 46 . The mid-turbine frame 57 includes airfoils 59 which are in the core airflow path. The turbine sections 46 , 54 rotationally drive the respective low speed spool 30 and high speed spool 32 in response to the expansion.
[0035] The engine 20 in one example is a high-bypass geared aircraft engine. The bypass ratio is the amount of air delivered into bypass path B divided by the amount of air into core path C. In a further example, the engine 20 bypass ratio is greater than about six (6), with an example embodiment being greater than ten (10), the geared architecture 48 is an epicyclic gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3 and the low pressure turbine section 46 has a pressure ratio that is greater than about 5. In one disclosed embodiment, the engine 20 bypass ratio is greater than about ten (10:1), the fan diameter is significantly larger than that of the low pressure compressor section 44 , and the low pressure turbine section 46 has a pressure ratio that is greater than about 5:1. In some embodiments, the high pressure turbine section may have two or fewer stages. In contrast, the low pressure turbine section 46 , in some embodiments, has between 3 and 6 stages. Further the low pressure turbine section 46 pressure ratio is total pressure measured prior to inlet of low pressure turbine section 46 as related to the total pressure at the outlet of the low pressure turbine section 46 prior to an exhaust nozzle. The geared architecture 48 may be an epicycle gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.5:1. It should be understood, however, that the above parameters are only exemplary of one embodiment of a geared architecture engine.
[0036] A significant amount of thrust is provided by the bypass flow B due to the high bypass ratio. The fan section 22 of the engine 20 is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet. The flight condition of 0.8 Mach and 35,000 ft, with the engine at its best fuel consumption—also known as “bucket cruise Thrust Specific Fuel Consumption (“TSFC”). TSFC is the industry standard parameter of the rate of lbm of fuel being burned per hour divided by lbf of thrust the engine produces at that flight condition. “Low fan pressure ratio” is the ratio of total pressure across the fan blade alone, before the fan exit guide vanes. The low fan pressure ratio as disclosed herein according to one non-limiting embodiment is less than about 1.45. “Low corrected fan tip speed” is the actual fan tip speed in ft/sec divided by an industry standard temperature correction of [(Ram Air Temperature deg R)/518.7)̂0.5]. The “Low corrected fan tip speed” as disclosed herein according to one non-limiting embodiment is less than about 1150 ft/second. Further, the fan 42 may have 26 or fewer blades.
[0037] An exit area 400 is shown, in FIG. 1 and FIG. 2 , at the exit location for the high pressure turbine section 54 is the annular area of the last blade of turbine section 54 . An exit area for the low pressure turbine section is defined at exit 401 for the low pressure turbine section and is the annular area defined by the blade of that turbine section 46 . As shown in FIG. 2 , the turbine engine 20 may be counter-rotating. This means that the low pressure turbine section 46 and low pressure compressor section 44 rotate in one direction (“−”), while the high pressure spool 32 , including high pressure turbine section 54 and high pressure compressor section 52 rotate in an opposed (“+”) direction. The gear reduction 48 , which may be, for example, an epicyclic transmission (e.g., with a sun, ring, and star gears), is selected such that the fan 42 rotates in the same direction (“+”) as the high spool 32 . With this arrangement, and with the other structure as set forth above, including the various quantities and operational ranges, a very high speed can be provided to the low pressure spool. Low pressure turbine section and high pressure turbine section operation are often evaluated looking at a performance quantity which is the exit area for the turbine section multiplied by its respective speed squared. This performance quantity (“PQ”) is defined as:
[0000] PQ ltp =( A lpt ×V lpt 2 ) Equation 1:
[0000] PQ hpt =( A hpt ×V hpt 2 ) Equation 2:
[0000] where A lpt is the area of the low pressure turbine section at the exit thereof (e.g., at 401 ), where V lpt is the speed of the low pressure turbine section, where A hpt is the area of the high pressure turbine section at the exit thereof (e.g., at 400 ), and where V hpt is the speed of the high pressure turbine section.
[0038] Thus, a ratio of the performance quantity for the low pressure turbine section compared to the performance quantify for the high pressure turbine section is:
[0000] ( A lpt ×A lpt 2 )/( A hpt ×V hpt 2 )= PQ ltp /PQ hpt Equation 3:
[0000] In one turbine embodiment made according to the above design, the areas of the low and high pressure turbine sections are 557.9 in 2 and 90.67 in 2 , respectively. Further, the speeds of the low and high pressure turbine sections are 10179 rpm and 24346 rpm, respectively. Thus, using Equations 1 and 2 above, the performance quantities for the low and high pressure turbine sections are:
[0000] PQ ltp =( A lpt ×V lpt 2 )=(557.9 in 2 )(10179 rpm) 2 =57805157673.9 in 2 rpm 2 Equation 1:
[0000] PQ hpt =( A hpt ×V hpt 2 )=(90.67 in 2 )(24346 rpm) 2 =3742622009.72 in 2 rpm 2 Equation 2:
[0000] and using Equation 3 above, the ratio for the low pressure turbine section to the high pressure turbine section is:
[0000] Ratio= PQ ltp /Q hpt =57805157673.9 in 2 rpm 2 /53742622009.72 in 2 rpm 2 =1.075
[0039] In another embodiment, the ratio was about 0.5 and in another embodiment the ratio was about 1.5. With PQ ltp /PQ hpt ratios in the 0.5 to 1.5 range, a very efficient overall gas turbine engine is achieved. More narrowly, PQ ltp /PQ hpt ratios of above or equal to about 0.8 are more efficient. Even more narrowly, PQ ltp /PQ hpt ratios above or equal to 1.0 are even more efficient. As a result of these PQ ltp /PQ hpt ratios, in particular, the turbine section can be made much smaller than in the prior art, both in diameter and axial length. In addition, the efficiency of the overall engine is greatly increased.
[0040] The low pressure compressor section is also improved with this arrangement, and behaves more like a high pressure compressor section than a traditional low pressure compressor section. It is more efficient than the prior art, and can provide more compression in fewer stages. The low pressure compressor section may be made smaller in radius and shorter in length while contributing more toward achieving an overall pressure ratio design target of the engine. In some examples, engine 20 is designed at a predetermined design target defined by performance quantities for the low and high pressure turbine sections 46 , 54 . In further examples, the predetermined design target is defined by pressure ratios of the low pressure and high pressure compressors 44 , 52 .
[0041] In some examples, the overall pressure ratio corresponding to the predetermined design target is greater than or equal to about 35:1. That is, after accounting for a pressure rise of the fan 42 in front of the low pressure compressor 44 , the pressure of the air entering the low (or first) compressor section 44 should be compressed as much or over 35 times by the time it reaches an outlet of the high (or second) compressor section 52 . In other examples, an overall pressure ratio corresponding to the predetermined design target is greater than or equal to about 40:1, or greater than or equal to about 50:1. In some examples, the predetermined design target is defined at sea level and at a static, full-rated takeoff power condition. In other examples, the predetermined design target is defined at a cruise condition.
[0042] As shown in FIG. 3 , the engine as shown in FIGS. 1 and 2 may be mounted such that the high pressure turbine 54 is supported on a rear end by a mid-turbine frame 110 . The mid-turbine frame 110 may be provided with a guide vane 112 that is an air turning vane. Since the high pressure turbine 54 and the low pressure or fan drive turbine 46 rotate in opposed directions, the use of the turning vane intermediate the two will ensure that the gases leaving the high pressure turbine 54 approach the low pressure turbine 46 traveling in the proper direction. As is clear from FIG. 3 , the mid-turbine frame 110 also includes a bearing 116 which supports a shaft that rotates with the low spool 30 in an “overhung” manner. That is, the bearing 116 is at an intermediate position on the shaft, rather than adjacent the end.
[0043] Static structure 102 and 108 support other bearings 100 and 110 to support the shafts driven by spools 30 and 32 on the compressor end. The high pressure turbine 54 can be said to be “straddle-mounted” due to the bearings 110 and 114 on the outer periphery of the shaft 32 .
[0044] While this invention has been disclosed with reference to one embodiment, it should be understood that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention. | A turbine section of a gas turbine engine according to an example of the present disclosure includes, among other things, a fan drive turbine section and a second turbine section. The fan drive turbine section has a first exit area at a first exit point and is configured to rotate at a first speed. The second turbine section has a second exit area at a second exit point and is configured to rotate at a second speed, which is faster than the first speed. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of U.S. patent application Ser. No. 13/065,511 filed on Mar. 23, 2011, which claims priority under 35 U.S.C. §119 of German Application No. 10 2010 033 878.8 filed Aug. 10, 2010 and German Application No. 10 2011 100 521.1 filed May 5, 2011, the disclosures of which are incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for the production of a piston for an internal combustion engine, having a piston base body and a piston ring element. The piston base body has at least a piston skirt, and the piston ring element has at least a piston crown, a circumferential top land, and a circumferential ring belt provided with ring grooves. The piston base body and the piston ring element form a circumferential, closed cooling channel. The present invention furthermore relates to such a piston for an internal combustion engine.
2. The Prior Art
Friction-welded pistons having cooling channels in the piston head that are open toward the bottom and can be closed off by means of a sheet-metal cover are described in German Patent Application No. DE 10 2004 019 012 A1 and International Application No. WO 2007/128265 A1. In this connection, piston base body and piston ring belt each have only one joining surface. In WO 2007/128265 A1, it is proposed that the joining surfaces are not in contact over their complete area before friction welding, in order to reduce the size of the friction-welding bead that is present below the cooling channel after friction welding, in a controlled manner, so that it is easier to remove subsequent to friction welding. German Patent Application No. DE 10 2004 019 012 A1 discloses a piston base body and a piston ring element whose joining surfaces form a cavity, in order to accommodate excess material during friction welding.
However, neither of these two methods is suitable for producing pistons having a closed, circumferential cooling channel, since the typical pair of rolled-in friction-welding beads formed during friction welding projects radially into the cooling channel. These circumferential friction-welding beads take up a lot of space in the cooling channel. Thus, the volume of the cooling channel is excessively reduced, and the flow of the cooling oil in the cooling channel is hindered. In the case of pistons having a comparatively large combustion chamber bowl, the cooling channel can be configured to be so narrow, in the radial direction, that it would not even be able to accommodate the friction-welding beads.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a friction-welding method for the production of a piston having a closed cooling channel, in such a manner that the cooling channel of the finished piston does not experience any excessive volume reduction.
The solution consists in a method having the following steps: (a) making available a blank of a piston base body, in which an inner joining surface and an outer joining surface and a circumferential lower cooling channel part that runs between the two joining surfaces are pre-machined; (b) making available a blank of a piston ring element, in which an inner joining surface and an outer joining surface as well as a circumferential upper cooling channel part that runs between the two joining surfaces are pre-machined; (c) forming a circumferential widened region on at least one joining surface, whereby the widened region extends toward the related cooling channel part; (d) connecting the blank of the piston base body with the blank of the piston ring element by way of their joining surfaces, by means of friction welding, to produce a piston blank; (e) machining the piston blank further and/or finish-machining it to produce a piston. The piston according to the invention has the features that the piston base body and piston ring element are connected with one another by friction welding, and the cooling channel is free of friction-welding beads, to a great extent.
In material strength studies, it has been shown that when beads are rolled in, great excessive increases in notch stress occur; these are attributable to the sharp notches at the exit of the rolled-in beads. In the case of the newly developed method listed above, these sharp edges are avoided. As a result, clear increase in strength, which ranges between 85 and 100% of the base material strength, is achieved, and thus greater freedom in designing individual designs is made possible.
The idea according to the invention consists in configuring the joining surfaces in such a manner that the region of the joining surfaces on the cooling chamber side can accommodate excess material during friction welding. As a result, the radial expanse of the cooling channel is maintained practically unchanged during friction welding, in the region of the friction-welding seam. Using the method according to the invention, it is possible to produce multi-part pistons having a closed, circumferential cooling channel that is capable of functioning, by friction-welding methods.
The present invention is suitable for all the piston construction variants according to the claims. The piston ring element or its blank can particularly have a combustion chamber bowl. The piston ring element or its blank, instead, can also have at least one wall region of a combustion chamber bowl. Then, the piston base body or its blank has at least one crown region of a combustion chamber bowl, so that the two components jointly form the complete combustion chamber bowl.
A preferred embodiment consists in that in step (d), the blank of the piston base body or the blank of the piston ring element is put into rotation, the blank of the piston base body and the blank of the piston ring element are pressed together, at a speed of rotation of 1500 rpm to 2500 rpm, at a contact pressure, with reference to the joining surfaces, of 10 N/mm 2 to 30 N/mm 2 , the rotation is stopped after 1 second to 3 seconds, while maintaining the contact pressure, and subsequently, the blank of the piston base body and the blank of the piston ring element are pressed together at a contact pressure, with reference to the joining surfaces, of 100 N/mm 2 to 140 N/mm 2 . These method parameters promote the avoidance of typical friction-welding beads, so that the formation of the circumferential widened region requires particularly little work effort, because of the smaller dimensions under these circumstances.
The widened regions provided according to the invention can be produced in different ways. In particular, in step (c), widened regions can be made on the inner and outer joining surface of the blank of the piston base body and/or on the inner and outer joining surface of the blank of the piston ring element.
Furthermore, the one circumferential widened region can be formed in any desired manner, for example in the form of a slanted surface, a chamfer, or a bowl. The widened regions can be formed with an axial expanse of 1.0 mm to 1.5 mm and/or with a radial expanse of at least 0.5 mm, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.
In the drawings, wherein similar reference characters denote similar elements throughout the several views:
FIG. 1 shows a blank of a piston base body and of a blank of a piston ring element, for the production of a piston according to one embodiment of the invention, in section;
FIG. 2 shows an enlarged detail representation of the joining surface region according to FIG. 1 ;
FIG. 3 a shows the piston blank produced from the components according to FIG. 1 , for a piston according to the invention, in section;
FIG. 3 b shows an enlarged detail representation of the joining region according to FIG. 3 a;
FIG. 4 a shows the piston according to the invention, produced from the piston blank according to FIG. 3 a;
FIG. 4 b shows an enlarged detail representation of the joining region of the piston according to FIG. 4 a;
FIG. 5 shows a blank of a piston base body and of a blank of a piston ring element for the production of a piston according to another embodiment of the invention, in section;
FIG. 6 shows another exemplary embodiment of a blank of a piston base body and of a blank of a piston ring element for the production of a piston according to the invention, in section;
FIG. 7 a shows the piston blank produced from the components according to FIG. 5 and FIG. 6 , respectively, for a piston according to the invention, in section; and
FIG. 7 b shows an enlarged detail representation of the joining region of the piston according to FIG. 7 a.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in detail to the drawings, FIGS. 4 a and 4 b show a finished piston 10 according to the invention. Piston 10 consists of a piston base body 11 and a piston ring element 12 . The two components can consist of any metallic material, for example according to DIN EN 10083 or DIN EN 10267, which can be subjected to hardening and tempering and is suitable for friction welding.
In the exemplary embodiment, the piston base body consists of a steel material, for example AFP steel. The piston base body 11 has a piston skirt 15 that is provided, in known manner, with pin bosses 16 and pin bores 17 for accommodating a piston pin (not shown), as well as skirt regions 18 having working surfaces (not shown). In the exemplary embodiment, the piston ring element 12 is also produced from a steel material, for example 42CrMo4. The piston ring element 12 has a piston crown 19 as well as a circumferential top land 21 . The piston base body 11 and the piston ring element 12 form a circumferential ring belt 22 for accommodating piston rings (not shown), a circumferential, closed cooling channel 23 , as well as a combustion chamber bowl 24 .
The piston base body 11 and the piston ring element 12 are connected with one another by friction welding. It is particularly evident from FIG. 4 b that the circumferential, closed cooling channel 23 nevertheless does not have any typical friction-welding beads. The entire volume of the cooling channel 23 , as originally provided, is therefore available for cooling the piston 10 according to the invention during engine operation. Furthermore, the flow of the cooling oil in the cooling channel is not impaired.
The piston 10 according to the invention is produced in the manner described below.
According to FIGS. 1 and 2 , first a pre-machined blank 11 ′ of a piston base body 11 as well as a pre-machined blank 12 ′ of a piston ring element 12 are made available. The blanks 11 ′, 12 ′ essentially correspond to the finished piston base body 11 and the finished piston ring element 12 , respectively, so that the same structures are provided with the same reference symbols, and in this regard, reference is made to the above description of FIG. 4 a . The essential difference consists in that no ring belt is machined out, but rather a smooth mantle surface 25 on the blank 11 ′ of the piston base body 11 as well as a smooth mantle surface 26 on the blank 12 ′ of the piston ring element 12 are provided.
The blanks 11 ′, 12 ′ can be cast, forged, or sintered by means of powder metallurgy, depending on the selection of the material. In the exemplary embodiment, the crown region 27 a part 28 of the wall region of the combustion chamber bowl 24 is pre-machined, for example lathed, into the blank 11 ′ of the piston base body 11 . Furthermore, a circumferential cooling channel part 23 a of the cooling channel 23 is pre-machined. This results in an outer joining surface 29 and an inner joining surface 31 . In the exemplary embodiment, the remaining part 28 ′ of the wall region of the combustion chamber bowl is machined, for example lathed, into the blank 12 ′ of the piston ring element 12 . Furthermore, a circumferential upper cooling channel part 23 b of the cooling channel 23 is machined in. This results in an outer joining surface 32 and an inner joining surface 33 . The outer joining surface 29 of the blank 11 ′ corresponds to the outer joining surface 32 of the blank 12 ′. In corresponding manner, the inner joining surface 31 of the blank 11 ′ corresponds to the inner joining surface 33 of the blank 12 ′. This means that the two blanks 11 ′, 12 ′ can be connected with one another along their joining surfaces 29 , 31 and 32 , 33 , respectively, to form a piston blank 10 ′.
In the exemplary embodiment, a circumferential widened region 34 a , 34 b , in the form of a chamfer, is formed out at the two joining surfaces 29 , 31 of the blank 11 ′ as well as at the two joining surfaces 32 , 33 of the blank 12 ′, in each instance. The widened regions 34 a , 34 b extend in the direction of the cooling channel part 23 a of the blank 11 ′. In corresponding manner, the widened regions 34 b extend in the direction of the cooling channel part 23 b of the blank 12 ′. The maximal axial expanse of the widened regions 34 a , 34 b each amounts to about 1.0 mm in the exemplary embodiment, while the radial expanse of each of the widened regions 34 a , 34 b amounts to about 0.5 mm. When the joining surfaces 29 , 31 and 32 , 33 , respectively, of the blanks 11 ′, 12 ′ come into contact with one another at the beginning of the friction-welding process (see below), the widened regions 34 a , 34 b form two joins, in the exemplary embodiment, that lie opposite one another, having a maximal axial expanse of about 2 mm, which can accommodate excess material. Of course, widened regions having a different geometry can also be combined with one another.
To connect the two blanks 11 ′, 12 ′, these are braced so as to align, in known manner. Then, one of the two blanks 11 ′, 12 ′ is put into rotation, until a speed of rotation of 1,500 rpm to 2,500 rpm is achieved. Now, the blanks 11 ′, 12 ′ are brought into contact with one another by way of their joining surfaces 29 , 31 and 32 , 33 , respectively, and pressed together at a constant initial contact pressure, with reference to the joining surfaces 29 , 31 and 32 , 33 , respectively, of 10 N/mm 2 to 30 N/mm 2 . The rotational movement and the constant contact pressure produce a friction that heats up the joining surfaces 29 , 31 and 32 , 33 , respectively. The speed of rotation and the contact pressure are selected in such a manner, as a function of the materials used, so that the joining surfaces 29 , 31 and 32 , 33 , respectively, heat up to a temperature close to the melting point of the material or the materials. When this has been reached (after 1 to 3 seconds, depending on the material or materials), the rotation is ended, while maintaining the initial contact pressure, i.e. the spindle used for rotation is braked and stopped as quickly as possible (within less than 1 second, if at all possible). During this process, the contact pressure is maintained. After movement has been stopped, the contact pressure is increased to a joining pressure, with reference to the joining surfaces 29 , 31 and 32 , 33 , respectively, that is a multiple of the initial contact pressure, of 100 N/mm 2 to 140 N/mm 2 , and the blanks 11 ′, 12 ′ are pressed together under this joining pressure for about 5 seconds. In this connection, the excess material is taken up into the joins described above.
FIGS. 3 a and 3 b show the piston blank 10 ′ that has been produced in this manner. The piston blank 10 ′ essentially corresponds to the finished piston 10 , so that the same structures are provided with the same reference symbols, and reference is made to the above description of FIG. 4 a in this regard. As the result of the friction-welding process described above, the piston blank 10 ′ does not have any typical friction-welding bead 35 along the friction-welding seams as well as on the mantle surfaces 25 , 26 of the blanks 11 ′ and 12 ′, respectively, as well as on the wall region 28 , 28 ′, in each instance. It can particularly be seen in FIG. 3 b that the cooling channel 23 formed from the cooling channel parts 23 a , 23 b of the blanks 11 ′ and 12 ′, respectively, does not have any typical rolled-in friction-welding beads along the friction-welding seams. The melted, excess material released during the friction-welding process described above, which would form rolled-in friction-welding beads in the state of the art, was accommodated by the joins by the widened regions 34 a , 34 b , during the friction-welding process.
The piston blank 10 ′ is machined further or machine-finished in known manner, depending on the configuration of the blanks 11 ′, 12 ′. For example, the outer shape, surfaces, combustion chamber bowl, pin bores, etc. can be machine-finished. In particular, the ring belt 22 is machined in, and the friction-welding beads 35 are removed. In the end result, the finished piston according to FIGS. 4 a and 4 b , as described above, is obtained.
FIG. 5 shows an alternative embodiment of a blank 111 ′ of a piston base body 11 , as well as of a blank 112 ′ of a piston ring element 12 for a piston 10 according to the invention. The blanks 111 ′, 112 ′ essentially correspond to blanks 11 ′, 12 ′ according to FIG. 1 , so that the same structures are provided with the same reference symbols, and reference is made to the above description of FIG. 1 in this regard. It is pointed out that the representation according to FIG. 5 is rotated by 90° as compared with the representation according to FIG. 1 .
Analogous to the blanks 11 ′, 12 ′ according to FIG. 1 , the blank 111 ′ has an outer joining surface 129 , and the blank 112 ′ has a corresponding outer joining surface 132 . Also analogous to the blanks 11 ′, 12 ′ according to FIG. 1 , the blank 111 ′ has an inner joining surface 131 , and the blank 112 ′ has a corresponding inner joining surface 133 . This means that the two blanks 111 ′, 112 ′ can be connected with one another along their joining surfaces 129 , 131 and 132 , 133 , respectively, to produce a piston blank 110 ′.
In the exemplary embodiment, a circumferential widened region 134 b in the form of a slant is formed on both joining surfaces 132 , 133 of the blank 112 ′ of the piston ring element 12 , in each instance. The widened regions 134 b extend in the direction of the cooling channel part 23 b of the blank 112 ′. The maximal axial expanse of each of the widened regions 134 b amounts to about 1 mm, in the exemplary embodiment. When the joining surfaces 129 , 131 and 132 , 133 , respectively, come into contact with one another, at the beginning of the friction-welding process described above, the widened regions 134 b form a clear space, in the exemplary embodiment, in the shape of a right triangle, with a maximal axial expanse of about 1 mm, in which the melted material is distributed. Of course, widened regions having a different geometry can also be combined with one another.
FIG. 6 shows a further exemplary embodiment 211 ′ of a piston base body 11 , as well as of a blank 212 ′ of a piston ring element 12 for a piston 10 according to the invention. The blanks 211 ′, 212 ′ essentially correspond to the blanks 11 ′, 12 ′ according to FIG. 1 , so that the same structures are provided with the same reference symbols, and reference is made to the above description of FIG. 1 in this regard. It is pointed out that the representation according to FIG. 6 is rotated by 90° as compared with the representation according to FIG. 1 .
Analogous to the blanks 11 ′, 12 ′ according to FIG. 1 , the blank 211 ′ has an outer joining surface 229 , and the blank 212 ′ has a corresponding outer joining surface 232 . Also analogous to the blanks 11 ′, 12 ′ according to FIG. 1 , the blank 211 ′ has an inner joining surface 231 , and the blank 212 ′ has a corresponding inner joining surface 233 . This means that the two blanks 211 ′, 212 ′ can be connected with one another along their joining surfaces 229 , 231 and 232 , 233 , respectively, to produce a piston blank 110 ′.
In the exemplary embodiment, a circumferential widened region 234 a , 234 b in the form of a slant is formed on both joining surfaces 229 , 231 of the blank 211 ′ as well as on both joining surfaces 232 , 233 of the blank 212 ′. The widened regions 234 b extend in the direction of the cooling channel part 23 a of the blank 211 ′. In corresponding manner, the widened regions 234 b extend in the direction of the cooling channel part 23 b of the blank 212 ′. The maximal axial expanse of each of the widened regions 234 a , 234 b amounts to about 1 mm, in the exemplary embodiment. When the joining surfaces 229 , 231 and 232 , 233 , respectively, of the blanks 211 ′, 212 ′ come into contact with one another, at the beginning of the friction-welding process described above, the widened regions 234 a , 234 b form two clear spaces that lie opposite one another, in the exemplary embodiment, in the shape of an equilateral triangle, with a maximal axial expanse of about 2 mm, in which the melted material is distributed. Of course, widened regions having a different geometry can also be combined with one another.
With the friction-welding method described above, essentially the same piston blank 110 ′ as the one shown in FIGS. 7 a and 7 b is obtained from the blanks 111 ′, 112 ′ according to FIG. 5 and from the blanks 211 ′, 212 ′ according to FIG. 6 . The piston blank 110 ′ essentially corresponds to the piston blank 10 ′ according to FIGS. 3 a and 3 b , so that the same structures are provided with the same reference symbols, and reference is made to the above description of FIG. 3 a in this regard. As the result of the friction-welding process described above, the piston blank 110 ′ has the friction-welding beads or thickened regions shown in FIG. 7 b . Also in the cooling channel 23 formed from the cooling channel parts 23 a , 23 b of the blanks 111 ′ and 112 ′, respectively, as well as the blanks 211 ′ and 212 ′, respectively, contains friction-welding beads or thickened regions, as indicated above. The melted, excess material released during the friction-welding process described above, which would form friction-welding beads in the state of the art, was taken up by the clear spaces formed by the widened regions 134 b or 234 a , 234 b , respectively, so that a distribution of the melted material occurs, which ensures that the friction-welding beads or thickened regions, which are formed in the direction toward the cooling chamber, are smaller than the friction-welding beads or thickened regions that are situated on the sides facing away from the cooling chamber.
The piston ring 110 ′ is machined further or machine-finished in known manner, depending on the configuration of the blanks 111 ′, 112 ′ or the blanks 211 ′ 212 ′, respectively. For example, the outer shape, surfaces, combustion chamber bowl, pin bores, etc. can be machine-finished. In particular, the ring belt 22 is machined in. In the end result, the finished piston 10 , as described above in connection with FIGS. 4 a and 4 b , is obtained.
Accordingly, while only a few embodiments of the present invention have been shown and described, it is obvious that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention. | A method for the production of a piston has the following method steps: (a) providing a blank of a piston base body, having an outer joining surface, an inner joining surface and a circumferential lower cooling channel part that runs between the two joining surfaces, (b) providing a blank of a piston ring element, having an outer joining surface, an inner joining surface and a circumferential upper cooling channel part that runs between the two joining surfaces, (c) forming a circumferential widened region on at least one joining surface, the widened region extending toward the related cooling channel part, (d) connecting the blank of the piston base body with the blank of the piston ring element by way of their joining surfaces, by friction welding, to produce a piston blank, and (e) machining the piston blank further and/or finish-machining it to produce a piston. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of application Ser. No. 11/951,946, filed Dec. 6, 2007, which is a continuation-in-part of application Ser. No. 11/702,810, filed Feb. 6, 2007 now U.S. Pat. No. 7,472,589 issued Jan. 6, 2009, which is a continuation-in-part of application Ser. No. 11/438,764, filed May 23, 2006 now U.S. Pat. No. 7,596,995 issued Oct. 6, 2009, which is a continuation-in-part of application Ser. No. 11/268,311, filed Nov. 7, 2005, now U.S. Pat. No. 7,197,923 issued Apr. 3, 2007.
TECHNICAL FIELD OF THE INVENTION
This invention relates, in general, to testing and evaluation of subterranean formation fluids and, in particular, to a wireline conveyed single phase fluid sampling apparatus for obtaining multiple fluid samples and maintaining the fluid samples above saturation pressure using a self-contained pressure source during retrieval from the wellbore.
BACKGROUND OF THE INVENTION
Without limiting the scope of the present invention, its background is described with reference to testing hydrocarbon formations, as an example.
It is well known in the subterranean well drilling and completion art to perform tests on formations intersected by a wellbore. Such tests are typically performed in order to determine geological or other physical properties of the formation and fluids contained therein. For example, parameters such as permeability, porosity, fluid resistivity, temperature, pressure and saturation pressure may be determined. These and other characteristics of the formation and fluid contained therein may be determined by performing tests on the formation before the well is completed.
One type of testing procedure that is commonly performed is to obtain a fluid sample from the formation to, among other things, determine the composition of the formation fluids. In this procedure, it is important to obtain a sample of the formation fluid that is representative of the fluids as they exist in the formation. In a typical sampling procedure, a sample of the formation fluids may be obtained by lowering a sampling tool having a sampling chamber into the wellbore on a conveyance such as a wireline, slick line, coiled tubing, jointed tubing or the like. When the sampling tool reaches the desired depth, one or more ports are opened to allow collection of the formation fluids. The ports may be actuated in variety of ways such as by electrical, hydraulic or mechanical methods. Once the ports are opened, formation fluids travel through the ports and a sample of the formation fluids is collected within the sampling chamber of the sampling tool. After the sample has been collected, the sampling tool may be withdrawn from the wellbore so that the formation fluid sample may be analyzed.
It has been found, however, that as the fluid sample is retrieved to the surface, the temperature of the fluid sample decreases causing shrinkage of the fluid sample and a reduction in the pressure of the fluid sample. These changes can cause the fluid sample to reach or drop below saturation pressure creating the possibility of asphaltene deposition and flashing of entrained gasses present in the fluid sample. Once such a process occurs, the resulting fluid sample is no longer representative of the fluids present in the formation. Therefore, a need has arisen for an apparatus and method for obtaining a fluid sample from a formation without degradation of the sample during retrieval of the sampling tool from the wellbore. A need has also arisen for such an apparatus and method that are capable of maintaining the integrity of the fluid sample during storage on the surface.
SUMMARY OF THE INVENTION
The present invention disclosed herein provides a single phase fluid sampling apparatus and a method for obtaining fluid samples from a formation without the occurrence of phase change degradation of the fluid samples during the collection of the fluid samples or retrieval of the sampling apparatus from the wellbore. In addition, the sampling apparatus and method of the present invention are capable of maintaining the integrity of the fluid samples during storage on the surface.
In one aspect, the present invention is directed to a method for obtaining a fluid sample in a subterranean well. The method includes running a fluid sampler on a wireline conveyance to a target location in the well, establishing a fluid communication path between an exterior of the fluid sampler and a sampling chamber of the fluid sampler by operating an actuator, obtaining a fluid sample in the sampling chamber of the fluid sampler and pressurizing the fluid sample using a self-contained pressure source of the fluid sampler that is in fluid communication with the sampling chamber.
The method may also include receiving a predetermined input signal with a signal detector, activating a trigger to create a failure of a barrier with a control circuit to enable a fluid to flow from a first chamber to a second chamber in the actuator and shifting a piston from a first position to a second position in the actuator. In addition, the method may include obtaining a first portion of the fluid sample in a debris chamber, displacing a debris trap piston within the sampling chamber to receive a remainder of the fluid sample in the sampling chamber and determining the volume of the fluid sample based upon the position of the magnetic locator associated with the debris trap piston. The method may further include maintaining a differential pressure across a valving assembly disposed within the sampling chamber, actuating the valving assembly by contacting the valving assembly with a piston, piercing through at least a portion of a pressure disk associated with the valving assembly with a piercing assembly associated with the piston, equalizing the pressure across the valving assembly and pressurizing the fluid sample to a pressure greater than a saturation pressure of the fluid sample.
In another aspect, the present invention is directed to a method for obtaining a plurality of fluid samples in a subterranean well. The method includes running a fluid sampler on a wireline conveyance to a target location in the well, establishing a fluid communication path between an exterior of the fluid sampler and a plurality of sampling chambers of the fluid sampler by operating an actuator, obtaining a fluid sample in each of the plurality of sampling chambers of the fluid sampler and pressurizing the fluid samples using a self-contained pressure source of the fluid sampler that is in fluid communication with the sampling chambers.
The method may also include running the fluid sampler on a slickline conveyance to the target location in the well, running the fluid sampler on an electric line conveyance to the target location in the well, simultaneously obtaining the fluid samples in the plurality of sampling chambers, sequentially obtaining the fluid samples in the plurality of sampling chambers and simultaneously pressurizing the fluid samples in the plurality of sampling chambers.
In a further aspect, the present invention is directed to an apparatus for obtaining a plurality of fluid samples in a subterranean well. The apparatus includes a wireline conveyance and a fluid sampler supported by and positioned with the wireline conveyance in the well. The fluid sampler includes an actuator operable to establish a fluid communication path between an exterior and an interior of the fluid sampler, a plurality of sampling chambers operable to receive fluid samples and a self-contained pressure source in fluid communication with the sampling chambers operable to pressurize the fluid samples obtained in the sampling chambers to a pressure above saturation pressure.
In one embodiment, the wireline conveyance may be a slickline. In another embodiment, the wireline conveyance may be an electric line. In certain embodiments, the actuator may includes a signal detector, a control circuit and a trigger, wherein upon receipt of a predetermined input signal by the signal detector, the control circuit activates the trigger to create a failure in a barrier such that fluid flows from a first chamber to a second chamber in the actuator and a piston moves from a first position to a second position in the actuator. In some embodiments, each of the sampling chambers includes a debris trap piston that is operable to receive a first portion of the fluid sample in a debris chamber then displace within the sampling chamber. In these embodiments, a magnetic locator may be operably associated with the debris trap piston to provide a reference to determine the level of displacement of the debris trap piston.
In one embodiment, each of the sampling chambers may includes a valving assembly having a pressure disk that is initially operable to maintain a differential pressure thereacross, wherein the valving assembly is actuated by longitudinally displacing a piston having a piercing assembly relative to the valving assembly such that at least a portion of the piercing assembly travels through the pressure disk, thereby allowing fluid flow therethrough. In other embodiments, the self-contained pressure source may include pressurized nitrogen.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, including its features and advantages, reference is now made to the detailed description of the invention, taken in conjunction with the accompanying drawings in which like numerals identify like parts and in which:
FIG. 1 is a schematic illustration of a fluid sampler system embodying principles of the present invention;
FIG. 2 is a cross-sectional view of an embodiment of a sampler assembly of a fluid sampler embodying principles of the present invention;
FIG. 3 is a cross-sectional view of an embodiment of a sampler assembly of a fluid sampler embodying principles of the present invention;
FIG. 4 is a cross-sectional view of an embodiment of a sampler and pressure source assembly of a fluid sampler embodying principles of the present invention;
FIG. 5A is a cross-sectional view of an actuator assembly for controlling fluid communication into a fluid sampler embodying principles of the present invention in a run in configuration;
FIG. 5B is a cross-sectional view of an actuator assembly for controlling fluid communication into a fluid sampler embodying principles of the present invention in an actuated configuration; and
FIGS. 6A-6F are cross-sectional views of successive axial portions of an embodiment of a sampling chamber of a fluid sampler embodying principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
Referring initially to FIG. 1 , therein is representatively illustrated a fluid sampler system 10 and associated methods which embody principles of the present invention. A fluid sampler 12 is being run in a wellbore 14 that is depicted as having a casing string 16 secured therein with cement 18 . Although wellbore 14 is depicted as being cased and cemented, it could alternatively be uncased or open hole. Fluid sampler 12 includes a cable connector 20 that enables fluid sampler 12 to be coupled to or operably associated with a wireline conveyance 22 that is used to run, retrieve and position fluid sampler 12 in wellbore 14 . Wireline conveyance 22 may be a single strand or multistrand wire, cable or braided line, which may be referred to as a slickline or may include one or more electric conductors, which may be referred to as an e-line or electric line. Even though fluid sampler 12 is depicted as being connected directly to cable connector 20 , those skilled in the art the understand that fluid sampler 12 could alternatively be coupled within a larger tool string that is being positioned within wellbore 14 via wireline conveyance 22 including a tool string having multiple fluid samplers interconnected therein.
In the illustrated embodiment, fluid sampler 12 includes an actuator assembly 24 , a sampler assembly 26 and a self-contained pressure source assembly 28 . Preferably, sampler assembly 26 includes multiple sampling chambers, two being visible in FIG. 1 . In order to route the fluid samples into the desired sampling chamber, fluid sampler 12 includes a manifold assembly 30 positioned between actuator assembly 24 and sampler assembly 26 . Valving or other fluid flow control circuitry within manifold assembly 30 may be used to enable fluid samples to be taken in all of the sampling chambers simultaneously or to allow fluid samples to be sequentially taken into the various sampling chambers. In slickline conveyed embodiments, actuator assembly 24 preferably includes timing circuitry such as a mechanical or electrical clock which is used to determine when the fluid sample or samples will be taken. Alternatively, a pressure signal or other wireless input signal could be used to initiate operation of actuator assembly 24 . In electric line conveyed embodiments, actuator assembly 24 preferably includes electrical circuitry operable to communicate with surface systems via the electric line to initiate operation of actuator assembly 24 .
After the fluid samples are taken, in order to route pressure into the desired sampling chamber, fluid sampler 12 includes a manifold assembly 32 positioned between sampler assembly 26 and self-contained pressure source 28 . Self-contained pressure source 28 may include one or more pressure chambers that initially contain a pressurized fluid, such as a compressed gas or liquid, and preferably contain compressed nitrogen at between about 10,000 psi and 20,000 psi. Those skilled in the art will understand that other fluids or combinations of fluids and/or other pressures both higher and lower could be used, if desired. Depending on the number of sampling chambers and the number of pressure chambers, valving or other fluid flow control circuitry within manifold assembly 32 may be operated such that self-contained pressure source 28 serves as a common pressure source to simultaneously pressurize all sampling chambers or may be operated such that self-contained pressure source 28 independently pressurizes certain sampling chambers sequentially. In the case of multiple sampling chambers and multiple pressure chambers, manifold assembly 32 may be operated such that pressure from certain pressure chambers of self-contained pressure source 28 is routed to certain sampling chambers.
Even though FIG. 1 depicts a vertical well, it should be noted by one skilled in the art that the fluid sampler of the present invention is equally well-suited for use in deviated wells, inclined wells, horizontal wells, multilateral wells and the like. As such, the use of directional terms such as above, below, upper, lower, upward, downward and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure.
Referring now to FIG. 2 , therein is depicted a cross-sectional view of one embodiment of a sampler assembly of a fluid sampler embodying principles of the present invention that is generally designated 40 . In the illustrated portion, sampler assembly 40 includes two sampling chambers 42 , 44 . As discussed above, valving or other fluid flow control circuitry within the manifold assembly between sampler assembly 40 and the actuator assembly may be used to enable fluid samples to be taken in sampling chambers 42 , 44 simultaneously or sequentially. Likewise, valving or other fluid flow control circuitry within the manifold assembly between the pressure source and sampler assembly 40 may be used to enable simultaneous or independent pressurization of the fluid samples in sampling chambers 42 , 44 .
Sampler assembly 40 includes a support assembly 46 that may be in the form of a carrier assembly that extends longitudinally along a portion of or substantially the entire length of sampling chambers 42 , 44 . Alternatively, support assembly 46 may be formed in discontinuous sections that are distributed at intervals along the length of sampling chambers 42 , 44 . In the illustrated embodiment, support assembly 46 includes a chamber receiving assembly 48 , a retainer member 50 that is securably attachable to chamber receiving assembly 48 by mechanical means such as bolting and an outer housing 52 . In this configuration, chamber receiving assembly 48 , retainer member 50 and outer housing 52 provide longitudinal stability to sampling chambers 42 , 44 .
Referring now to FIG. 3 , therein is depicted a cross-sectional view of one embodiment of a sampler assembly of a fluid sampler embodying principles of the present invention that is generally designated 60 . In the illustrated portion, sampler assembly 60 includes three sampling chambers 62 , 64 , 66 . As discussed above, valving or other fluid flow control circuitry within the manifold assembly between sampler assembly 60 and the actuator assembly may be used to enable fluid samples to be taken in sampling chambers 62 , 64 , 66 simultaneously or sequentially. Likewise, valving or other fluid flow control circuitry within the manifold assembly between the pressure source and sampler assembly 60 may be used to enable simultaneous or independent pressurization of the fluid samples in sampling chambers 62 , 64 , 66 .
Sampler assembly 60 includes a support assembly 68 that may be in the form of a carrier assembly that extends longitudinally along a portion of or substantially the entire length of sampling chambers 62 , 64 , 66 . Alternatively, support assembly 68 may be formed in discontinuous sections that are distributed at intervals along the length of sampling chambers 62 , 64 , 66 . In the illustrated embodiment, support assembly 68 includes a chamber receiving assembly 70 , a plurality of retainer members 72 that are securably attachable to chamber receiving assembly 70 by mechanical means such as bolting and an outer housing 74 . In this configuration, chamber receiving assembly 70 , retainer members 72 and outer housing 74 provide longitudinal stability to sampling chambers 62 , 64 , 66 .
Referring now to FIG. 4 , therein is depicted a cross-sectional view of one embodiment of a sampler and pressure source assembly of a fluid sampler embodying principles of the present invention that is generally designated 80 . Unlike fluid samplers 12 , 40 and 60 described above wherein the sampler assembly and pressure source assembly are longitudinally separated by a manifold, in fluid sampler 80 , the sampler assembly and the pressure source assembly occupy the same longitudinal portion of fluid sampler 80 . Specifically, in the illustrated portion, sampler and pressure source assembly 80 includes two sampling chambers 82 , 84 and two pressure chambers 86 , 88 . As discussed above, valving or other fluid flow control circuitry within the manifold assembly between sampler and pressure source assembly 80 and the actuator assembly may be used to enable fluid samples to be taken in sampling chambers 82 , 84 simultaneously or sequentially. Likewise, valving or other fluid flow control circuitry within a manifold assembly functionally between sampling chambers 82 , 84 and pressure chambers 86 , 88 may be used to enable simultaneous or independent pressurization of the fluid samples in sampling chambers 82 , 84 .
Sampler and pressure source assembly 80 includes a support assembly 90 that may be in the form of a carrier assembly that extends longitudinally along a portion of or substantially the entire length of sampling chambers 82 , 84 and pressure chambers 86 , 88 . Alternatively, support assembly 90 may be formed in discontinuous sections that are distributed at intervals along the length of sampling chambers 82 , 84 and pressure chambers 86 , 88 . In the illustrated embodiment, support assembly 90 includes a chamber receiving assembly 92 , a plurality of retainer members 94 that are securably attachable to chamber receiving assembly 92 by mechanical means such as bolting and an outer housing 96 . In this configuration, chamber receiving assembly 92 , retainer members 94 and outer housing 96 provide longitudinal stability to sampling chambers 82 , 84 and pressure chambers 86 , 88 .
Referring now to FIGS. 5A-5B , an actuator for controlling fluid communication into a fluid sampler is generally designated 100 . Actuator 100 may be a part of an actuator assembly of a fluid sampler such as actuator assembly 22 of FIG. 1 . Actuator 100 has an axially extending generally tubular body or housing assembly 102 including two housing members 104 , 106 that are securably coupled together at a threaded coupling 108 . Housing member 106 includes a port 110 that is in fluid communication with the exterior of the fluid sampler and a fluid passageway 112 that is in fluid communication with one or more sampling chambers via the manifold. Slidably and sealingly disposed within housing member 106 is a piston 116 that initially blocks communication between port 110 and fluid passageway 112 , as best seen in FIG. 5A . Piston 116 is biased to the left by pressure acting on a differential piston area 118 . Initially, displacement of piston 116 to the left is substantially prevented by a fluid 120 disposed within a fluid chamber 122 . Preferably, while fluid 120 prevents piston 116 from moving sufficiently to the left to open communication between port 110 and fluid passageway 112 , piston 116 is able to float as pressure differences between port 110 and fluid passageway 112 are balanced.
Securably and sealingly positioned between housing member 104 and housing member 106 is a barrier assembly 124 that includes a barrier 126 and a support assembly 128 having a fluid passageway 130 defined therethrough. Barrier 126 initially prevents fluid 120 from escaping from chamber 122 into a chamber 132 of housing member 104 . Positioned within housing member 104 is a control system 134 that includes or is operably associated with a signal detector, a control circuit, a power supply, optional timing devices and an output signal generator or trigger depicted in FIG. 5A as a chemically initiated piercing assembly 136 . Chemically initiated piercing assembly 136 includes a chemical element or energetic material 138 , an ignition agent 140 and a piercing element 142 slidably disposed within a cylinder 144 . Chemical element 138 is preferably a combustible element such as a propellant that has the capacity for extremely rapid but controlled combustion that produces a combustion event including the production of a large volume of gas at high temperature and pressure.
In an exemplary embodiment, chemical element 138 may comprises a solid propellant such as nitrocellulose plasticized with nitroglycerin or various phthalates and inorganic salts suspended in a plastic or synthetic rubber and containing a finely divided metal. Chemical element 138 may comprise inorganic oxidizers such as ammonium and potassium nitrates and perchlorates such as potassium perchlorate. It should be appreciated, however, that substances other than propellants may be utilized without departing from the principles of the present invention, including other explosives, pyrotechnics, flammable solids or the like. In the illustrated embodiment, ignition agent 140 is connected to the control circuit via an electrical cable 146 so that, when it is determined that actuator 100 should be operated, the control circuit supplies electrical current to ignition agent 140 . In slickline conveyed embodiments, actuator 100 may include one or more batteries to supply electrical energy to control system 134 . In electric line conveyed embodiments, electrical energy may be supplied to control system 134 from the surface.
In operation, the signal detector of control system 134 receives the predetermined input signal that is verified by the control circuit. The input signal may be generated by a downhole timer operably associated with control system 134 or sent from the surface via the wireline or via wireless telemetry. If the control circuit determines that actuator 100 should be operated, electrical power is supplied from the power supply to ignition agent 140 to initiate the chemical reaction in chemical element 138 . The chemical reaction causes piercing element 142 to move to the right piecing barrier 126 , as best seen in FIG. 5B . Fluid communication is thus established between chamber 122 and chamber 132 through opening 148 , which allows fluid 120 to exit chamber 122 as piston 116 is urged to the left by pressure from the exterior of the fluid sampler acting on differential piston area 118 . Fluid communication is now open between port 110 and fluid passageway 112 , as best seen in FIG. 5B . Even though a particular actuator 100 has been depicted and described, those skilled in the art will understand that other types of actuators having other types of signal detectors, control circuits, power supplies, timing devices, output signal generators, triggers, pistons and the like may be used in the present fluid sampler without departing from the principle of the present invention.
Referring now to FIGS. 6A-6F a fluid sampling chamber for use in a fluid sampler that embodies principles of the present invention is representatively illustrated and generally designated 200 . Preferably, one or more of sampling chambers 200 are positioned in a sampler assembly 24 that is coupled to an actuator assembly 22 and a self-contained pressure source assembly 26 as described above.
As described more fully below, a passage 210 in an upper portion of sampling chamber 200 (see FIG. 6A ) is placed in communication with fluid passageway 112 of the actuator (see FIG. 5B ) when the fluid sampling operation is initiated using actuator 100 . Passage 210 is in communication with a sample chamber 214 via a check valve 216 . Check valve 216 permits fluid to flow from passage 210 into sample chamber 214 , but prevents fluid from escaping from sample chamber 214 to passage 210 .
A debris trap piston 218 is disposed within housing 202 and separates sample chamber 214 from a meter fluid chamber 220 . When a fluid sample is received in sample chamber 214 , debris trap piston 218 is displaced downwardly relative to housing 202 to expand sample chamber 214 . Prior to such downward displacement of debris trap piston 218 , however, fluid flows through sample chamber 214 and passageway 222 of piston 218 into debris chamber 226 of debris trap piston 218 . The fluid received in debris chamber 226 is prevented from escaping back into sample chamber 214 due to the relative cross sectional areas of passageway 222 and debris chamber 226 as well as the pressure maintained on debris chamber 226 from sample chamber 214 via passageway 222 . An optional check valve (not pictured) may be disposed within passageway 222 if desired. In this manner, the fluid initially received into sample chamber 214 is trapped in debris chamber 226 . Debris chamber 226 thus permits this initially received fluid to be isolated from the fluid sample later received in sample chamber 214 . Debris trap piston 218 includes a magnetic locator 224 used as a reference to determine the level of displacement of debris trap piston 218 and thus the volume within sample chamber 214 after a sample has been obtained.
Meter fluid chamber 220 initially contains a metering fluid, such as a hydraulic fluid, silicone oil or the like. A flow restrictor 234 and a check valve 236 control flow between chamber 220 and an atmospheric chamber 238 that initially contains a gas at a relatively low pressure such as air at atmospheric pressure. A collapsible piston assembly 240 includes a prong 242 which initially maintains check valve 244 off seat, so that flow in both directions is permitted through check valve 244 between chambers 220 , 238 . When elevated pressure is applied to chamber 238 , however, as described more fully below, piston assembly 240 collapses axially, and prong 242 will no longer maintain check valve 244 off seat, thereby preventing flow from chamber 220 to chamber 238 .
A piston 246 disposed within housing 202 separates chamber 238 from a longitudinally extending atmospheric chamber 248 that initially contains a gas at a relatively low pressure such as air at atmospheric pressure. Piston 246 includes a magnetic locator 247 used as a reference to determine the level of displacement of piston 246 and thus the volume within chamber 238 after a sample has been obtained. Piston 246 included a piercing assembly 250 at its lower end. In the illustrated embodiment, piercing assembly 250 is spring mounted within piston 246 and includes a needle 254 . Needle 254 has a sharp point at its lower end and may have a smooth outer surface or may have an outer surface that is fluted, channeled, knurled or otherwise irregular. As discussed more fully below, needle 254 is used to actuate the pressure delivery subsystem of the fluid sampler when piston 246 is sufficiently displaced relative to housing 202 .
Below atmospheric chamber 248 and disposed within the longitudinal passageway of housing 202 is a valving assembly 256 . Valving assembly 256 includes a pressure disk holder 258 that receives a pressure disk therein that is depicted as rupture disk 260 , however, other types of pressure disks that provide a seal, such as a metal-to-metal seal, with pressure disk holder 258 could also be used including a pressure membrane or other piercable member. Rupture disk 260 is held within pressure disk holder 258 by hold down ring 262 and gland 264 that is threadably coupled to pressure disk holder 258 . Valving assembly 256 also includes a check valve 266 . Valving assembly 256 initially prevents communication between chamber 248 and a passage 280 in a lower portion of sampling chamber 200 . After actuation the pressure delivery subsystem by needle 254 , check valve 266 permits fluid flow from passage 280 to chamber 248 , but prevents fluid flow from chamber 248 to passage 280 . Preferably, passageway 280 is placed in fluid communication with pressure from the self-contained pressure source via the manifold therebetween.
Once the fluid sampler has been run downhole via the wireline conveyance to the desired location and is in its operable configuration, a fluid sample can be obtained into one or more of the sample chambers 214 by operating actuator 100 . Fluid from passage 112 then enters passage 210 in the upper portion of each of the desired sampling chambers 200 . For clarity, the operation of only one of the sampling chambers 200 after receipt of a fluid sample therein is described below. The fluid sample flows from passage 210 through check valve 216 to sample chamber 214 . It is noted that check valve 216 may include a restrictor pin 268 to prevent excessive travel of ball member 270 and over compression or recoil of spiral wound compression spring 272 . An initial volume of the fluid sample is trapped in debris chamber 226 of piston 218 as described above. Downward displacement of piston 218 is slowed by the metering fluid in chamber 220 flowing through restrictor 234 . This prevents pressure in the fluid sample received in sample chamber 214 from dropping below its saturation pressure.
As piston 218 displaces downward, the metering fluid in chamber 220 flows through restrictor 234 into chamber 238 . At this point, prong 242 maintains check valve 244 off seat. The metering fluid received in chamber 238 causes piston 246 to displace downwardly. Eventually, needle 254 pierces rupture disk 260 which actuates valving assembly 256 . Actuation of valving assembly 256 permits pressure from the self-contained pressure source to be applied to chamber 248 . Specifically, once rupture disk 260 is pierced, the pressure from the self-contained pressure source passes through passage 280 and valving assembly 256 including moving check valve 266 off seat. In the illustrated embodiment, a restrictor pin 274 prevents excessive travel of check valve 266 and over compression or recoil of spiral wound compression spring 276 . Pressurization of chamber 248 also results in pressure being applied to chambers 238 , 220 and thus to sample chamber 214 .
When the pressure from the self-contained pressure source is applied to chamber 238 , pins 278 are sheared allowing piston assembly 240 to collapse such that prong 242 no longer maintains check valve 244 off seat. Check valve 244 then prevents pressure from escaping from chamber 220 and sample chamber 214 . Check valve 216 also prevents escape of pressure from sample chamber 214 . In this manner, the fluid sample received in sample chamber 214 is pressurized such that the fluid sample may be retrieved to the surface without degradation by maintaining the pressure of the fluid sample above its saturation pressure, thereby obtaining a fluid sample that is representative of the fluids present in the formation.
While this invention has been described with a reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments. | An apparatus ( 10 ) for obtaining fluid samples in a subterranean well ( 14 ). The apparatus ( 10 ) includes a wireline conveyance ( 22 ) and a fluid sampler ( 12 ) supported by and positioned with the wireline conveyance ( 22 ) in the well ( 14 ). The fluid sampler ( 12 ) includes an actuator ( 24 ) operable to establish a fluid communication path between an exterior and an interior of the fluid sampler ( 12 ), a plurality of sampling chambers ( 26 ) operable to receive fluid samples therein and a self-contained pressure source ( 28 ) in fluid communication with the sampling chambers ( 26 ) operable to pressurize the fluid samples obtained in the sampling chambers ( 26 ) to a pressure above saturation pressure, thereby preventing phase change degradation for the fluid samples during retrieval of the fluid sampler ( 12 ) to the surface. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to variable positioning and securing mounting shafts and, more particularly, to an apparatus for variably securing and positioning mounting shafts of a car radio, stereo, television, or the like so that the same chassis frame may be mounted on differently sized frames or enclosures having diversely spaced openings for receiving the mounting shafts.
2. Description of the Prior Art
It has been the desire of the automobile accessory industry to make and carry in inventory a standard car radio or stereo chassis unit which can be used in a variety of car makes and models in order to decrease cost. Because car manufacturers do not produce cars with dashboards having uniformly spaced mounting openings, it has become necessary to provide movable mounting shafts which carry the control knobs so that their position may be changed to accommodate different dashboard structures.
In the past, this positioning problem has been resolved primarily by single direction variations of the relative positions of the shafts. A typical prior device included an alignment bracket for matching engagement with different pairs of horizontally aligned holes on the chassis plate. Thus, it was not possible to vary the horizontal and vertical position of the control mechanism simultaneously relative to the chassis.
Since many car radios are installed by the car owner, the devices employed had to be simple enough to be used by the average person.
Some of the prior devices also did not sufficiently prevent undesired rotation of the control knob wires if the mounting shaft became loose. Many times this rotation caused wires which were attached to the mechanism to be broken whereby the radio or television was rendered inoperative.
Similar goals and problems are present when dealing with television chassis and the like where it is desired to produce a single chassis frame installable in a variety of cabinets.
SUMMARY AND OBJECTS OF THE INVENTION
The above mentioned problems of the prior art have been overcome by the present invention which provides apparatus for variable positioning and securing of the mounting shafts carrying the tuning and/or volume control knobs and the like of a radio, stereo, or the like.
The general object of the invention is to provide an apparatus for variably positioning and securing a control mechanism of a radio or other device which is simply constructed, economical to produce, and capable of being used by the average person.
Another object of the present invention is to provide a positioning apparatus which is sturdy, reliable and easy to use.
Still another aspect of the invention is to provide an apparatus for variably positioning and securing the control mechanism of a radio which is capable of permitting simultaneous variations in the horizontal and vertical locations of the control mechanisms of radios, television and the like.
Yet another object of the invention is to provide an apparatus for variably positioning and securing a control mechanism of a radio and the like which will prevent the control mechanism from rotating about its longitudinal axis during use even if the device becomes loosened.
Other objects and advantages of the invention will appear from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a frontal view of the apparatus interconnected with an automobile radio;
FIG. 2 is a perspective view of the alignment member; and
FIG. 3 is a cross-sectional view of the apparatus taken along line 3--3 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the present invention is susceptible to various modifications and alternative constructions, an illustrative embodiment is shown in the drawings and will be described in detail hereinbelow. It should be understood, however, that it is not the intention to limit the invention to the particular form disclosed; but, on the contrary, the invention is to cover all modifications, equivalences and alternative constructions falling within the spirit and scope of the invention as expressed in the appended claims.
In the drawing as illustrated a chassis 10 has an enlarged shaft outlet 12 formed by the edge 14.
The exemplary shaft is shown as a projecting threaded finger 18 of the control mechanism 16 which passes through a hole 22 of a backing plate 20 adjacent a collar 26 on the control mechanism 16. The forward end of the projecting finger is encircled by an inner edge 30 of an alignment bracket member 32.
The threaded finger 18 is slightly rectangular in lateral cross section as is the hole 22 in the backing plate 20. Thus, relative circular movement between the projecting finger 18 of the control mechanism 16 and the backing plate 20 is prevented. The outlet 12 is sufficiently small to prevent the passage of the backing plate 20, yet large enough to allow horizontal, vertical and/or diagonal movement of the control mechanism shaft to a desired location.
There is an cut-out 44 on the side, and extending around to the front, of the chassis to accommodate the backing plate 20 when the control mechanism is in a horizontally extended position so that the edge of the plate extends beyond the chassis 10. The backing plate 20 has a rectangular extension 46 abutting the rearward portion of a chassis 10 in the vicinity of the edge 14 of the hole 12 so that the plate 20 will remain on the inner side of the chassis 10 while the control mechanism is in such extended position.
An alignment bracket member 32 is provided having a substantially rectangular body portion 31 and non-aligned leg portions 34 extending from the body portion 31 on the right and left sides thereof and in opposite vertical directions.
At the end of each leg portion 34 there is a rearwardly projecting rectangular tooth 36. The body portion 31 of the alignment member 32 has a centrally located aperture 37 sufficiently large to accommodate the projecting threaded finger 18 of the control mechanism 16. The body portion 31 has a plurality of bumpers 35 extending inwardly and rearwardly from the inner edge 30 of the alignment member. The surfaces of the bumpers 35 which are perpendicular to the forward surface 29 of the alignment member may be machined to a smooth curved or flat surface, to correspond to the shape of the portion of the projecting threaded finger of the control mechanism in contact with the surface, and are positioned in rectangular alignment to prevent relative circular movement between the alignment member and the control mechanism when the projecting threaded finger is inserted in the opening of the alignment member. The machined inner surface of the bumpers protect the threads of the finger from being damaged during insertion and removal.
Alignment slots or holes 38 in the chassis 10 are preferably formed into two groups, one above and slightly to the right of the opening 12 and the other below and slightly to the left of the opening 12. The pattern formed by each group is identical and comprises a plurality of rows and columns of the alignment.
Each group of alignment holes is arranged so that every alignment hole in one group has a complimentary alignment hole in the other group. The two alignment holes are spaced apart and have the same relative position to each other as do the teeth 36 of the alignment member 32. Thus the position of the alignment member can be inverted and has no top or bottom.
The projecting threaded finger 18 of the control mechanism 16 is then inserted into the opening 37 of the alignment member 32 so that the teeth 36 point toward the chassis 10. The teeth 36 are then inserted into a pair of alignment holes 38.
A washer 40 is inserted over the projecting finger 18 so as to abut the alignment member 32 and a threaded nut 42 is rotated on the projecting finger so as to abut the washer 40.
Each of the pairs of alignment holes 38 in the chassis 10 are located so that the position of the control mechanism 16 is in the desired location when the teeth 36 of the alignment member 32 are inserted into said alignment holes.
The apparatus is assembled so that the plate 20 abuts the collar 26 of the control mechanism 16 on one side and the inner side of the chassis 10 on the other. The alignment member 32 is then inserted on the projecting threaded finger 18 and located in the desired position. The teeth 36 are then inserted into the alignment holes 38. A washer 40, a nut 42 are inserted upon the projecting finger 18 and the nut 42 is tightened.
As mentioned previously due to the fact that the projecting finger 18 and the inner edge of the opening 37 of the alignment member 32 are both rectangular, relative circular movement between the two elements will be eliminated even when the nut 42 is slightly loose.
If it is desired to realign the control mechanism 16, the nut 42 is sufficiently loosened so as to allow the teeth 36 to be removed from the alignment holes 38. The teeth 36 are then repositioned into the desired new alignment holes and the nut 42 tightened.
It will be noted that in order to best accomplish the foregoing operations, the peripheral pattern of the rows and columns of the alignment holes or slots correspondends generally to the peripheral pattern of the outlet 12. | Apparatus for variably positioning and securing car radio units and the like, including a mounting shaft securable on a front chassis plate in a number of different positions spaced horizontally, vertically and diagonally from each other. A bracket member has an opening to receive the shaft and a plurality of legs extend therefrom for insertion into different sets of alignment holes on the front chassis plate. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to minimizing energy consumption in staged externally-controlled systems.
Staged externally-controlled processes where temperature is the control include distillation processes and chemical reactor processes. Other staged processes can be pressure controlled, such as membrane separation processes like isotope diffusion processes and reverse osmosis processes. Further, staged mechanical controls can apply to staged centrifugation processes.
At the present time, distillation processes account for more than 10% of industrial energy consumption in the United States. Any significant improvement in the efficiency of such processes would result in substantial savings of energy. The traditional fractional distillation column is structured with: (a) one point of heat input (i.e., a reboiler contained in a bottom tray); and (b) a point of heat removal (i.e., a condenser contained in a top tray). Articles suggesting the use of additional heat sources or heat sinks to improve the efficiency of distillation systems include:
1a. “Control of Sidestream and Energy Conservation Distillation Towers,” H. A. Mosler, Industrial Process Control (AIChE, NY, 1979);
1b. Conserving Energy in Distillation, T. W. Mix and J. S. Dweck, (MIT Press, Cambridge, 1982);
1c. Distillation Control, F. G. Shinskey (McGraw-Hill, NY, 1984);
2a. “Distillation with Intermediate Heat Pumps and Optimal Sidestream Return,” AIChE Jrnl. 32:1347-1359 (August 1986);
2b. “Minimum Energy Requirements of Thermally Coupled Distillation Systems”, AIChE Jrnl. Vol. 33, No. 4, (pp. 643-653, April 1987);
2c. “Heat Pumps for Distillation Columns,” A. Meili, Chemical Engineering Progress, 86:60 (1990);
2d. “Energy Requirements for Nonconventional Distillation Systems,” Z. Fidkowski and L. Krolikowski, AIChE Jrnl., 36, 1275 (1990);
2e. “Consider Thermally Coupled Distillation,” A. J. Finn, Chemical Engineering Progress, 89, 41 (1993);
2f. “On the Use of Intermediate Reboilers in the Rectifying Section and Condensers in the Stripping Section of a Distillation Column,” R. Agrawal and Z Fidkowski, Ind. Ch. Res., 35:2801-2807 (1996);
3a. “Thermodynamic Analysis of Rectification I and II, Reversible Model of Rectification & Finite Cascade Models,” Z. Fonyo, Int. Chemical Engng. 14:18 (1974) and 14:203 (1974);
3b. “The Ideal Column Concept: Applying Exergy to Distillation,” V. Kaiser and J. P. Gourlia, Chem. Eng., P. 45 (Aug. 19, 1985);
3c. Industrial Energy Management, V. Kaiser (Institut Francais du Petrole Paris, 1993);
3d. “Equipartition of Entropy Production: An Optimality Criterion for Transfer and Separation Processes”, D. Tondeur and E. Kvaalen, Ind. Eng. Chem. Res., V. 26, 50-56 (1987);
3e. “Analysis of Entropy Production Rates for Design of Distillation Columns,” S. Ratkje, E. Sauar, E. M. Hansen, K. M. Lien, and B. Hafskjold, I & EC Research, 34:3001-3007 (1995);
4. “Finite Time Thermodynamics: Limiting Performance of Rectification and Minimal Entropy Production in Mass Transfer,” A. M. Tsirlin, V. A. Kazakov, and R. S. Berry, J. P. Chm., 98:3300-3336 (1994);
5a. “Thermodynamic Length and Dissipated Availability,” P. Salamon & R. S. Berry. Physical Review Letters, 51:1127-1130 (1983); and
5b. “Quasistatic Processes as Step Equilibrations,” J. Nulton, P. Salamon, B. Andresen, and Qi Anmin, J. of Chem. Physics, 83, 334 (1985).
The articles listed above are categorized according to technical content in relation to the present invention. Articles 1a-1c are directed to general methodologies of adding heat pumps to effect energy savings from column operation. Articles 2a-2f describe specific examples of these methodologies, but are limited to one additional reboiler and condenser. In some of the examples, a heat pump uses the distillate as its working fluid (vapor recompression). In others, sidestream removal and readdition is used with possible thermal contact outside the column. Articles 3a-3e are directed to examples of multi-tray systems in which the possibility of heat addition and removal at each tray is raised. Their analyses are purely for comparison as idealized aids to analysis of real processes. The specific nature and amount of control at each stage is discussed only in article 3d, which does not present a means for effecting the equal entropy production criterion. This proposition is examined further in article 3e with disappointing results. Article 4 suggests controlling continuous (as opposed to staged) distillation process by adjusting the concentration profile. Articles 5a and 5b describe application of the equal thermodynamic distance principle in a multi-step process for one working fluid traversing a sequence of states.
The approach to heat integration can include the use of a heat pump with at most two points of contact with the column augmented by possible removal and readdition of the distillate material. Prior U.S. patents that address efficiency-improved distillation columns include, for example: F. G. Shinskey, U.S. Pat. No. 4,030,986, “Control for Maximizing Capacity and Optimizing Product Cost of Distillation Column”; G. Emmrich, et al., U.S. Pat. No. 5,080,761, “Method of Optimizing the Operation of a Distillation Column Provided with a Side Heating Device”; R. Agrawal, et al., U.S. Pat. No. 5,230,217, “Inter-Column Heat Integration for Multi-Column Distillation System”; and R. Agrawal, U.S. Pat. No. 5,289,688, “Inter-Column Heat Integration for Multi-Column Distillation System.”
SUMMARY OF THE INVENTION
The invention is directed to maintaining equal thermodynamic distances between stages in a thermodynamic process. The invention relates, in one embodiment, to a distillation system which minimizes exergy consumption in a distillation column by using heat exchange optimally distributed along the column. The system employs a plurality of thermostatted trays which are maintained at a sequence of temperatures specified by maintaining equal thermodynamic distances between the trays. The system can include a unique employment of heat pumps to attain the desired control. The total heat requirement at the boiler decreases by a factor between two and ten when the temperature of each tray in a column is controlled. The decreased heat requirement is accompanied by a similar reduction in the exergy loss.
In one aspect, the invention features a thermal distillation system. The system includes a plurality of thermostatically controlled trays distributed along a length of a distillation column and a means connected to the trays effective to maintain equal thermodynamic distances between the trays. The means can be a heat flow controller. The means can include a heat pump. The heat pump can be a tandem heat pump, which can be integrated in the design of the distillation column.
The heat pump can include an evaporator, a condenser, a compressor, and a throttling valve connected in series through a conduit. The throttling valve is adapted to circulate a refrigerant to perform a heat exchange cycle. The throttling valve is thermally connected to each of the trays and effective to control the amount of heat transferred to or extracted from the trays. The throttling valve can be an elongated small diameter tube.
In preferred embodiments, the distillation system includes: a distillation column having a bottom tray and top tray; a plurality of intermediate trays disposed between the bottom tray and the top tray, the bottom tray serving as a distillation bottom; a heat source in thermal contact with the bottom tray and effective to supply significant heat energy to the distillation bottom; and a first heat exchanger connected to the intermediate trays. The first heat exchanger can be distributed among the intermediate trays. The first heat exchanger can operate in a reversed Brayton cycle. Alternatively, the first heat pump can include a first conventional heat exchanger. The heat source can be an absorption heat pump and can supply significant heat energy to the column and the absorption heat pump.
The distillation system can also include a heat sink in thermal contact with the top tray and effective to extract significant heat energy from the top tray. The heat sink can include a second conventional heat exchanger. The first and second conventional heat exchangers can be interconnected to form a complete heat pump system.
In another aspect, the invention features a method of minimizing energy consumption in a staged thermodynamic process by maintaining equal thermodynamic distances between each stage in the process. The method can include controlling the amount of heat transferred to or extracted from each stage, controlling the pressure of each stage, or controlling the concentration of a reactant in each stage.
In preferred embodiments, the method includes setting the temperature of each stage in the thermodynamic process. The thermodynamic process can include a first stage and the controlling step can include supplying significant heat energy to the first stage. The thermodynamic process can also include an intermediate stage in which the controlling step includes supplying heat energy to the intermediate stage. The thermodynamic process can further include a last stage, where the controlling step includes extracting significant heat energy from the last stage.
In preferred embodiments, the thermodynamic process is a distillation process.
The invention may include one or more of the following advantages. The system applies the equal thermodynamic distance principle to the steady state operation of a distillation column. This extension is far from obvious and requires mapping the processes in the column to a different transformation of a multicomponent multiphase system. In particular, this required dealing with the “null directions problem” (directions along which the system can move with zero distance traversed and thus with zero dissipation as measured by the geometry) corresponding to changing the amount of any phase (scaling). In addition, the use of additional heat sources or heat sinks can result in possible energy savings.
These and other features and advantages of the invention will be apparent from the following detailed description, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the distillation system of the present invention showing a plurality of staged trays on which heat flows are adjusted to maintain a desired temperature profile.
FIG. 1A is a schematic diagram of two adjacent trays in the column showing the flow of v moles of vapor and l moles of liquid while operating between two temperatures and pressures.
FIG. 2 is a graph showing the comparative heat requirements for a conventional distillation column, an optimally adjusted column containing four trays, and an equal thermodynamic distance column containing 71 trays.
FIG. 3 is a diagram, also in schematic form, showing a multiple tray distillation column.
FIG. 4 is a diagram showing the components of an individual tray of FIG. 3 .
FIG. 5 is a schematic diagram of the interior of the tray of FIG. 4 .
FIG. 6 is a schematic diagram of a distillation column employing two heat exchangers.
FIG. 6A is a graph of the operational cycle of the column of FIG. 6 .
FIG. 7 is a schematic diagram of a vapor recompression column employing only one heat exchanger.
FIG. 8 is a graph of a reversed Brayton cooling cycle.
FIG. 9 is a schematic diagram of a distillation column employing an absorption refrigeration system.
DETAILED DESCRIPTION
Energy consumption in staged externally-controlled processes, such as in thermally-controlled process (e.g., a distillation system), can be minimized by maintaining equal thermodynamic distances between stages in the process. In this example, this is achieved by optimally distributing heat exchange on each stages. The geometry of a thermodynamic system is obtained by using the second derivative of the entropy of the system as a Riemannian metric on its manifold of equilibrium states. See, e.g., G. Ruppeiner, “Riemannian Geometry in Thermodynamic Fluctuation Theory,” Reviews of Modern Physics, 67:605 (1995), F. Weinhold, “The Metric Geometry of Equilibrium Thermodynamics I-V,” Journal of Chemical Physics, 63:2479 (1975); 63:2484 (1975); 63:2488 (1975); 63:2496 (1975); and 65:559 (1976), P. Salamon, and R. S. Berry, “Thermodynamic Length and Dissipated Availability,” Physical Review Letters, 51:1127 (1983), and J. Nulton, P. Salamon, B. Andresen, and Qi Anmin, “Quasistatic Processes as Step Equilibrations,” Journal of Chemical Physics, 83:334 (1985).
If X denotes the vector of extensive variables of the thermodynamic system, X=(E,V,N 1 ,N 2 , . . . ) and the entropy S is expressed as a function of X, the metric matrix in the coordinates X in this entropy representation takes the form of the second derivative D 2 S. Accordingly, the length associated with an infinitesimal displacement dX is shown in equation 1:
∥ dX∥=dX t D 2 S dX (1)
The distance traversed along a process X(t) is described by equation 2: X = ∫ t initial t final X t D 2 SX t ( 2 )
where X=dX/dt.
One convenient method of performing the calculation in the alternative energy representation is to work with the second derivative matrix of the internal energy with respect to the extensive variables, where the entropy S has replaced the internal energy. Once the length element has been computed for this metric, the length element for the metric above differs exactly by a factor of the temperature. See, e.g., P. Salamon, J. Nulton and E. Ihrig, “On the Relation between Energy and Entropy Versions of Thermodynamic Length,” Journal or Chemical Physics, 80:436 (1984).
The thermodynamic distance can be calculated between stages in a staged thermodynamic process. For example, the thermodynamic distance for a two-phase binary mixture is calculated by a sequence of reductions in dimension until we reach the three-dimensional submanifold of coexistence between the two phases. The mass balance equations (establishing the net tray-to-tray transport) determine a curve in that submanifold, along which the distance is calculated.
Initially, the two-phase binary mixture is described in the eight-dimensional space of the variables:
N ij =moles of component i in phase j, where i,j=1 or 2;
S j =entropy of phase j, where j=1 or 2; and
V j =volume of phase j, where, j=1 or 2.
Accordingly, the metric matrix in this coordinate system is block diagonal: [ ∂ 2 E ∂ S 1 2 ∂ 2 E ∂ S 1 ∂ V 1 ∂ 2 E ∂ S 1 ∂ N 11 ∂ 2 E ∂ S 1 ∂ N 21 0 0 0 0 ∂ 2 E ∂ S 1 ∂ V 1 ∂ 2 E ∂ V 1 2 ∂ 2 E ∂ V 1 ∂ N 11 ∂ 2 E ∂ V 1 ∂ N 21 0 0 0 0 ∂ 2 E ∂ S 1 ∂ N 11 ∂ 2 E ∂ V 1 ∂ N 11 ∂ 2 E ∂ N 11 2 ∂ 2 E ∂ N 11 ∂ N 21 0 0 0 0 ∂ 2 E ∂ S 1 ∂ N 21 ∂ 2 E ∂ V 1 ∂ N 21 ∂ 2 E ∂ N 11 ∂ N 21 ∂ 2 E ∂ N 21 2 0 0 0 0 0 0 0 0 ∂ 2 E ∂ S 2 2 ∂ 2 E ∂ S 2 ∂ V 2 ∂ 2 E ∂ S 2 ∂ N 12 ∂ 2 E ∂ S 2 ∂ N 22 0 0 0 0 ∂ 2 E ∂ S 2 ∂ V 2 ∂ 2 E ∂ V 2 2 ∂ 2 E ∂ V 2 ∂ N 12 ∂ 2 E ∂ V 2 ∂ N 22 0 0 0 0 ∂ 2 E ∂ S 2 ∂ N 12 ∂ 2 E ∂ V 2 ∂ N 12 ∂ 2 E ∂ N 12 2 ∂ 2 E ∂ N 12 ∂ N 22 0 0 0 0 ∂ 2 E ∂ S 2 ∂ N 22 ∂ 2 E ∂ V 2 ∂ N 22 ∂ 2 E ∂ N 12 ∂ N 22 ∂ 2 E ∂ N 22 2 ]
It is thus sufficient to treat the two four-by-four matrices of each phase separately, omitting the index j which indicates the phase. Each four-by-four matrix can be further block diagonalized with a change of coordinates to the variables:
T=temperature;
p=pressure;
N 1 =moles of component 1 ; and
N 2 =moles of component 2 .
Using subscripts to indicate partial derivatives of the terms, the metric for one phase is described by matrix 3 in terms of Gibbs free energy G. [ - G TT G Tp 0 0 G Tp - G pp 0 0 0 0 G N 1 N 1 G N 1 N 2 0 0 G N 1 N 2 G N 2 N 2 ] ( 3 )
By restricting the conditions to constant pressure, for example, one degree of freedom is eliminated by replacing N 1 and N 2 with:
x=N 1 /( N 1 +N 2 )=mole fraction of component 1 ;
and
N=N 1 +N 2 =total number of moles.
These changes reduce matrix 3 to metric matrix 4. [ - G TT 0 0 0 - G N 1 N 2 N 2 x ( 1 - x ) 0 0 0 0 ] ( 4 )
The third degree of freedom in this coordinate system is N, which is a scaling direction and can be neglected. The relationship x(T) between the remaining two coordinates is valid along the coexistence curve. The resulting length squared of a displacement dT is described by equation 5: L ɛ 2 = ( - G TT + - G N 1 N 2 N 2 x ( 1 - x ) ( x T ) 2 ) T 2 ( 5 )
The squared length elements are combined using the fact that the temperatures T j of the two phases must be equal for two coexistent phases. The resulting length squared is shown in equation 6. L ɛ 2 = ( - G TT v + - G N 1 v N 2 v v N v2 y ( 1 - y ) ( y T ) 2 - G TT l + - G N 1 l N 2 l l N l2 x ( 1 - x ) ( x T ) 2 ) T 2 ( 6 )
In equation 6, the superscripts v and 1 refer to the vapor and the liquid phase, respectively, and y represents the mole fraction of component 1 (i=1) in the vapor phase.
By maintaining the thermodynamic distance between stages, the exergy consumed by the process is minimized. The method can be applied to any staged externally-controlled systems, such as, for example, distillation processes, chemical reactor processes, membrane separation processes (e.g., isotope diffusion processes), and centrifugation processes.
Without further elaboration, it is believed that one skilled in the art can, based on the description herein, utilize the present invention to its fullest extent. All publications cited herein are hereby incorporated by reference. The following specific examples are, therefore, to be construed as illustrative, and not limitive of the remainder of the disclosure.
A Distillation Column
Referring to FIG. 1, the operation of the invention requires controlled flow of heat at each tray. The controls employed serve to thermostat each tray to a specific temperature. The sequence of temperatures is specified by making the thermodynamic distance between trays constant.
Referring to FIG. 1A, the thermodynamic distance between tray l and tray 2 is given by equation 7: ∫ ( T 1 , p 1 ) ( T 2 , p 2 ) ( T S + p V ) / T ( 7 )
where, in the limits of integration, T i and p i are the temperature and pressure in tray i, where i=1 or 2. The thermodynamic quantities in the integrand correspond to a two phase equilibrium system consisting of l moles of liquid and v moles of vapor having the initial compositions of the liquid and vapor on tray 1 . l is the molar amount of liquid moving from tray 2 to tray 1 in a unit of time. v is the molar amount of vapor moving from tray 1 to tray 2 in a unit of time. If the pressure does not change appreciably between the two trays, the second term in the radicand vanishes and the integral simplifies to give equation 8: Tray to Tray Distance S = ∫ T 1 T 2 T E 2 T = ∫ T 1 T 2 C R T T ( 8 )
where C R is the heat capacity of the two phase thermodynamic system that consists of l moles of liquid and v moles of vapor (i.e., the coefficient of (dT) 2 in equation 6). For an ideal binary mixture, for example, C R is given by equation 9: C R = v [ yC p1 v + ( 1 - y ) C p2 l + T Γ v y ( 1 - y ) ( y T ) 2 ] + 1 + [ xC p1 l + ( 1 - x ) C p2 l + T Γ l x ( 1 - x ) ( x T ) 2 ] ( 9 )
In this formula, x and y are the equilibrium mole fractions of component 1 in the liquid and vapor phases, respectively. C pi 1 and C pi v are the partial molar heat capacities of each component i (where i=1 or 2) in the liquid and vapor phases, respectively. The values for Γ v and Γ l are given by equations 10 and 11, respectively. Γ l = - l ∂ μ 2 l ∂ l 1 = - l ∂ μ 1 l ∂ l 2 ( 10 ) Γ v = - v ∂ μ 2 v ∂ v 1 = - v ∂ μ 1 v ∂ v 2 ( 11 )
The quantities μ i l and μ i v are chemical potentials of each component i (where i=1 or 2) in the liquid and vapor phases, respectively, and where:
l
1
=xl;
l 2 =(1− x ) l;
v
1
=yv;
and
v 2 =(1− y ) v.
Finally, v and l are given by equations 12 and 13, respectively. v = xM Flow - x Flow x - y ( 12 ) l = x Flow - yM Flow x - y ( 13 )
The quantities x Flow and M Flow are the net tray-to-tray material transport. For a distillation column with no sidestream addition or removal, material transport is described by the equations x Flow =x D D and M Flow =D for the rectification portion of the column and x Flow =−x B B and M Flow =−B for the stripping portion of the column. In these equations, D is the number of moles of distillate extracted per unit of time, B is the number of moles of bottoms removed per unit of time, and x D and x B are the mole fractions of one component (i=1) in the bottom and distillate, respectively. For columns with sidestream flows, these quantities are adjusted according to Kirchoff's laws.
Referring to FIG. 2, the comparative heat requirements for three different distillation columns are plotted. This example compares the separation of a 50/50 mole percent solution of benzene and toluene into 99% pure products using a 71 tray column. For a conventional column (CC), heat is added at the bottom of the column, corresponding to point (CC) B , and extracted at the top, point (CC) D . The need to add or remove heat is substantially reduced by employing as few as four thermally active trays (4TA), as shown by points (4TA) 1 -(4TA) 4 . The truly significant improvement of employing a multiplicity of trays (71 in the example shown) spaced at equal thermodynamic distances is shown by curve ETD on the graph. The heat extracted for the first two trays (points (ETD) 1 and (ETD) 2 ) is significant, but is substantially less than that of the conventional column, or the 4TA column. Similarly, the heat added at the bottom tray (point (ETD) 71 ) is also significant but is still less than for the other two columns. The best overall measure of the energy efficiency of the three designs is given by the exergy consumption. Calculations based on T 0 =273 K multiplied by the entropy produced by the process give:
CC: 842 J/mole of feed
4 TA: 423 J/mole of feed
ETD: 191 J/mole of feed
The equal thermodynamic distance column thus represents an exergy savings of 55% over the column with four thermally active trays (4TA), and a savings of 77% over the conventional column (CC).
To achieve this sort of savings in operation, it is necessary to use more trays than would be employed in conventional operation. The capital equipment costs of the additional trays and the tandem heat pump to supply the heats required by ETD operation are offset by the significantly smaller heat exchangers required and by the energy savings.
Referring to FIG. 3, distillation column 10 has a multiplicity of trays 11 , a distillation bottom 28 and a distillation top 29 . Referring to FIG. 4, each of the trays 11 include a cylindrical vessel 12 wrapped with heat exchange coils 13 . Referring to FIG. 5, vessel 12 is sealed by contacting another tray 11 located on top of the vessel, except for bubble cap tubes 14 and a weir tube 15 mounted in and extending through the bottom 16 of the vessel 12 .
During distillation, distillation liquid 20 is contained in the vessel 12 . Vapor formed in a lower tray enters the next upper tray via bubble tubes 14 and bubbles through the liquid 20 . Overflow liquid drains back to the lower tray through the weir tube 15 . Each of the heat exchange coils 13 is connected to a supply conduit 17 and an outlet coil 18 . The temperature of each tray 11 is maintained by controlling the flow of heat transfer fluid through the coil 13 using an RTD 21 and a solenoid valve 22 , which are interposed in the inlet conduit 17 , and a second RTD 23 and a mass flowmeter 24 , which are interposed in the outlet conduit 18 . Optional sampling conduits 25 and 26 extend through the side wall 27 of the vessel 12 through which samples may be taken of the gas and liquid phases, respectively.
The Tandem Heat Pump
A tandem heat pump system is preferably utilized to control the temperature of the trays and the heat flow in the distillation system. Referring to FIG. 6, distillation system 30 includes a distillation column 31 , a first upper heat exchanger 32 , a second lower heat exchanger 33 , a compressor 34 , and a throttling. valve 35 . Feedstock is introduced into the column 31 through a feed conduit 36 and removed as a top product through a distillate conduit 37 , and as a bottom product through a bottom conduit 38 . Part of the bottom product is fed back to the column 31 through a return conduit 39 . Likewise, part of the distillate is returned to the column as reflux through reflux conduit 44 .
The upper heat exchanger 32 is in thermal contact with the distillate conduit 37 and serves as a condenser for the distillation column 31 . It also serves as an evaporator for the heat pump. The lower heat exchanger 33 is in thermal contact with the return conduit 39 , and serves as reboiler for the distillation column 31 as well as a condenser for the heat pump. Refrigerant is circulated between the heat exchangers 32 and 33 by a compressor 34 . The compressor 34 is connected to the bottom heat exchanger 33 by a first refrigerant conduit 40 and to the upper heat exchanger through a second refrigerant conduit 41 . A third refrigerant conduit 42 completes the circuit by connecting the heat exchangers 32 and 33 . A throttling valve 35 is interposed in the third refrigerant conduit 42 and serves to restrict the flow of refrigerant between the heat exchangers 32 and 33 . In one example, the distillation column 31 operates between the temperatures of 383 K at the bottom and 353 K at the top.
In operation, vapor from the top of the distillation column 31 is condensed in the upper heat exchanger 32 which transfers heat to evaporate the refrigerant. The refrigerant is then compressed by the compressor 34 and fed to the lower heat exchanger 33 . The compressed refrigerant is condensed at a higher temperature in the lower heat exchanger 33 . The condensed high pressure refrigerant is throttled through the valve 35 and returned to the upper heat exchanger 32 .
This type of system has been employed in the prior art and has the advantage of being able to utilize conventional heat pumps if the temperatures do not exceed 130° C., at which temperature the refrigerant could become chemically unstable. The main disadvantage of this system is that two heat exchangers are required, creating large temperature and pressure drops within the refrigerant system.
Referring to FIG. 7, there is illustrated another distillation system coupled to a heat pump and called a vapor recompression system 50 . The system 50 includes a distillation column 51 , a heat exchanger 52 , a compressor 53 , and a throttling valve 54 . Feedstock is supplied to the column 51 through a feed conduit 55 , and removed as a top product through a distillate conduit 56 , and as a bottom product through a bottom conduit 57 . A portion of the bottom product extracted through bottom conduit 57 is returned to the column 51 through a return conduit 58 . The compressor 53 is connected to the heat exchanger 52 by a refrigerant conduit 59 , and the circuit is completed by a conduit 60 connecting the exchanger 52 to the top of the column 51 through the throttling valve 54 .
In operation, the low temperature, low pressure vapor is extracted from the top of the distillation column 51 through distillate conduit 56 and compressed by the compressor 53 raising its temperature and pressure. The vapor then condenses in the heat exchanger 52 where it transfers heat to the bottom of the distillation column 51 through refrigerant conduit 59 . Much of the condensate is removed as product, but some of it is directed back to the top of the distillation column 51 through conduit 60 .
This system shown in FIG. 7 has an advantage over the system of FIG. 6 in that only one heat exchanger is required, with correspondingly smaller temperature and pressure drops within the system. In theory, this system could be used with any distillation column. In practice, very few distillates are acceptable refrigerants.
Referring again to FIG. 2, it is noted that in the graph of the equal thermodynamic distance (ETD) system, large amounts of heat are extracted at the first two trays (corresponding to points (ETD) 1 and (ETD) 2 at the top of the column). Also, a large amount of heat is added at the bottom (corresponding to point (ETD) 71 ). The absolute amounts of heat are roughly one-third of what would be required in a conventional column (in comparison to points (CC) D and (CC) B ). A conventional vapor compression heat pump, as shown and described in FIG. 6, could be employed to add and extract heat at each end of the curve, except that the heat pump could be roughly one-third the size of what would otherwise be required.
Referring to FIG. 6A, it is to be noted that the refrigerant working fluid goes through its maximum temperature change twice in traveling along the paths from one heat exchanger to the other. The temperature change the refrigerant experiences corresponds to the full temperature change in the distillation column. It is proposed that the forms of heat transfer at each of the trays between (ETD) 3 and (ETD) 70 could be exchanged with the heat pump refrigerant while traveling along one or both of these heat pump paths. For example, consider the path through the compressor 34 . It is well known that intercooled compression reduces the amount of work required for a compression process and improves the performance of heat pumps. At the trays where heat needs to be added (between (ETD) F and (ETD) 70 ), this heat could be supplied by the refrigerant used for intercooling the heat pump. In practice, intercoolers are widely used to improve the performance of heat pumps, but using more than one or two is impractical. The multiple tray ETD system of this invention requires some form of heat exchange at each tray.
Referring again to FIG. 6A, the refrigerant passing through the throttling valve 35 experiences the same maximum temperature change as that passing through the compressor 34 . The resulting temperature differential can serve as a heat source or sink, as required, at the optimized temperatures for each of the trays 11 in distillation column 31 . In a preferred embodiment, the throttling valve 35 takes the form of a long small bore tube. The drag. imposed on the refrigerant as it moves through the third refrigerant conduit 42 alters the pressure, thus throttling the refrigerant. Coincident with this pressure drop, the temperature of the refrigerant drops from the highest to the lowest values in the distillation column. Consequently, steady state temperatures in this tube can be associated with specific points along the conduit. In this embodiment and FIG. 4, the conduit 17 is wrapped as a heat exchange coil 13 around the vessel 12 in each tray 11 of the distillation column 10 . The result is an integrated system comprising a multiplicity of distillation trays in tandem with a heat pump system for thermally controlling each tray at a prescribed optimum temperature.
As an alternative embodiment, the heat exchange function can be obtained by utilizing two different types of heat pumps. For the top and the bottom trays of the column, where large amounts of heat are added or extracted, a conventional vapor compression heat pump or vapor recompression heat pump can be employed as previously described. The only difference in this pump would be its heat exchange capacity, which would need to be only about one-third that of a conventional heat pump. For the intermediate trays (between points (ETD) 3 and (ETD) 70 ) a different type of heat pump can be employed based on the reversed Brayton cycle. A graph of the reversed Brayton cycle is shown in FIG. 8 . This type of heat pump is used in specialized heat pumping or cooling applications, as for example, in the air-conditioning of commercial aircraft. The operational characteristics of this heat pump are not ideal for air-conditioning because it absorbs heat through a range of temperatures shown between points 1 and 2 in FIG. 8 . Similarly, this pump rejects heat through a range of temperatures as shown between points 3 and 4 . These characteristics are not optimum for most one temperature heat pumping or cooling applications, and are typically competitive only in situations where weight is a consideration in selecting an appropriate heat pump. However, these same characteristics are a close match for the heat transfer requirements of the intermediate trays of the ETD system. As can be seen from the example in FIG. 8, heat is absorbed between the temperatures of about 353 K and 368 K, and removed between the temperatures of about 383 K and 365 K. In the example shown for the ETD system, the average temperature for each of the intermediate trays in which heat is extracted is 359.5 K, and the average temperature for the trays in which heat is added is 374 K. This operating range makes the reversed Brayton cycle more. efficient than the conventional vapor compression heat pump which operates through a wider average temperature difference between 353 K and 383 K. Thus, the combination of tandem heat pumps using a conventional vapor compression pump for the ends of the column, and the reversed Brayton pump for the intermediate trays can control the temperature and heat transfer precisely as required throughout the system.
Other embodiments are within the scope of the claims. For example, as a second alternative embodiment, the Brayton cycle, supplying heat exchanges (ETD) 3 through (ETD) 70 , can be used with conventional reboilers and condensers which can be of significantly reduced capacities. This embodiment is similar to the 4TA operation, except that the intermediate heat exchangers occur along the entire length of the column rather than at one intermediate tray resulting in a significant exergy savings as compared with the 4TA design.
In another embodiment, an absorption heat pump 70 , such as the one shown in FIG. 9, can be employed instead of the compressor powered system described in the first and second embodiments to thermally control distillation column 71 . Evaporator 72 and condenser 74 are in thermal contact 80 with column 71 . This would have the benefit of a less drastic change in current designs since it could be powered by heat from the reboiler at the bottom tray as in a conventional column. Suitable wrapping of the columns and throttling by means of small diameter tubing can again provide a good match to the heat requirements (ETD) 1 through (ETD) 71 of the column as the refrigerant in the absorption heat pump system moves from the condenser to the evaporator.
OTHER EMBODIMENTS
From the above description, the essential characteristics of the present invention can be ascertained. Without departing from the spirit and scope thereof, various changes and modifications of the invention can be made to adapt it to various usages and conditions. Thus, other embodiments are also within the claims. The other standard parts of the absorption heat pump, namely generator ( 73 ), pump ( 75 ), and absorber ( 76 ) function as normal without contact with the column. Pump ( 75 ) carries strong solution ( 77 ) from absorber ( 76 ) to generator ( 73 ), which receives high temperature heat ( 78 ) from a heat source ( 79 ) and acts as the primary power source for the column. Generator ( 73 ) produces high pressure refrigerant vapor ( 81 ) which is passed to condenser ( 74 ) and weak solution ( 82 ) which is throttled though throttling valve ( 54 ) and returned to absorber ( 76 ). Absorber ( 76 ) receives low pressure vapor ( 83 ) from evaporator ( 72 ) and passes waste heat ( 84 ) to the atmosphere or other heat sink. | The method and system of the present invention is designed to minimize exergy consumption consistent with a given level of product purity. For example, in a distillation system, the design employs a plurality of thermostatted trays which are maintained at a sequence of temperatures specified by finding the optimal control for an irreversible thermodynamic process. The specified temperatures at each tray are achieved with the help of a tandem heat pump which works over the range of required temperatures and which delivers the specified heat demands. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a window stay.
2. Discussion of the Background
The so called 4 bar window stay consists of a frame mounting plate or plates and a sash mounting plate (or plates) which are coupled by a pair of arms. Typically one arm is significantly shorter than the other arm. A pair of such stays mounted between a sash and window frame provide an effective means of controlling the opening and closing of the sash. Generally the pivot joint or bearing which couples an arm to a mounting plate is a friction joint or bearing and thus the window sash can be held at any adjusted degree of openness.
Due to the absence of sliding components and the low number of components the 4 bar stay concept provides a robust, uncomplicated and long life solution to the adjustable mounting of a window sash in a window frame. However, successful use of a 4 bar stay for large heavy side hung sashes (i.e. a casement window) which open to 90° to provide good access to the outer surface of the glass for cleaning purposes is difficult. In particular if a small stay of low cost and/or compact size is used with such windows the sash tends to drop or sag. Also the operating life of the stay can prove to be inadequate.
To provide good accessibility to the outside surface of the glass for cleaning purposes, a comparatively long "short arm" is required. Such a short arm, however, has high bending moments induced in it when heavy sashes are supported. In a casement application it therefore tends to deflect downwardly allowing the sash to drop or sag. Also to provide 90° opening of the sash for good cleaning accessibility 4 bar stays must have the long arm to sash plate pivot situated between the frame plate to short arm pivot and the sash plate to short arm pivot. This results in a so called "overlap" but this is usually achieved at the expense, in structural terms, of the short arm.
A further problem commonly occurring with known constructions of 4 bar stays with significant "overlap" to obtain 90° opening in a stay of short overall length is that there are high internal loads in the bearings and components. Structural load analysis reveals that the bearing and arm loads can be reduced by off-setting the frame plate to the long arm bearing in a direction towards the sash outer surface (for an outwardly opening window). The effect of this is to put the loads generated in the long arm during final closing or initial opening of the sash at a more favorable angle to the sash plate and short arm. This reduces the long arm and bearing loads and hence the size of these components for a given stay life can also be reduced.
Previously known designs using an off-set frame plate to long arm bearing use either frame plates of sufficient width for the offset plus bearing width or a plate with an extension to carry the bearing (see, for example, Australian patent specification 166853). Such a design leads to unnecessary use of more expensive structural material where structural properties are not warranted.
SUMMARY OF THE INVENTION
An object of the present invention is thus to provide a window stay of the 4 bar type having an overlap configuration and being operable to substantially 90° yet with a short arm exhibiting good strength characteristics.
Broadly therefore the invention consists of a four bar window stay of a geometry whereby in the closed position of the stay the long arm to the sash plate pivot is situated between the frame plate to short arm pivot and the sash plate to short arm pivot characterized in that the short arm is provided with a fold located substantially in the length of the arm between the pivot points thereof and extends substantially diagonally relative to an imaginary line between said pivot points.
The concept of providing a fold in the short arm results in the short arm having a substantially "Z" cross-sectional shape when a section is taken transverse to the fold. Such an arrangement is simpler to produce than separately cranked arms with structural flanges as is commonly in current use. The design of short arm according to the invention allows good "overlap" but without sacrificing compact width and thickness of the stay. The invention results in good utilization of material to maximize the bending modulus (and moment of inertia) within compact dimensions. As a consequence the invention leads to a reduction in sash sag or drop.
According to a second broad aspect of the invention therefore the invention consists of a 4 bar window stay of a geometry whereby in the closed position of the stay the long arm to sash plate pivot is situated between the frame plate to short arm pivot and the sash plate to short arm pivot and the short arm to frame plate pivot is offset to a line between the long arm to frame plate pivot and short arm to sash plate pivot when the stay is in the closed position characterised in that to provide said offset the stay when in the closed position has the frame mounting plate located such that a line between the pivot joints thereof is located at an angle to a line representing the length of the frame member to which said frame plate is, in use, attached.
According to the invention therefore the geometry of the stay when in the closed position is such that the frame mounting plate can be of a simple generally straight sided length of material as is typically found with 4 bar window stays not having an offset bearing. As a result the frame mounting plate is located at an angle to the frame member to which it is mounted.
To facilitate correct location of the frame mounting plate a locating member which fits into the window stay cavity can be provided. This locating member can have a recess or other locating means into which or with which the frame mounting plate can be located such as to be at the correct angle relative to the length of the frame member.
This locating member can be of a lower cost material such as a plastics material. In a preferred form of the material the locating member can be molded in different thicknesses to provide for an inexpensive adaptation of the stay for differing cavity thicknesses.
Furthermore a "riser block" can also be molded into the locating member to sliding engage with the sash during opening but more especially closing of the stay so as to directly carry the weight of the sash at final closing of the stay.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts throughout the several views and wherein:
FIG. 1 is a perspective view of a window stay in the fully open position,
FIG. 2 is a perspective view of the window stay but showing it in a fully closed position,
FIG. 3 is a plan view of the window stay shown in FIG. 2,
FIG. 4 is a side elevation view of the window stay in the direction of arrow "A",
FIG. 5 is a similar view to FIG. 4 but in the direction of arrow "B",
FIGS. 6 and 7 are end views in the directions of arrows "C" and "D" respectively,
FIG. 8 is a perspective view of the short arm,
FIG. 9 is a perspective view of the locating, and
FIG. 10 is a detail view of forming the end of a frame/sash mounting plate during manufacture.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description of the invention the stay will be described as having a single sash mounting plate and a single frame mounting plate. It will, however, be appreciated by those having knowledge of the window stay art that one or both of the sash and frame mounting plates can be formed in two separate pieces with each piece locating a respective pivot bearing joining the plates to the short and long arms. In the preferred form of the invention, however, a single mounting plate as described is used.
In broad terms the window stay being of a 4 bar design includes a frame mounting plate 10, a sash mounting plate 11, a short arm 12 and a long arm 13. These components (which are preferably of stainless steel construction) are coupled together by pivot bearings (preferably of a friction type) and preferably have a hollow center such that a fastener for fastening the stay to the sash and frame of the window can pass therethrough. However, the frame and sash plates 10 and 11 can be provided with openings 18 and 19 respectively through which fasteners can be passed to fasten the plates to the window frame and sash respectively. In the drawings the pivot bearings are as follows:
______________________________________Reference Number Pivot Bearing______________________________________14 Short arm to frame mounting plate15 Short arm to sash mounting plate16 Long arm to sash mounting plate17 Long arm to frame mounting plate.______________________________________
The frame and sash mounting plates 10 and 11 and long arm 13 are constructed in accordance with known techniques in the window stay art. This can include, for example, cranking of the long arm at a point in its length and providing the long arm with suitable strengthening ribs, recesses and the like.
According to the present invention the short arm 12 is folded in its diagonal length by a fold line or step 20 as can be more clearly seen in FIG. 3. This fold line 20 lies at an angle to a line L1 extending between the centers of the openings 21 and 22 through which pivot bearings 14 and 15 pass. Thus fold 20 can be described as passing diagonally across the width of the short arm 12.
As illustrated, frame plate 10 is in accordance with known techniques a single length of generally straight sided material. Thus when the stay is assembled and in the closed position (see FIG. 3) an imaginary line L2 (representing a central line of symmetry) passing between the centers of the pivot bearings 14 and 17 lies at an angle to a line L3 passing between pivot bearings 15 and 16. As a consequence pivot 17 is offset from pivot 14 toward line L3. The more pivot 17 can be moved toward line L3 the better the reduction in load on the pivots. Preferably therefore pivot 17 is substantially in line with pivots 15 and 16, i.e. lies substantially on line L3.
Therefore the geometry of the stay is such that it not only provides the required "overlap" for 90° opening of the sash (see FIG. 3) but also the required off-set of pivot 14 relative to pivots 15, 16 and 17 is provided so as to reduce bearing and arm loadings.
As illustrated in the drawings a locating member 24 can be provided, this locating member (more clearly shown in FIG. 9) being formed from a lower cost material such as plastics. Locating member 24 is provided with means of correctly locating the frame plate 10. This means can take different forms but preferably is a recess 25.
Recess 25 is of a depth substantially equal to the thickness of frame plate 10. Integrally formed in floor 36 of recess 25 is a heated bifurcated stud 35 which snap locks through an opening in frame plate 10 (see FIG. 1). Floor 36 also includes an opening 37 which aligns with fastener opening 19 in frame plate 10 and a pair of openings 38 and 39 which align with and accommodate the projecting part of pivots 14 and 17 respectively.
As shown in FIGS. 2, 3, when the stay is in a closed position, the longitudinal edges of locating member 24 are at an angle with respect to a line L2 between pivots 14 and 17. Locating members of different thicknesses can be provided so as to allow for inexpensive adaptation of the stay for different cavity thicknesses.
In the preferred form of the locating member 24 as illustrated one end of the locating member can be provided with an area of increased thickness 26 which provides a stop against which the short arm engages (preferably at the step provided by fold 20) and partially overlaps when the stay is in the fully closed position.
At the other end of the locating member 24 a "riser" block 27 can be provided, this block 27 forming an inclined ramp. The ramp can engage with the sash as the sash closes such as to directly carry the weight of the sash and position it upon final closing of the stay. Generally the sash will be supported, when in the closed position, on the flat upper portion 28 of riser block 27.
The locating member 24 thus not only provides convenience for correct location of the frame plate 10 at an angle to the frame at installation but also provides other useful features connected with correct operation of the stay and positioning of the sash. However, this locating member can, in an alternative arrangement, be dispensed with and other means such as a template or the like can be used to correctly locate holes in the frame for mounting of the frame plate.
To maximize the bearing off-set for a given overall width of frame mount, a radius or chamfer is required on the frame plate. For example, the frame mounting width may be limited by a frame upstand for a weatherseal to seat thereon. Accordingly the present invention also proposes that the ends of the frame and/or sash mounting plates 10 and 11 have a profile consisting of a radius 29 with a flat 30. This flat 30 locates in a correspondingly shaped portion 40 in the wall of recess 25 in locating member 24.
This profile is manufactured in two stages with the first stage being shown in FIG. 10 in which one end of one plate is still connected to the other end of the next plate being produced in a progression staged press tool. The completion of the first stage provides the radius 29. In the final stage of the tool the plates are shear cut from each other this providing the flat 30 but does not involve the removal of a "slug".
Generally it has been the case that the frame and sash mounting plates have fully radiused ends. Thus, in conventional processing of these radiused ends, a slug is produced when cutting the component off the end of the strip. This is because a minimum thickness of punch must be provided for sufficient punch strength. This slug is an added cost during manufacture which the current proposal avoids.
In the preferred form of the stay, sash plate 11 has a projection 31 which in the fully open position of the stay engages with the edge of long arm 13 though preferably in a recess 32. Likewise an upstand or projection 33 of frame plate 10 engages in a recess 34 of short arm 12. These stops 31 and 33 interengaging with recesses 32 and 34 form limiters at the fully open position to prevent damage in the event the window is opened forcefully such as, for example, a high wind gust.
According to the present invention therefore the fold in the short arm provides a construction of a high moment of inertia which can withstand high forces applied to the short arm and, more particularly, when the stay is used to carry a large heavy side hung sash. Also the off-set bearing geometry can be achieved by using a conventionally configured frame mounting plate by locating the frame plate on an angle. This is a simple and a cost effective means of reducing high internal loadings in the bearings and stay components. | A window stay of a geometry whereby, in the closed position of the stay, the pivot coupling the long arm to the sash plate is situated between the pivots respectively coupling the frame and sash plates to the short arm. The short arm is provided with a fold located between the pivot points thereof and extends substantially diagonally relative to an imaginary line between the pivot points. The pivot coupling the short arm to the frame plate is offset to the other pivots when the stay is closed by the frame plate forms an angle with respect to the length of the frame member to which the frame plate is, in use, attached. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a tripod bearing assembly particularly for a motor vehicle.
BACKGROUND OF THE INVENTION
[0002] Tripod bearing assemblies of the prior art include a spider with three trunions drivably engaged with an outer member to transmit torque from a first shaft to a second shaft. The tripod bearing assembly permits angular and axial displacement between the two shafts during dynamic rotation of the assembly. Typically, a needle bearing is provided between each trunion and the outer member.
[0003] The needle bearing of the prior art is generally assembled to the trunion in one of two manners and particularly designed therefor. A first bearing type and assembly method is illustrated in FIG. 1. The trunion supports a plurality of needles which support a roller which engages a branch of an outer member of a constant velocity joint. In the prior art assembly shown in FIG. 1, the needles bear directly on a bearing surface machined onto the trunion. An outer bearing is provided between the needles and the outer member (the outer member is not shown). The needles are therefore assembled between the trunion and the outer bearing. Such an assembly requires a large amount of labor or specialized machinery to enable the assembly of the individual needles in this manner. It would therefore be desirable to provide an assembly in which the needles were assembled in a subassembly prior to installation onto the trunion.
[0004] A second type of bearing is illustrated in FIGS. 2 and 3. This assembly includes a preassembled needle bearing interposed between a trunion and outer member. The needles are assembled into a bearing assembly prior to installation of the bearing assembly onto a trunion.
[0005] The prior art assembly shown in FIGS. 2 and 3 includes a means for displacing the bearing assembly relative to the trunion. As illustrated in FIG. 2, the displacement comprises an angular movement of the trunion relative to the inner race of the bearing assembly.
[0006] [0006]FIG. 3 illustrates an alternate means for displacing the bearing assembly relative to the trunion comprising an axial movement of the trunion relative to the inner race of the bearing assembly. These prior art configurations require a bearing provided between the trunion and the needle bearing and also require additional machining of the trunion to permit the axial sliding movement. It would be desirable to provide a trunion assembly which includes needle bearings which are preassembled into a bearing assembly which is subsequently assembled onto the trunion, but which does not require relative axial or rotational movement to the trunion, so machining of the trunion is minimized.
SUMMARY OF THE INVENTION
[0007] In accordance with the objects of this invention, an improved tripod assembly is provided. The tripod bearing assembly includes a spider assembly with a trunion. A bearing assembly is press fit onto the trunion. The bearing assembly has an inner race, an outer race, and a plurality of needle rollers to permit relative rotation between the inner and outer races. The bearing assembly is axially retained to the spider. The trunion therefore does not require machining and the bearing is preassembled prior to installation onto the trunion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is an exploded view of a prior art trunion of a tripod bearing assembly.
[0009] [0009]FIG. 2 is a partial side sectional view of an alternative prior art tripod bearing assembly.
[0010] [0010]FIG. 3 is a partial end sectional view of the prior art tripod shown in FIG. 2.
[0011] [0011]FIG. 4 is a partial sectional view of a needle roller assembly being installed on a trunion according to the present invention.
[0012] [0012]FIG. 5 is a partial sectional view of a needle roller assembly being installed on a trunion according to an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0013] [0013]FIG. 4 illustrates a tripod bearing assembly 10 . The assembly 10 includes a spider 12 having three trunions 20 equally spaced. A bearing 40 is pressed fit onto the trunion 20 . The bearing 40 includes an inner race 42 supporting a plurality of needles 46 , and an outer race 48 supported by the needles 46 . In a preferred embodiment, the inner race comprises a formed cup, preferably formed by drawing the inner race to the necessary shape. The outer race 48 is rotatable relative to the inner race 42 on the needles 46 . The outer race 48 drivably engages an outer member (not shown) in a manner known to one skilled in the art.
[0014] The trunion 20 includes an outer diameter 30 which is sized to be press fit to the inner surface 44 of the inner bearing 40 . The press fit of the bearing 40 to the trunion 20 and the inner race 42 eliminate the need for machining (such as turning or grinding) of the outer diameter 30 of the trunion 20 , since it is not a bearing surface. Thus, the trunion may be assembled “as formed” without finish machining in this embodiment. The spider 12 could, for example, be forged, then have the bearing assemblies 40 press fit onto the trunions 20 , then finally assembled into a constant velocity joint assembly for use in an automobile.
[0015] An undercut 52 is preferably formed on the trunion to further eliminate the need for any finish machining of the spider at this surface. The bearing 40 is axially restrained in a first direction by a shoulder 54 provided on the spider adjacent undercut 52 . A snap ring groove 50 is provided at the distal end of the trunion 20 to engage a snap ring (not shown) to axially retain the bearing 40 to the spider 12 in the opposite direction. Thus, during operation of the joint 10 , the bearing 40 is axially fixed to the trunion 20 between the snap ring groove 50 and the shoulder 54 without the need for finish machining. The press fit also aids in axially retaining the bearing 40 to the trunion 20 .
[0016] The outer race 48 rotates circumferentially about the trunion 20 . The outer member (not shown) is able to rotate or move axially relative to the outer race 48 in a manner known to one skilled in the art, similar to the manner described in U.S. Pat. No. 4,693,698, which is incorporated herein by reference. The tripod thus accommodates any angular deflection of the joint or relative axial movement.
[0017] The bearing surface 30 of the trunion 20 comprises a cylinder. The engagement of this cylindrical trunion with the inner surface 44 of the bearing 40 prevents angular displacement therebetween.
[0018] In an alternative embodiment, as shown in FIG. 5, a bearing assembly 60 is fit onto a spider 14 . The spider includes three trunions 72 as described above with reference to FIG. 4. Each trunion 72 includes a finished bearing surface 74 . The needles 64 of the bearing 60 rotate at 62 on the bearing surface 74 as an inner race in a manner similar to that described in the '698 patent. The bearing 60 includes a plurality of needles 64 , an outer race 66 , and a cage 68 to retain the needles 64 after assembly to the outer race 66 , prior to installation onto the trunion 72 . Thus the bearing assembly 60 is shipped as a modular unit and pressed fit onto the trunion 14 in a simple manner, without the need to handle loose needles at the tripod assembly source. The cage is preferably made from a glass-filled polymer as is known to one skilled in the art. The cage includes a plurality of pockets for retaining the needles to the outer race as is known to one skilled in the art. In an alternative embodiment, the cage is formed from steel.
[0019] In a manner similar to that described above with reference to FIG. 4, the bearing 60 is retained after assembly in a first axial direction by a shoulder 80 provided on the spider 14 adjacent trunion 72 . An undercut 78 is provided on the trunion 72 to simplify finish machining. A groove 76 is provided at the opposite end of the trunion 72 . A snap ring 77 is installed in the groove 76 after the bearing 60 is assembled to retain the bearing 60 in the second axial direction. In this embodiment, the trunion preferably includes a ground surface 74 , since it is a bearing surface. The cage 68 serves as an assembly aid to prevent the need for assembling the needles at final assembly of the joint, as the bearing 60 is shipped as an assembly.
[0020] The above spider assembly has been describe with reference to a constant velocity joint. However, one skilled in the art recognizes that these concepts maybe used in a universal joint.
[0021] It is to be understood that the embodiments of the invention described above are merely illustrative of application of principals of the present invention. Numerous modifications maybe made to the methods and apparatus described above without departing from the true spirit and scope of the invention. | A tripod bearing assembly is provided including a spider assembly with a trunion. A bearing assembly is press fit onto the trunion. The bearing assembly has an inner race, an outer race, and a plurality of needle rollers to permit relative rotation between the inner and outer races. The bearing assembly is axially retained to the spider. | 5 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates in general to sewing machines and in particular to a new and useful needle oscillation drive for a sewing machine which utilizes a step motor to rotate an eccentric transmission of the oscillation drive.
Sewing machines with step motor drives for the oscillation of the needle bar have been known up until now, only as zig-zag drives in household sewing machines. For the step motor drives used in the household sector, no such precision and accuracy is required as for industrial sewing machines. Due to the greater mass of the needle swinging drive existing in industrial sewing machines and also due to the required greater speed, much more stringent requirements and greater efficiency are set for such a swinging drive.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a step motor drive suitable for the swinging-out of a needle bar, which is suitable for smooth transmission of the motion supplied by the step motor to the needle bar rocker even at high speeds.
According to the invention, the problems of inaccuracy and low speed are solved by connecting the step motor to an eccentric transmission that moves a lever arm and rocker of the needle bar.
This results in the exceedingly great advantage that the dynamic reactions of the needle rocker drive to the step motor are negligibly small, as the reaction forces pass almost through the axis of the eccentric even in extreme positions of the eccentric drive.
A further object of the invention is to provide the eccentric transmission with an eccentric that is secured directly to the shaft of the step motor. The eccentric may also be provided with a bearing journal which is mounted for rotation in the housing and which is coaxial with the output shaft of the step motor.
A still further object of the present invention is to provide a sewing machine with a step motor-operated needle bar rocker that is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the present invention is illustrated in the drawings wherein:
FIG. 1 is a front elevational view of a sewing machine equipped with needle advance of the invention, partly in section;
FIG. 2 is an enlarged side elevational view of the sewing machine according to FIG. 1, partly in section;
FIG. 3 is a sectional view taken along line III--III of FIG. 2;
FIG. 4 is an enlarged sectional view taken through a part of the roll foot drive mechanism;
FIG. 5 is a back view of the step motor drive for the swinging-out of the needle bar, partly in section; and
FIG. 6 is a block circuit diagram of the electronic circuit for the forward feed device of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1 above, the sewing machine consists of the base plate 1, column 2, standard 3, arm 4, and head 5, all forming a housing. In arm 4, a main shaft 6 is mounted in the usual manner, which is driven via a V-belt 7 by a motor (not shown) mounted below the base plate 1. From the main shaft there is driven, by a toothed belt 9, a rotary hook shaft 10 which is mounted in the base plate 1 and which is in drive connection with a rotary hook (not shown). Via a crank 11 and a link 12, the main shaft 6 drives a needle bar 14 equipped with a needle 13, in reciprocating up and down motion. Link 12 is articulated to the needle bar 14 via a joint 15 (FIG. 2).
The needle bar is mounted in a rocker 17 carried by a rocker shaft 16 (FIG. 1). The rocker shaft 16 is mounted parallel to the main shaft 6 in arm 4.
The end of the rocker shaft 16 protruding into the standard 3 carries a lever arm 18 which is connected to an eccentric bar 20 via a joint pin 19. The eccentric bar engages around an eccentric 21 (FIG. 5) which is firmly connected to an output shaft 22 of a step motor 23 secured in arm 4. The eccentric 21 is guided with a journal 24 in a bore 25 in the housing extending coaxially with the output shaft 22.
In the lower part of column 2 (FIG. 2) a support 30 is mounted on an eccentric bolt 31 which has bearing journals 34 and 35 protruding into bores 32 and 33 in column 2. Bearing journal 35 is provided with a slot 36. Eccentric 31 is clamped on support 30 by a screw 37. Mounted in support 30 is a vertical shaft 38 which is guided or held in the axial direction by an adjusting ring 39 and a coupling 40. At its lower end the support 30 is equipped with a flange plate 41 on which a step motor 42 is secured, whose output shaft 43 is coupled rigidly with the vertical shaft 38 by the coupling 40. At the upper end the vertical shaft 38 carries a pinion 44 of a spiroid gearing 45, the ring gear 46 of which is firmly connected to a sliding wheel 47 which is mounted with ball bearings, in known manner, and comprises an inner part with an axial end 48. The axial end 48 is received by a bore in an arm 30a of support 30 and can be fixed, after adjustment in the axial direction, by a screw 49.
By rotation of the eccentric bolt 31 with the aid of slot 36, the sliding wheel 47 is adjustable over the support 30 in its height position relative to a stitch plate 50 which terminates column 2 at the top, and through which wheel 47 protrudes through a slot 50a.
The support 30 is fixed after adjustment on column 2, by a screw 51 which passes through a slot 52 in column 2 and which is screwed into the upper part of support 30. The sideways position of the sliding wheel 47 can be aligned relative to slot 50a in stitchplate 50 using axle end 48 and screw 49.
A vertical shaft 53 is loosely mounted in the sewing machine head 5 for rotation and axial movement. On shaft 53 a clamping piece 54 is screwed tight. The piece 54 has a radial bore into which a pin 55 is pressed. A coupling piece 56 is loosely mounted on shaft 53. A lug 57 on its side protrudes through a slot in head 5 and secures the coupling piece 56 against rotation. The coupling piece 56 is formed in its lower region as a circular sector and embraces therewith the clamping piece 54. The circular sector has a recess 59 into which the pin 55 protrudes and which terminates at one end in a ratchet groove 60, while at its other end it terminates in a wall 61. A compression spring 62, which braces itself against an adjusting ring 63 fastened on shaft 53, pushes the coupling piece 56 and hence the upper wall of its circular sector slightly downward against pin 55.
On lug 57 (FIG. 3) rests the free end of a leaf spring 64 which is fastened in arm 4 and pushes the coupling piece 56 downward. Protruding after lug 57 is a lever arm 65 of an angle lever 66 mounted in head 5, which lever is connected through a link 67 with a lifting linkage (not shown) to be actuated by the operator. Under the lever arm 65, a cam 68 is fastened on a shaft 69 mounted in head 5. On its end extending to the outside, shaft 69 carries a hand lever 70 (FIG. 2).
At the lower end of shaft 53 a block 71 is fastened, which is equipped with a groove guideway 72. An angular slotted lobe 73 is screwed tight in the guideway 72. Lobe 73 is firmly connected to a roll foot carrier 74. The carrier 74 comprises a tubular piece 75 (see also FIGS. 3 and 4) which terminates in a downwardly extending end piece 76. In it a bore is provided for attachment of an axle end 78 of a ball-bearing roll foot 80 by a screw 79. Roll foot 80 has a race 81 firmly connected to a ring gear 82 of a spiroid gearing 83 whose pinion 84 is eccentrically in engagement with the ring gear 82. Received in the tubular piece 75 is a tubular support 85 which is fixed in its position by screws 86 inserted in tubular piece 75. The support 85 consists of a tube 87, a hollow cylinder 88 directly above it, and an annular end flange 89. Mounted in tube 87 is a shaft 90 which carries at its lower end the pinion 84 and is firmly connected to an annular shoulder 91 which abuts against the lower end of tube 87.
In the region of its upper end, shaft 90 is embraced by the inner race of a ball bearing 93 pressed into the hollow cylinder 88. The upper end of shaft 90 is coupled rigidly with an output shaft 95 of a step motor 96, whose housing is screwed tight on the end flange 89.
A strobe disk 100 is mounted on the main shaft 6 (FIG. 1) of the sewing machine, which has two pulse tracks, each cooperating with a pulse generator 101, 102. One track comprises a plurality of pulse markers 103 uniformly distributed on its circumference (FIG. 6), while the other track has only two pulse markers 104, one of which passes by the pulse generator 101 as needle 13 emerges from the workpiece, while the other does so when needle 13 enters the workpiece.
The pulse generator 101 is connected to a control unit 105. Control unit 105 is connected via a control line 106a to a reversing arrangement 106 and, via control lines 107a 108a and 109a, to AND elements 107, 108 and 109 respectively. A bus line 110 connects counters 111, 112 and 113 to unit 105 Further, there are connected to the control unit 105 via a bus line 114a, a key panel 114, via a bus line 115a a display unit 115, and via a bus line 116a a data memory 116.
The outputs of the counters 111, 112 and 113 are connected to inputs of power stages 117, 118 and 119 for the respective step motors 23, 42 and 96. Further, the outputs of the counters 111, 112 and 113 are connected to the control unit 105 via lines 111a, 112a and 113a. Lines 117a, 118a and 119a lead from the control unit 105 to the power stages 117, 118 and 119. Also connected to the control unit 105 are three switches 120, 121 and 122, of which switch 120 serves to actuate a backward sewing process, while the two switches 121 and 122 are provided for slow drive of the step motors 42 and 96 in forward and backward directions respectively during standstill of the sewing machine, preferably in a needle-up position. To this end an oscillator 123 is connected to the two power stages 118 and 119 via a divider 124 and a switch 125. Switch 125 is connected to the control unit 105 via a control line 125a. In addition, oscillator 123 is connected to the input E1 of the reversing arrangement 106, whose input E2 is connected to the pulse generator 102. The output of the reversing arrangement 106 leads to the inputs E1 of the three AND elements 107, 108 and 109, whose outputs are connected to the respective counters 111, 112 and 113, which are designed as downcounters and which are presettable singly by the control unit 105 via the bus line 110.
With the key panel 114 one can preselect the number of steps of the step motors 23, 42 and 96 to be executed per sewing stitch and hence the feed length of the individual transport elements--needle 13, sliding sheel 47 and roll foot 80--between each stitch formation, with the possibility of setting different feed amounts of the sliding wheel 47 relative to the roll foot 80. The preselected stitch length is indicated in the display unit 115.
The device operates as follows:
Via the key panel 114, the operator sets the desired feed amounts of the needle 13, of the sliding wheel 47 and of the roll foot 80, corresponding digital values being taken out of the data memory 116 via the control unit 105 and thus the counters 111, 112 and 113 preset. At the same time, values corresponding to the feed amounts are indicated in the display unit 115.
During operation of the sewing machine, the sewing motor (not shown) drives the V-belt 7 and thus the main shaft 6 which moves the needle bar 14 up and down via the drive connection of crank 11 and link 12. In addition, via the toothed belt 9 and the rotary hook drive shaft 10, the main shaft 6 drives the rotary hook (not shown). The drive for advancing of the workpiece is actuated via the pulse generator 101 whenever the needle 13 penetrates into the workpiece and when it leaves the workpiece again The pulse generator 101 then sends a pulse to the control unit 105. Via the control lines 107a, 108a and 109a, the control unit 105 now switches the potential at the inputs E2 of the AND elements 107, 108 and 109 to the counters 111, 112 and 113 via the reversing arrangement 106 switched to input E2 during drive of the sewing machine.
When one of the counters 111, 112 or 113 has reached the status "0", it delivers a control pulse to the respective power stage 117, 118 or 119, whereby the corresponding step motor 23, 42 or 96 is advanced by one step. At the same time this counter 111, 112 or 113 delivers, via the associated control lines 111a, 112a or 113a, a pulse to the control unit 105, which again presets this counter 111, 112 or 113 to a new value. The control unit 105 calls the corresponding values out of the data memory 116. At the same time the control unit 105 determines, via the control lines 117a, 118a and 119a connected to the power stages 117, 118 and 119, whether the particular step motor 23, 42 or 96 is being moved forward or backward. The values presettable at the counters 111, 112 and 113 are chosen so that the step motors 23, 42 and 96 can execute their maximum number of steps in the withdrawn phase of the needle 13 as well as in its inserted phase.
The stepping pulses acting on the step motors 23, 42 and 96 drive the rocker 17, the sliding wheel 47 and the roll foot 80 for joint transport action on the workpiece. Via the vertical shaft 38 firmly coupled with its output shaft 43 and via the miter gear 45, the step motor 42 rotates the sliding wheel 47, while step motor 96 drives at the same time the roll foot 80 via the shaft 90 firmly coupled with its output shaft 95 and via the miter gear 83. Step motor 23 rotates at the same time, via its output shaft 22, the eccentric 21 stepwise in one direction, which transmits these deflection movements of its eccentricity to the rocker 17 via the eccentric rod 20 and the lever arm 18, causing the rocker to swing out by corresponding angle amounts. This takes place with needle 13 inserted in the workpiece synchronously with the advance of the sliding wheel 47 and of the roll foot 80, and with the needle withdrawn by drive of the eccentric 21 in the opposite direction.
In the feed direction, the needle bar 14 executes, in known manner, a sinusoidal swinging motion. During its phase with needle 13 inserted in the workpiece, it swings in the forward direction and during the withdrawn phase it swings in the opposite direction. For this reason the control of step motor 23 for the swinging-out of the needle bar 14 is laid out so that it imparts to the step motor 96 during one revolution of the main shaft 6, that is, with every advance between two stitch formations, two sinusoidal partial step sequences, of which one drives the step motor 23 in forward direction and the other in a direction opposite thereto. Advantageously the drive of the step motors 42 and 96 for the sliding wheel 47 and for the roll foot 80 occurs, again not as a constant sequence of steps, but in two sinusoidal partial step sequences.
After the individual step motors 23, 42 and 96 have traveled the number of steps set on the key panel 114 and depending on the correspondingly called data values from the data memory 116, the input E2 of the respective AND element 107, 108 or 109 is switched to L (low) potential by the control unit 105 via the control line 107a, 108a or 109a, so that by the corresponding AND element 107, 108 or 109, further passage of clock pulses from the pulse generator 102 is suppressed.
For backward sewing, for example for making a bar at the end of a seam, switch 120 is actuated, whereby, at the beginning of a new pulse from the pulse generator 101 via the control lines 117a, 118a and 119a at the power stages 117, 118 and 119, the control unit 105 reverses the direction of movement of the step motors 23, 42 and 96, so that they drive the sliding wheel 47, the roll foot 80 and the needle bar 14 in reverse direction, as long as the actuation of switch 120 lasts. Execution of the step sequence of the step motors 23, 42 and 96 occurs by polling of the respective values set in the key panel 114 from the data memory 116 in the manner described above.
During the stopping process of the sewing machine, which usually ends in the upper dead center of needle 13, the control unit 105 switches the reversing arrangement 106 to input E1, so that the pulses delivered by oscillator 123 are applied to the inputs E1 of the AND elements 107, 108 and 109. As soon as the sewing machine stops, clock pulses from oscillator 123 are thus placed on the inputs E1 of the AND elements 107, 108 and 109 instead of the clock pulses from pulse generator 102. In this manner the preselected advance of needle 13, of sliding wheel 47 and of roll foot 80 is completed also after the last emergence of needle 13 from the work, so that needle 13 is already above the next needle insertion point. As soon as the end position of the preselected feed amount has been reached, the control unit 105 turns the AND elements 107, 108 and 109 off via the control lines 107a, 108a and 109a.
To correct the position of the workpiece relative to needle 13 as it results when the sewing machine is stopped, slow transport of the workpiece in the forward feed direction while the sewing machine is turned off is possible by actuation of switch 121. Slow transport of the work in the backward direction is possible when the sewing machine is off, by actuation of switch 122. Actuation of the respective switch 121 or 122 brings about a closing of switch 125 via line 125a, so that pulses delivered by oscillator 123 and forwarded in reduced frequency from the divider 124 are sent to the two power stages 118 and 119, whereby the two step motors 42 and 96 are driven slowly for the drive of the sliding wheel 27 and of the roll foot 80. The movement direction of the step motors 42 and 96 is then set for forward or backward rotation via the control lines 118a and 119a at the power stages 118 and 119, depending on the actuation of switch 121 or 122.
The roll foot 80 is lifted off the work by turning the hand lever 70, with the cam 68 raising the coupling piece 56, via lever arm 65 of angle lever 66, over the lug 57 counter to the pressure of leaf spring 64. The same effect results also by actuation of the lifting linkage (not shown) which rotates the angle lever 66 via link 67.
Via the compression spring 62, the coupling piece 56 raises shaft 53 with the roll foot 80 fastened thereto and with the support 85. The compression spring 62 ensures the abutment of pin 55 in the ratchet groove 60 of the coupling piece 56.
To pivot the roll foot 80 downward, the latter is rotated by hand about the axis of shaft 53. Pin 55 then disengages from the ratchet groove 60 counter to the force of the compression spring 62, and shaft 53 can be rotated to bring pin 55 into abutment on wall 61 of recess 59.
The above described rocker drive is, of course, not limited to sewing machines with forward feed of the needle, but with appropriate modification it can be used also for the swinging out of the needle bar crosswise to the forward direction and hence to produce a zig-zag movement.
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 sewing machine with a needle bar mounted in a rocker, has a step motor drive for the oscillation of the rocker. A memory is used in which are contained selected digital data for influencing the step motor and a control unit is inserted between the memory and the step motor for selection and conversion of the digital data into stepping pulses for the step motor. A pulse generator operating synchronously with a main shaft of the sewing machine is used for triggering the transmission of stepping pulses to the step motor. To improve the drive transmission and to avoid reactions on the step motor, the step motor is connected to a lever arm of the rocker via an eccentric transmission. | 3 |
TECHNICAL FIELD
The present invention relates to a wireless communication system and, more particularly, to a base station device and a handover control method, which perform handover control.
BACKGROUND ART
As one of measures to improve a system throughput in a cellular network, there is a technique of arranging a plurality of small base-station devices in a macrocell provided by a base station device. Because an area of a small cell provided by the small base-station device is small, a mobile terminal device is not necessarily present in the small cell. Accordingly, in a state in which no mobile terminal device is present in the small cell, electric power consumed by the small base-station device is wasted. Thus, in 3GPP (3rd Generation Partnership Project), Energy Saving function is proposed as one of SON (Self Organization Networks) functions (NPTL1).
A small base-station device having the Energy Saving function has an active state and an inactive state. In the active state, such device performs a normal operation as the small base-station device. In the inactive state, power saving of the entire network is realized by stopping radio transmission in a part or the whole of the cells. The state-transition of the active state/inactive state of the cell can be controlled according to a traffic amount. For example, based on statistical data of traffic change, the number of the small base-station devices in operation is increased in a time zone, such as a traffic peak time, in which the traffic amount is large. In a time zone, such as an off-peak time, in which the traffic amount is small, the number of the small base-station devices in operation is reduced.
However, the stopping of the radio transmission may have a large impact on the mobile terminal device and neighboring cells. Thus, when an own cell transfers to an inactive state, specification of a signal notifying the neighboring cell of the transition of the own cell to an inactive state is performed as specific processing for reducing the impact. In addition, a signal requesting an inactive cell to become active is specified (NPTL2). The notification and request messages are usually transmitted via an inter-base-station interface between the base station devices which control target cells.
Furthermore, in a mobile communication system having a plurality of base station devices like a cellular network, mobility control or handover control is performed, which switches base stations so that communication is continued when a mobile terminal device moves from a cell provided one of the base station devices to another cell provided by another of the base station devices. Handover of the mobile terminal device is controlled, based on a value measured and reported by the mobile terminal device, by the base station device providing a cell in which the mobile terminal device is located. Generally, the base station device controls the handover to select a better cell (or best cell) in respect of radio wave reception environment for the mobile terminal device and to hand over the mobile terminal to the selected cell.
Hereinafter, a general handover control procedure is briefly described with reference to FIG. 1 . Incidentally, a cell in which a mobile terminal device is present is referred to as a serving cell. A base station device of a serving cell is referred to as a serving base station device. A handover destination cell is referred to as a target cell. A base station device of a target cell is referred to as a target base station device.
In FIG. 1 , a serving base station device sets measurement conditions, measurement reporting conditions, and the like by transmitting a measurement setting message M 100 to a mobile terminal device. The mobile terminal device measures reference signal received power (RSRP: Reference Signal Received Power), reference signal received quality (RSRQ: Reference Signal Received Quality), or other parameters of each of the serving cell and the neighboring cell according to the measurement conditions set by the serving base station device (operation S 100 ). The parameters includes reference signal received power (RSRP: Reference Signal Received Power), reference signal received quality (RSRQ: Reference Signal Received Quality), or other parameters. Then, if a measurement result satisfies the measurement reporting conditions, a measurement reporting message M 101 is transmitted to the serving base station device.
The serving base station device performs handover execution determination, based on a measurement report received from the mobile terminal device (operation S 101 ). In the handover execution determination, a target cell is determined by judging whether handover execution is necessary. In the determination of a target cell, generally, a cell is selected, which is better in radio wave reception environment for the mobile terminal device. Subsequently, the serving base station device transmits, when the target cell is determined, a handover request message M 102 including information concerning the mobile terminal device to the target base station device.
The target base station device performs, upon the handover request received from the serving base station device, judging of acceptance of a mobile terminal device (operation S 102 ). The judging of acceptance is performed, based on access control rules such as access authority of the mobile terminal device and a load of the target base station device. If the mobile terminal device is determined to be acceptable, handover preparation such as securement of data resources for the mobile terminal device is executed. Then, if handover is determined to be acceptable, the target base station device transmits, to the serving base station device, a handover request response message M 103 including a handover instruction to the mobile terminal device.
Upon the handover request response, the serving base station device transmits, to the mobile terminal device, a handover instruction message M 104 received from the target base station device. In response to the handover instruction, the mobile terminal device transmits a handover instruction response to the target base station device. Thus, the handover control procedure is completed.
Incidentally, a method is proposed, which determines, when a target base station is determined, a preferential order by considering not only quality of the radio wave reception environment but capability of the neighboring base station (see PTL1).
CITATION LIST
Patent Literature
[PTL1] Japanese Patent Application Laid-Open No. 2011-525759
Non-Patent Literatures
[NPTL1] 3GPP TS36.300, Evolved Universal Terrestrial Radio Access (E-UTRA) and Evolved Universal Terrestrial Radio Access Network; Overall description; Stage 2, V10.2.0
[NPTL2] 3GPP TS36.423, Evolved Universal Terrestrial Radio Access Network (E-UTRAN); X2 Application Protocol (X2AP), V9.2.0
SUMMARY OF INVENTION
Technical Problem
However, when a base station device makes an inactive cell of a small base-station device transfer to an active state, radio wave reception environment of the activated cell may be better for a mobile terminal device being present in vicinity of the activated cell than radio wave reception environment of the serving cell. When many such mobile terminal devices are present, many mobile terminal devices are simultaneously handed over to the small base-station device by the handover control. Generally, the small base-station device is low in processing capability, compared to the base station device. Thus, increase in local processing load has a high probability of causing a congestion state of the small base-station. Consequently, there is a problem that service quality is degraded due to a handover failure and a processing delay.
Accordingly, an object of the present invention is to provide a base station device and a handover control method capable of avoiding, when a cell transfers from an inactive state to an active state, a situation in which a base station device of the cell is overloaded.
Solution to Problem
A base station device according to the present invention is a base station device in a wireless communication system, which includes a neighboring base station information storage means that stores neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device, and a handover control means that limits that, when the neighboring cell transfers from an inactive state to an active state, a mobile terminal device hands over to the activated neighboring cell, based on the handover inhibition information and the processing capability index.
A handover control method according to the present invention is a handover control method in a wireless communication system, which includes storing neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device, and limiting that, when the neighboring cell transitions from an inactive state to an active state, a mobile terminal hands over to the activated neighboring cell, based on the handover inhibition information and the processing capability index.
Advantageous Effects of Invention
According to the present invention, when a neighboring cell is activated, handover of a mobile terminal device which communicates with a serving base station to the neighboring cell is limited. Thus, a situation can be avoided, in which a base station device of the neighboring cell is overloaded.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a sequence diagram illustrating a general handover control procedure.
FIG. 2 is a schematic diagram illustrating a schematic configuration of a wireless communication system according to a first exemplary embodiment of the present invention.
FIG. 3 is a block diagram illustrating a configuration of a base station device according to the present exemplary embodiment.
FIG. 4 is a schematic diagram illustrating an example of a neighboring base station information table in the present exemplary embodiment.
FIG. 5 is a sequence diagram illustrating a handover control procedure according to the present exemplary embodiment.
FIG. 6 is a flowchart illustrating a handover control operation of a base station device according to the present exemplary embodiment.
FIG. 7 is a schematic diagram illustrating a schematic configuration of a wireless communication system according to a second exemplary embodiment of the present invention.
FIG. 8 is a sequence diagram illustrating a handover control procedure according to the present exemplary embodiment.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
According to exemplary embodiments of the present invention, a base station device acquires a processing capability index of a neighboring base station device by inter-base-station communication. When the base station device detects that a cell of the neighboring base station device transfers from an inactive state to an active state, the base station device inhibits handover of a mobile terminal device to the activated cell, based on the processing capability index of the neighboring base station device, for a specified period of time. Consequently, increase in processing-load of the neighboring base station can be suppressed. Even a small base-station device with low processing capability can avoid a congestion state due to overload. Hereinafter, exemplary embodiments of the present invention are described in detail with reference to the drawings.
1. First Exemplary Embodiment
1. 1) System Configuration
In FIG. 2 , in order not to complicate description, it is assumed that a wireless communication system according to a first exemplary embodiment is configured by a base station device 100 , a small base-station device 200 , and a mobile terminal device 300 , and that the base station device 100 and the small base-station device 200 are connected via an inter-base-station interface to each other. Here, a cell configuration is illustrated, in which a small cell 200 a of the small base-station device 200 is included in a macrocell 100 a of the base station device 100 . However, the present exemplary embodiment is not limited thereto. Incidentally, the small cell 200 a may be either a picocell or a microcell. Additionally, the base station device 100 and the small base-station device 200 may be connected to another base station device (not illustrated) via an inter-base-station interface. Hereinafter, a case where the base station device 100 makes an inactive cell of the small base-station device 200 transition to an active state is described as an example.
1. 2) Base Station Device
As illustrated in FIG. 3 , the base station device 100 is configured by a wireless communication control unit 110 , an inter-base-station communication control unit 120 , a handover control unit 130 , an activation control unit 140 , and a neighboring base station device information table 150 . However, here, for simplicity of drawing, only a configuration relating to the present exemplary embodiment is illustrated. The base station device 100 has a control unit equivalent to a base station device used in a general mobile communication system.
The wireless communication control unit 110 is connected to a mobile terminal device via a wireless link, and performs data transmission and reception therewith. The inter-base-station communication control unit 120 establishes an inter-base-station interface with the neighboring base station device, and performs data transmission and reception with the neighboring base station device via the established inter-base-station interface. The handover control unit 130 executes handover execution determination and handover control, based on a measurement report from the mobile terminal device.
The activation control unit 140 determines whether to activate the inactive cell 200 a of the small base-station device 200 under the macrocell 100 a of the base station device 100 . Whether to activate the inactive cell 200 a can be determined, based on statistical traffic information in the macrocell 100 a . For example, in a traffic-peak time, the inactive cell is controlled to transfer to an active cell.
As illustrated in FIG. 4 , the neighboring base station information table 150 has a neighboring base station device ID concerning each of neighboring base station devices neighboring the base station device 100 , neighboring cell information concerning a cell of each of the neighboring base station devices, surrounding cell information concerning cells located around the cell of each of the neighboring base station devices, handover inhibition timer information associated with each neighboring cell, the number of times of executing handover to the neighboring cell during the handover inhibition timer is being activated, and information concerning a processing capability index of each of the neighboring base station devices. Information concerning a cell of the neighboring base station device, neighboring cell information concerning a cell of the neighboring base station device, and information concerning the processing capability index of the neighboring base station device are recorded, based on information received when the inter-base-station interface is established.
The handover timer information represents information indicating whether the handover inhibition timer is being activated (ON) or stopped (OFF), and an elapsed time if the timer is being activated. For example, in a cell C 1 a of a neighboring base station BS 1 illustrated in FIG. 4 , the handover inhibition timer is activated, and the elapsed time is T 1 a.
The processing capability index is the number of processable calls per second, or the like. Additionally, the number of times of executing handover represents the number of times of executing, during the handover inhibition timer is being activated, handover processing from the cell 100 a of the base station device 100 to the neighboring cell (here, the cell 200 a ).
Incidentally, functions of the inter-base-station communication control unit 120 , the handover control unit 130 , and the activation control unit 140 can be implemented by executing programs stored in a memory (not illustrated) on a computer (CPU: Central Processing Unit).
1. 3) Handover Inhibition Control
In FIG. 5 , first, the base station device 100 and the small base-station device 200 establish an inter-base-station interface by exchanging an inter-base-station interface establishment request message M 200 and a response message M 201 thereto. The inter-base-station interface establishment request message M 200 and the response message M 201 thereto include cell information concerning cells of the base station devices respectively transmitting these messages, neighboring cell information concerning cells of the neighboring base station devices respectively transmitting these messages, and information concerning a processing capability index of each of relevant neighboring base station devices. In the present exemplary embodiment, the base station device transmits the inter-base-station interface establishment request message M 200 , and the small base-station device transmits the response message M 201 . However, this may be vice versa.
The inter-base-station control unit 120 of the base station device 100 extracts the above information from the response message M 201 received from the small base-station device 200 and records the extracted information in a neighboring base station device information table 150 (operation S 200 ). Next, if it is determined (operation S 201 ) that an inactive cell of the small base-station device 200 is activated, the activation control unit 140 of the base station device 100 transmits a cell activation request message M 202 to the small base-station device 200 .
The small base-station device 200 activates a cell designated in the cell activation request message M 202 (operation S 202 ) and transmits a cell activation request response message M 203 to the base station device 100 after the cell is activated. Incidentally, in the present exemplary embodiment, the small base-station device 200 transmits the inter-base-station interface establishment response message M 201 in which the neighboring cell information concerning the cell of the small base-station device 200 and the processing capability index of the small base-station device 200 are included. However, the small base-station device 200 may transmit the cell activation request response message M 203 in which the neighboring cell information concerning the cell of the small base-station device 200 and the processing capability index of the small base-station device 200 are included. In this case, an operation S 200 of the base station device 100 is performed after the base station device 100 receives the cell activation request response message M 203 .
When the base station device 100 receives the cell activation request response message M 203 , the handover control unit 130 of the base station device 100 activates a handover inhibition timer associated with the activated designated-cell of the small base-station device 200 (operation S 203 ). When the handover inhibition timer is activated, the handover inhibition timer information in the neighboring base station device information table 150 is updated to ON.
If the handover inhibition timer is being activated, the handover control unit 130 inhibits the handover control conditionally, as is described below, even when receiving a measurement report message M 204 from the mobile terminal device 300 (operation S 204 ). Then, when the handover inhibition timer stops after elapse of a predetermined period of time, the handover control unit 130 updates the handover inhibition timer information in the relevant cell in the neighboring base station device information table 150 from ON to OFF, and initializes the number of times of executing handover (i.e., sets the number of times of executing handover to 0) (operation S 205 ).
Hereinafter, the handover inhibition control operation S 204 in the base station device 100 according to the present exemplary embodiment is described with reference to FIG. 6 .
In FIG. 6 , when the wireless communication control unit 110 of the base station device 100 receives the measurement report message M 204 from the mobile terminal device 300 , the handover control unit 130 determines, based on the received measurement report, a handover destination candidate cell (operation S 300 ). Handover destination candidate cell determination processing can select, e.g., all of neighboring cells, each of which is larger in reference signal received power than the serving cell, as the candidate cells. Hereinafter, the handover destination candidate cells are assumed to be determined, based on the reference signal received power. However, a technique of determining a handover destination cell according to a measurement report value other than the received power may be employed.
Next, the handover control unit 130 selects a cell (best cell), which is largest in reference signal received power, from the selected handover destination candidate cells and refers to the neighboring base station device information table 150 . Thus the handover control unit 130 determines whether the handover inhibition timer is being activated in the best cell (operation S 301 ). If the handover inhibition timer is being activated (operation S 301 ; YES), the handover control unit 130 acquires cell information concerning the best cell from the neighboring base station device information table 150 (operation S 302 ). The cell information includes the processing capability index of the neighboring base station device (here, the small base-station device 200 ) controlling the cell concerned, the number of neighboring cells, and the number of times of executing handover thereto.
Next, the handover control unit 130 determines whether a value (actual result value) obtained by dividing a number calculated by adding 1 to the number of times of executing handover included in the acquired cell information by a handover inhibition timer elapsed time is smaller than a value (capability threshold) obtained by dividing the processing capability index by the number of the neighboring cells (operation S 303 ).
If the actual result value is less than the capability threshold (operation S 303 ; YES), the handover control unit 130 can determine that the processing capability of the neighboring base station device has a margin. Therefore, the handover control unit 130 determines the best cell as a handover destination cell (operation S 304 ) and increments the number of times of executing handover of the best cell in the neighboring base station device information table 150 by 1.
If the actual result value is equal to or more than the capability threshold (operation S 303 ; NO), the processing capability of the neighboring base station device of the best cell has no margin. Thus, the handover control unit 130 determines whether there is still another cell among the selected handover destination candidate cells (operation S 305 ). If there is still another cell (operation S 305 ; YES), the handover control unit 130 excludes, from the handover destination candidate cells, the cell of the neighboring base station device concerned (operation S 306 ). Then, the handover control unit 130 returns to the above operation S 301 . If there are no other cells (operation S 305 ; NO), the handover control unit 130 inhibits handover to the mobile terminal device 300 to the best cell (operation S 307 ).
Incidentally, if the handover inhibition timer associated with the best cell is being stopped (operation S 301 ; NO), as normal, the handover control unit 130 determines the best cell as a handover destination cell (operation S 308 ). Thus, when the handover destination cell is determined, handover processing is executed as described with reference to FIG. 1 .
1. 4) Advantageous Effects
As described above, according to the first exemplary embodiment of the present invention, when a cell of the neighboring small base-station device 200 transitions from an inactive state to an active state, handover of the mobile terminal device 300 to the activated cell 200 a is inhibited, based on the processing capability index of the small base-station device 200 , for a certain period of time until the inhibition timer is timed out. Consequently, rapid increase in processing-load of the small base-station device 200 can be avoided. Degradation of service quality due to a handover failure and a processing delay can be reduced.
2. Second Exemplary Embodiment
2. 1) System Configuration
In FIG. 7 , in order not to complicate description, it is assumed that a wireless communication system according to a second exemplary embodiment is configured by base station devices 100 and 101 , a small base-station device 200 , and mobile terminal devices 300 and 301 , and that each of the base station devices 100 and 101 is connected to the small base-station device 200 via an inter-base-station interface. Here, a cell configuration is illustrated, in which a small cell 200 a of the small base-station device 200 is provided in a peripheral portion where a macrocell 100 a of the base station device 100 overlaps a macrocell 101 a of the base station device 101 . However, the present exemplary embodiment is not limited thereto. It is assumed that the mobile terminal device 300 is located in the cell 100 a of the base station device 100 , and that the mobile terminal device 301 is located in the cell 101 a of the base station device 101 . Hereinafter, a case where the base station device 100 makes an inactive cell of the small base-station device 200 transition to an active state is described as an example.
2. 2) Base Station Device
The base station devices 100 and 101 each have a configuration similar to the block configuration illustrated in FIG. 3 . Therefore, description of the base station devices 100 and 101 is omitted.
2. 3) Handover Inhibition Control
In a sequence diagram illustrated in FIG. 8 , a same operation as that in the handover inhibition control procedure according to the first exemplary embodiment illustrated in FIG. 5 is designated with same reference numeral. Therefore, description of such an operation is omitted. Only different operations in the procedure are described.
As already described, similarly to the procedure in which the base station device 100 and the small base-station device 200 establish the inter-base-station interface, the base station device 101 and the small base-station device 200 establish the inter-base-station interface by exchanging an inter-base-station interface establishment request message M 200 and a response message M 201 thereto. Then, the base station devices 100 and 101 extract the above information from the response message M 201 received from the small base-station device 200 and records the extracted information on a neighboring base station device information table 150 (operation S 200 ). In addition, as described above, the inter-base-station interface establishment request message M 200 and the response message M 201 thereto include cell information concerning cells located under the transmitting-side base station devices, neighboring cell information concerning cells respectively the neighboring cells of the transmitting-side base station devices, and information concerning a processing capability index of each of relevant neighboring base station devices. As a specific processing capability index, the number of processable calls per second is set.
The small base-station device 200 activates a designated cell according to the cell activation request message M 202 received from the base station device 100 (operation S 202 ). After the activation of the cell, the small base-station device 200 transmits a cell activation request response message M 203 and a cell state change notification message M 205 to the base station devices 100 and 101 , respectively. Incidentally, even in the present exemplary embodiment, similarly to the first exemplary embodiment, the neighboring cell information, and information concerning the processing capability index may be transmitted by being included in each of the cell activation request response message M 203 and the cell state change notification message M 205 . In this case, the operation S 200 of each of the base station devices 100 and 101 is performed after an associated one of the cell activation request response message M 203 and the cell state change notification message M 205 is received.
When the base station devices 100 and 101 receive the cell activation request response message M 203 and the cell state change notification message M 205 , respectively, a handover inhibition timer associated with the designated cell activated by the small base-station device 200 is activated (operation S 203 ). When the handover inhibition timer is activated, handover inhibition timer information in a neighboring base station device information table 150 of each of the base station devices 100 and 101 is updated to ON.
If the handover inhibition timer is being activated, the base station device 100 inhibits the handover control conditionally, as already described, even when receiving a measurement report message M 204 from the mobile terminal device 300 . Similarly, the base station device 101 inhibits the handover control conditionally, even when receiving a measurement report message M 204 from the mobile terminal device 301 (operation S 204 ). Then, when the handover inhibition timer stops after elapse of a predetermined period of time, each of the base station devices 100 and 101 updates the handover inhibition timer information in the relevant cell in the neighboring base station device information table 150 from ON to OFF, and initializes the number (=0) of times of executing handover (operation S 205 ). The handover inhibition control operation S 204 of the base station device 101 is similar to that of the base station device 100 described with reference to FIG. 6 . Therefore, description of the handover inhibition control operation S 204 of the base station device 101 is omitted.
3. Supplemental Notes
A part or all of the above exemplary embodiments can also be described as the following supplemental notes. However, the present invention is not limited thereto.
[Supplemental Note 1]
A base station device in a wireless communication system, including:
a neighboring base station information storage means which stores neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device; and
a handover control means which limits, when the neighboring cell transitions from an inactive state to an active state, handover to the activated neighboring cell of a subordinate mobile terminal device, based on the handover inhibition information and the processing capability index.
[Supplemental Note 2]
The base station device according to Supplemental Note 1, in which the handover inhibition information is a handover inhibition timer that is activated when the neighboring cell transitions from an inactive state to an active state, and that indicates a predetermined handover inhibition time, and in which the handover control means inhibits, during the handover inhibition time, handover of the mobile terminal device to the neighboring cell, based on the processing capability index.
[Supplemental Note 3]
The base station device according to Supplemental Note 2, in which the handover control means permits handover of the mobile terminal device to the neighboring cell only in a case where the processing capability of the neighboring base station device has a margin, if within the handover inhibition time.
[Supplemental Note 4]
The base station device according to Supplemental Note 3, in which the margin of the processing capability of the neighboring base station device is determined by the number of times of executing handover to the neighboring cell within the handover inhibition time, and by the processing capability index.
[Supplemental Note 5]
The base station device according to one of Supplemental Notes 1 to 4, in which the neighboring base station device is a small base-station device located under the base station device.
[Supplemental Note 6]
A handover control method for a base station device in a wireless communication system, including:
storing, in a neighboring base station information storage means, neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device; and
limiting, when the neighboring cell transitions from an inactive state to an active state, handover to the activated neighboring cell of a subordinate mobile terminal device, based on the handover inhibition information and the processing capability index.
[Supplemental Note 7]
The handover control method according to Supplemental Note 6, in which the handover inhibition information is a handover inhibition timer that is activated when the neighboring cell transitions from an inactive state to an active state, and that indicates a predetermined handover inhibition time, and in which, during the handover inhibition time, handover of the mobile terminal device to the neighboring cell is limited, based on the processing capability index.
[Supplemental Note 8]
The handover control method according to Supplemental Note 7, in which handover of the mobile terminal device to the neighboring cell is permitted only in a case where the processing capability of the neighboring base station device has a margin, if within the handover inhibition time.
[Supplemental Note 9]
The handover control method according to Supplemental Note 8, in which the margin of the processing capability of the neighboring base station device is determined by the number of times of executing handover to the neighboring cell during the handover inhibition time, and the processing capability index.
[Supplemental Note 10]
The handover control method according to one of Supplemental Notes 6 to 9, in which the neighboring base station device is a small base-station device located under the base station device.
[Supplemental Note 11]
A wireless communication system including a plurality of base station devices, one of the plurality of base station devices, including:
a neighboring base station information storage means which stores neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device; and
a handover control means which limits, when the neighboring cell transitions from an inactive state to an active state, handover to the activated neighboring cell of a subordinate mobile terminal device, based on the handover inhibition information and the processing capability index.
[Supplemental Note 12]
The wireless communication system according to Supplemental Note 11, in which the handover inhibition information is a handover inhibition timer that is activated when the neighboring cell transitions from an inactive state to an active state, and that indicates a predetermined handover inhibition time, and in which the handover control means inhibits, during the handover inhibition time, handover of the mobile terminal device to the neighboring cell, based on the processing capability index.
[Supplemental Note 13]
The wireless communication system according to Supplemental Note 12, in which the handover control means permits handover of the mobile terminal device to the neighboring cell only in a case where the processing capability of the neighboring base station device has a margin, if within the handover inhibition time.
[Supplemental Note 14]
The wireless communication system according to Supplemental Note 13, in which the margin of the processing capability of the neighboring base station device is determined by the number of times of executing handover to the neighboring cell within the handover inhibition time, and by the processing capability index.
[Supplemental Note 15]
The wireless communication system according to one of Supplemental Notes 11 to 14, in which the neighboring base station device is a small base-station device located under the base station device.
[Supplemental Note 16]
A program for implementing, in a computer, a handover control function of a base station device in a wireless communication system, the program implementing, in the computer:
a neighboring base station information storage function of storing neighboring base station information including handover inhibition information associated with a neighboring cell managed by a neighboring base station device, and a processing capability index of the neighboring base station device; and
a handover control function of limiting, when the neighboring cell transitions from an inactive state to an active state, handover to the activated neighboring cell of a subordinate mobile terminal device, based on the handover inhibition information and the processing capability index.
INDUSTRIAL APPLICABILITY
The present invention is applicable to a power saving technique in a wireless communication system and, more particularly, to reduction of a load on a small base-station device.
REFERENCE SIGNS LIST
100 , 101 base station devices
100 a , 101 a base station device cells
200 a small base-station cell
300 , 301 mobile terminal devices
110 wireless communication control unit
120 inter-base-station communication control unit
130 handover control unit
140 activation control unit
150 neighboring base station device information table | [Problem] To provide a base station device and a handover control method capable of avoiding a situation in which the base station device of a cell becomes overloaded when the cell transitions from an inactive state to an active state. [Solution] A base station device ( 100 ) having: an adjacent base station information table ( 150 ) for storing adjacent base station information that includes handover suppression information correlated with an adjacent cell ( 200 a ) managed by an adjacent base station device ( 200 ), and also includes the processing capacity index of the adjacent base station device; and a handover control unit ( 130 ) for limiting the handover of a mobile terminal device ( 300 ) under control to an activated adjacent cell on the basis of the handover suppression information and the processing capacity index when the adjacent cell transitions from an inactive state to an active state. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to three-dimensional printing with a blend of cycloolefin copolymer and another thermoplastic resin or with cycloolefin copolymer elastomer. Sometimes these resins are referred to as cyclic olefin copolymers or cyclo-olefin copolymers.
BACKGROUND
[0002] Thermoplastics are widely used in three-dimensional printing, particularly in connection with fused deposition modeling (FDM)(sometimes referred to as fused filament fabrication (FFF)), or selective heat sintering (SHS) or selective laser sintering (SLS).
[0003] Variants on widely used techniques and materials are seen in United States Patent Application Publication No. US 2014/0162033 which discloses a fabrication process and apparatus for producing three-dimensional objects by depositing a first polymer layer, printing a first ink layer on to the first polymer layer, depositing a second polymer layer on to the first ink layer, and printing a second ink layer on to the second polymer layer. The deposition and printing steps may be repeated until a three-dimensional object is formed. The inks used to form at least one of the first and second ink layers may include dyes or pigments so that the three-dimensional object may be a colored three-dimensional object.
[0004] Various additives are used with thermoplastics to enhance three-dimensional printing processing. There is seen in United States Patent Application Publication No. US 2007/0241482 a material system for three-dimensional printing comprising: a granular material including: a first particulate adhesive including a thermoplastic material; and an absorber capable of being heated upon exposure to electromagnetic energy sufficiently to bond the granular material.
[0005] So, also, there is seen in US 2011/0156301 a materials system provided to enable the formation of articles by three-dimensional printing. The material system includes (i) a substantially dry particulate material including an aqueous-insoluble thermoplastic particulate material, plaster, and a water-soluble adhesive; (ii) an aqueous fluid binder, and (iii) an infiltrant.
[0006] While various adjuvants may be employed in the art to facilitate processing or impart particular features to the article, the thermoplastics used are typically conventional materials such as nylons, acrylonitrile butadiene styrene polymers, other polyolefins and so forth which may be lacking in one or more properties such as dimensional stability, optical transparency or other characteristics, gloss and moisture barrier properties.
SUMMARY OF INVENTION
[0007] There is provided in a first aspect of the invention a method of producing a three-dimensional article comprising providing a melt-blend of a cycloolefin copolymer with another thermoplastic resin and producing the article by three-dimensionally printing the polymer blend into the three-dimensional article. The three-dimensional printing methodology is optionally selected from FDM, SHS or SLS. A preferred class of polymer blends utilized in connection with the invention includes cycloolefin copolymer melt-blended with a partially crystalline olefin polymer such as polypropylene, polyethylene or partially crystalline polymers of linear alkenes such as polyoctenes.
[0008] While the materials may be used in a wide variety of proportions in the polymer blend, weight ratio of cycloolefin copolymer:other thermoplastic of from 2:98 to 98:2 are typical. In some cases, a weight ratio of cycloolefin copolymer:other thermoplastic from 2:98 to 20:80 are preferred when certain properties such as dimensional stability or gloss of the thermoplastic in the blend are targeted for improvement.
[0009] In another aspect of the invention, there are provided three-dimensional articles produced by three-dimensionally printing polymer blends of cycloolefins and another thermoplastic. The three dimensional article of the invention exhibit improvement in at least one of the following properties as compared with the same article produced by the same method with the thermoplastic resin only: dimensional stability; optional transmission; gloss; or barrier properties.
[0010] There is provided in yet another aspect of the invention a method of producing a three-dimensional article comprising providing a thermoplastic composition comprising a cycloolefin elastomer copolymer, optionally blended with another thermoplastic resin and producing the article by three-dimensionally printing the thermoplastic composition into the three-dimensional article. The three-dimensional printing methodology is also suitably selected from FDM, SHS or SLS.
[0011] In still yet another aspect of the invention, there are provided three-dimensional articles produced by three-dimensionally printing polymer compositions including cycloolefin copolymer elastomers and optionally another thermoplastic.
[0012] Still further aspects of the invention are appreciated from the discussion which follows.
BRIEF DESCRIPTION OF DRAWING
[0013] The invention is described in detail below which is a schematic diagram of an FDM apparatus and process.
DETAILED DESCRIPTION
[0014] The invention is described in detail below with reference to the drawing and examples. Such discussion is for purposes of illustration only. Modifications within the spirit and scope of the present invention, set forth in the appended claims, will be readily apparent to one of skill in the art.
[0015] The articles of the invention are suitably formed by any three-dimensioal printing process, that is, by any process of producing a three-dimensional article one layer at a time, now known or hereafter developed. Known techniques are sometimes referred to as binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet lamination, vat photopolymerization and so forth. Preferred techniques include FDM, SHS or SLS as is noted above
[0016] The cycloolefin copolymer (COC) employed is typically a cycloolefin/acyclic olefin copolymer These polymers generally contain, based on the total weight of the cycloolefin copolymer, preferably from 0.1 to 99.9% by weight, of polymerized units which are derived from at least one polycyclic olefin of the formulae I, II, III, IV, V or VI, or a monocyclic olefin of the formula VII:
[0000]
[0000] wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and R 8 are the same or different and are H, a C 6 -C 20 -aryl or C 1- C 20 -alkyl radical or a halogen atom, and n is a number from 2 to 10.
[0017] Specific cycloolefin monomers are disclosed in U.S. Pat. No. 5,494,969 to Abe et al. Cols. 9-27, for example the following monomers:
[0000]
[0000] and so forth. The disclosure of U.S. Pat. No. 5,494,969 to Abe et al. Cols. 9-27 is incorporated herein by reference.
[0018] The cycloolefin units may also include derivatives of the cyclic olefins such as those having polar groups, for example, halogen, hydroxy, ester, alkoxy, carboxy, cyano, amido, imido or silyl groups.
[0019] Preferred cycloolefin copolymers include cycloolefin monomers and acyclic olefin monomers, i.e. the above-described cycloolefin monomers can be copolymerized with suitable acyclic olefin comonomers. A preferred comonomer is selected from the group consisting of ethylene, propylene, butylene and combinations thereof. A particularly preferred comonomer is ethylene. Preferred COCs contains about 10-80 mole percent of the cycloolefin monomer moiety and about 90-20 weight percent of the olefin moiety (such as ethylene, referred to as COCE resin). Cycloolefin copolymers which are suitable for the purposes of the present invention typically have a mean molecular weight M W in the range from more than 200 g/mol to 400,000 g/mol. COCs can be characterized by their glass transition temperature, Tg, which is generally in the range from 20° C. to 200° C., preferably in the range from 30° C. to 130° C. In one preferred embodiment the cyclic olefin polymer is a copolymer such as TOPAS® 8007F-04 which includes approximately 36 mole percent norbornene and the balance ethylene. TOPAS® 8007F-04 has a glass transition temperature of about 78° C. Other preferred embodiments include melt blends of partially crystalline cycloolefin elastomer and amorphous COC materials with low glass transition temperatures.
[0020] Especially preferred resins include Topas® COCE resins grades 8007 (Tg of 80° C., 5013, 6013 (Tg of 140° C.), and 9506 (Tg of 68° C.). These resins include ethylene and norbornene. Norbornene is also sometimes referred to as bicyclo[2.2.1]hept-2-ene or 2-norbornene as noted above.
[0021] The foregoing cycloolefin copolymer resins are usually amorphous; however, cycloolefin copolymer elastomers which have a partially crystalline morphology may also be employed, either alone or blended with another thermoplastic including an amorphous cycloolefin copolymer. Such compositions are described in United States Patent Application Publication 20110256373 entitled Melt blends of amorphous cycloolefin polymers and partially crystalline cycloolefin elastomers with improved toughness . COC elastomers are elastomeric cyclic olefin copolymers available from TOPAS Advanced Polymers. The elastomer features two glass transition temperatures, one of about 6° C. and another glass transition below −90° C. as well as a crystalline melting point of about 84° C. Unlike completely amorphous TOPAS COCE grades, COC elastomers typically contain between 10 and 30 percent crystallinity by weight. Typical properties appear in Table 1:
[0000] TABLE 1 Elastomer Properties Property Value Unit Test Standard Physical Properties Density 940 kg/m 3 ISO 1183 Melt volume rate (MVR) - @ 3 cm 3 /10 min ISO 1133 2.16 kg/190° C. Melt volume rate (MVR) - @ 12 cm 3 /10 min ISO 1133 2.16 kg/260° C. Hardness, Shore A 89 — ISO 868 WVTR - @ 23° C./85 RH 1.0 g*100 μm/ ISO 15106-3 m 2 * day WVTR - @ 38° C./90 RH 4.6 g*100 μm/ ISO 15106-3 m 2 * day Mechanical Properties Tensile stress at break (50 >19 MPa ISO 527-T2/1A mm/min) Tensile modulus (1 mm/min) 44 MPa ISO 527-T2/1A Tensile strain at break >450 % ISO 527-T2/1A (50 mm/min) Tear Strength 47 kN/m ISO 34-1 Compression set - @ 35 % ISO 815 24 h/23° C. Compression set - @ 32 % ISO 815 72 h/23° C. Compression set - @ 90 % ISO 815 24 h/60° C. Thermal Properties Tg—Glass transition 6 ° C. DSC temperature (10° C./min) <−90 T m —Melt temperature 84 ° C. DSC Vicat softening temperature, 64 ° C. ISO 306 VST/A50
As seen above, the elastomer has multiple glass transitions (Tg); one occurs at less than −90° C. and the other occurs in the range from −10° C. to 15° C.
[0022] The cycloolefin copolymers may be blended with another thermoplastic resin, including nylons, styrene, ABS resins or other polyolefins. Some especially preferred resins are noted below.
Polyethylene (PE)
[0023] The inventive polymer formulations include a polyethylene component in addition to the cycloolefin/ethylene copolymer resin. Polyethylene is a semicrystalline thermoplastic whose properties depend to a major extent on the polymerization process (Saechtling, Kunststoff-Taschenbuch [Plastics handbook], 27th edition).
[0024] “HDPE” is polyethylene having a density of greater or equal to 0.941 g/cc. HDPE has a low degree of branching and thus stronger intermolecular forces and tensile strength. HDPE can be produced by chromium/silica catalysts, Ziegler-Natta catalysts or metallocene catalysts. The lack of branching is ensured by an appropriate choice of catalyst (e.g. Chromium catalysts or Ziegler-Natta catalysts) and reaction conditions.
[0025] “LDPE” is polyethylene having a density range of 0.910 -0.940 g/cc. LDPE is prepared at high pressure with free-radical initiation, giving highly branched PE having internally branched side chains of varying length. Therefore, it has less strong intermolecular forces as the instantaneous-dipole induced-dipole attraction is less. This results in a lower tensile strength and increased ductility.
[0026] The term “LLDPE” is a substantially linear polyethylene, with significant numbers of short branches, commonly made by copolymerization of ethylene with short-chain α-olefins (e.g. copolymerization with 1-butene, 1-hexene, or 1-octene yield b-LLDPE, h-LLDPE, and o-LLDPE, respectively) via metal complex catalysts. LLDPE is typically manufactured in the density range of 0.915 -0.925 g/cc. However, as a function of the α-olefin used and its content in the LLDPE, the density of LLDPE can be adjusted between that of HDPE and very low densities of 0.865 g/cc. Polyethylenes with very low densities are also termed VLDPE (very low density) or ULDPE (ultra low density). LLDPE has higher tensile strength than LDPE. Exhibits higher impact and puncture resistance than LDPE. Lower thickness (gauge) films can be blown compared to LDPE, with better environmental stress cracking resistance compared to LDPE. Lower thickness (gauge) may be used compared to LDPE.
[0027] “MDPE” is polyethylene having a density range of 0.926 -0.940 g/cc. MDPE can be produced by chromium/silica catalysts, Ziegler-Natta catalysts or metallocene catalysts. MDPE has good shock and drop resistance properties. It also is less notch sensitive than HDPE, stress cracking resistance is better than HDPE.
[0028] “Polypropylene” includes thermoplastic resins made by polymerizing propylene with suitable catalysts, generally aluminum alkyl and titanium tetrachloride mixed with solvents. This definition includes all the possible geometric arrangements of the monomer unit, such as: with all methyl groups aligned on the same side of the chain (isotactic), with the methyl groups alternating (syndiotactic), all other forms where the methyl positioning is random (atactic), and mixtures thereof.
[0029] The blends of the invention may be prepared by any suitable method, including solution blending, melt compounding by coextrusion or melt blending followed by coextrusion. Extrusion blending techniques have the advantage that the blend may be directly melt spun into filaments for FDM processing. Typical extrusion, melt spinning and compounding conditions for representative compositions are set forth in Table 2.
[0000]
TABLE 2
Twin Screw Extrusion, Melt Spinning and Compounding Conditions
Machine Data ZSK-40MC
P max [kW]: 106 RPM max 1200
Structure
Thermoplastic I
92.00%
84.50%
39.75%
Thermoplastic II
92.00%
84.50%
Thermoplastic III
89.50%
39.75%
Cycloolefin
7.50%
15.00%
10.00%
7.50%
15.00%
20.00%
Copolymer
Hostanox 010
0.25%
0.25%
0.25%
0.25%
0.25%
0.25%
Licowax C
0.25%
0.25%
0.25%
0.25%
0.25%
0.25%
Screw #
Screw Speed
275
290
325
325
325
300
[1/min]
Torque [%]
93-95
92-93
90-91
86-90
88-90
91-93
Power [kW]
24.2
26.0
24.5
Rate [lb/hr]
402
402
402
402
400
400
S-mech (SEI)
0.136
0.142
0.135
[kWh/kg]
T melt (° C.) Die
251
252
280
280
280
271
PDie (psig) Die
340
340
310
300
280
300
[0030] Using a blended material made as noted generally above or a cycloolefin copolymer elastomer alone, three-dimensional articles are made by an FDM apparatus as shown schematically in the FIGURE. Feed assembly 12 dispenses polymer 14 in filament form onto build platform 18 , in a layer-by-layer process, to form three-dimensional object 16 . Once three-dimensional object 16 is completed, it may be removed from build platform 18 and a new project may begin.
[0031] While the invention has been described in detail, modifications within the spirit and scope of the invention will be readily apparent to those of skill in the art. In view of the foregoing discussion, relevant knowledge in the art and references discussed above in connection with the Background of the Invention and the detailed description, the disclosures of which are all incorporated herein by reference, further description is deemed unnecessary. In addition, it should be understood that aspects of the invention and portions of various embodiments may be combined or interchanged either in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention. | A method of making a three-dimensional article includes providing a polymer blend which includes a cycloolefin copolymer and another thermoplastic resin; and printing the polymer blend into the three-dimensional article. The articles exhibits superior performance in connection with at least one of the following properties: dimensional stability; optical transmission; gloss; or barrier properties as compared with a like article made by a like process made from the thermoplastic resin in the blend only. Articles may also be formed with cycloolefin copolymer elastomer which is optionally blended with another thermoplastic. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 095,854 filed Nov. 19, 1979 pending.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the art of selective printing apparatus.
2. Brief Description of the Prior Art
Various prior art U.S. Pat. Nos. 3,330,207 to De Man dated July 11, 1967; 3,886,862 to Hamisch, Jr. dated June 3, 1975; 3,908,543 to Wirth dated Sept. 30, 1975; 3,968,745 to Hamisch, Jr. dated July 13, 1976; 3,972,281 to Sams dated Aug. 3, 1976; and 4,055,118 to Yo Sato dated Oct. 25, 1977; and West German Offenlegungsschrift No. 2,350,537 are made of record.
SUMMARY OF THE INVENTION
The invention includes an improved, compact, low-cost print head. The print head is simple to construct, requiring relatively few parts, and yet the invention accomplishes effective detenting of a selector shaft of the selector mechanism in spite of a gear drive between the selector shaft and wheels which the selector shaft drives. According to a specific embodiment of the invention, the selector mechanism cooperates with a series of wheels. In the illustrated embodiment, each wheel has a printing member wrapped about is periphery, and each printing member has a series of different printing elements. The printing members are thus considered to be coupled to the respective wheels, but as far as the selector mechanism is concerned, each wheel could be coupled to a printing member by having the wheels and printing members being one-piece, e.g., a one-piece type wheel as in U.S. Pat. No. 3,908,543, or each wheel could be coupled to a printing member in the form of a printing band which is trained about the wheel and a fixed or movable support as in U.S. Pat. Nos. 3,886,862 and 3,968,745 and West German Offenlegungsschrift No. 23 50 537. In the illustrated embodiment, the selector shaft, which is both shiftable and rotatable, is engageable with any selected wheel. The detent mechanism for the selector shaft includes a slidably mounted yieldable detent member which can hold the selector shaft in any selected position, and there is a rotary connection between the detent member and the selector shaft. Thus, the selector shaft moves the detent member and yet the selector shaft is rotatable relative to the detent member. It is another feature of the invention to provide a slide which helps support the selector shaft. This slide performs the additional function of mounting the detent member. The selector shaft is preferably also supported at another location spaced from the slide. In addition to these features, the detent member is cooperable with the wheels with which the selector shaft engages. Detenting directly on the wheels enables wheels of any selected width or widths to be used without using a different detent member or selector shaft. The illustrated embodiment utilizes a gear drive between the selector shaft and the wheels.
The invention also includes an arrangement for visually indicating the indicia to be printed even though the print head is movably mounted with respect to an indicator. The print head moves between printing and non-printing positions and there is a connector between the print head and the indicator that allows such movement. According to an illustrative embodiment, there is a lost-motion connection between the selector shaft and the indicator. The illustrated connection is made by telescoping members. The indicator is shiftable in a stationary frame while the selector is both shiftable and rotatable.
In accordance with another feature of the invention, there is provided both an improved print wheel and an improved read wheel for a print head. These wheels have the feature of a generally annular base and a printing member received about the base. The base is provided with separate sockets and the marginal ends of the band has lugs which complement the sockets. The one socket and its complementary lug are dissimilar from the other socket and the lug which is complementary with the other socket. In this way the band can be connected to the wheel only one way. The wheel has means for orienting each wheel with respect to another similar wheel.
The invention also includes method of making the print head of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partly exploded perspective view of a print head assembly in accordance with the invention;
FIG. 2 is a sectional view of the assembled print head of the print head assembly;
FIG. 3 is a sectional view taken generally along line 3--3 of FIG. 2;
FIG. 4 is a sectional view taken generally along line 4--4 of FIG. 2;
FIG. 5 is a sectional view taken generally along line 5--5 of FIG. 2;
FIG. 6 is a top plan view taken along line 6--6 of FIG. 5;
FIG. 7 is a fragmentary sectional view of a print wheel;
FIG. 8 is a fragmentary sectional view of a read wheel;
FIG. 9 is a perspective view showing a fragmentary portion of a selector shaft and an associated slide and yieldable detent member;
FIG. 10, which appears on sheet 1, shows the print wheel with one of the printing elements in a printing position adjacent the platen; and
FIG. 11 is a perspective view of a fixture.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1, there is shown a print head assembly generally indicated at 20 which includes a print head 21 and an indicator mechanism generally indicated at 22. The print head 21 is shown to include a pair of side plates 23 and 24 connected by posts 25, 26 and 27. Threaded fasteners 28 are received by the respective posts 25, 26 and 27 and one of the fasteners 28 is threadably received by a support generally indicated at 29. The posts 25, 26 and 27 and the support 29 are thus securely connected to the side plates 23 and 24 by the fasteners 28. The print head 21 includes a printing section 30 and a reading section 31. The printing section includes a series of wheels 32 rotatably mounted on the support 29 as best shown in FIG. 2. In the illustrated embodiment, each wheel 32 includes a base 32' (FIG. 7) about the periphery of which a printing member 33 is wrapped. The printing band 33 is shown to have a series of different printing elements 34 so that, for example, characters 0 to 9 and one or more symbols can be printed. The base 32' has a pair of narrow gaps 35 and 36. The gap 35 opens to the periphery of the base 32' and to a socket 37 and the gap 36 opens to the periphery of the base 32' and to a socket 38. Marginal end portions 39 and 40 of the printing member 33 are received in the respective gaps 35 and 36, and lugs 41 and 42 are received in respective sockets 37 and 38. The entries to the sockets 37 and 38 are beveled as shown at 43 and 44 for ease of the insertion of the lugs 41 and 42. The lugs 41 and 42 are considerably wider than the respective gaps 35 and 36 so that the lugs 41 and 42 are captive in the sockets 37 and 38. The printing members 33 are under slight tension so that they are held securely on their respective bases 32'.
The wheels 32 are selectively settable. The selection is accomplished by a selector or selector mechanism generally indicated at 45 (FIG. 1) which includes a selector shaft 46 which carries a gear 47 and a manually engageable knob 48 suitably secured thereto as by a threaded fastener 49. The support 29 has an opening or aperture 50 which provides a surface for rotatably supporting the selector shaft 46. The support 29 includes a guideway or slideway 51 which is shown to extend in the lengthwise direction parallel to the axis of the wheels 32. The axis of the selector shaft 46 is also parallel to the axis of the wheels 32. The slideway 51 is shown to slidably mount a slide 52. The slide 52 mounts a yieldable detent member 53. The detent member 53 has a yieldable arm 53' (FIGS. 3 and 9) and a detent tooth 54. A generally central hole 55 in each wheel 32 is defined by an internal gear 56. The internal gear 56 has beveled side edges 57 into which the tooth 54 of the detent member 53 can move. The tooth 54 is shown in FIG. 3 to be detented between adjacent wheels 32 and the gear 47 is shown to be in mesh with a gear 56 of one of the wheels 32. By rotating the selector shaft 46, the wheel gear 56 with which the gear 47 is engaged is driven to bring a different printing element 34 to the printing position P adjacent a platen 58 to print on an intervening record R. The selector shaft 46 can be shifted by either pushing or pulling on the knob 48 to bring the gear 47 into meshing engagement with any one of the other wheel gears 56. The detent member 53 and the slide 52 are connected to the selector shaft 46 as best shown with reference to FIGS. 3 and 9. The selector shaft 46 has an outwardly converging head 59 which merges with a reduced portion 60. The reduced portion 60 is disposed between the head 59 and the gear 47 as shown in FIG. 3. The end of the head 59 adjacent the reduced portion 60 provides a shoulder 61. A socket 62 which is connected to the slide 52 and the detent member 53 provides a rotary connection with the selector shaft 46. The socket 62 has an inwardly extending projection with opposed shoulders 64 and 65. The shoulder 64 abuts the shoulder 61 and the shoulder 65 abuts the side of the gear 47. Thus, the socket 62 is captive between the shoulder 61 and the gear 47 so that the slide 52 and the detent member 53 move together with the selector shaft 46 whenever the selector shaft 46 is shifted. Moreover, the projection 62 is generally annular as is the outer surface of the reduced portion 60 and thus the selector shaft 46 can rotate relative to the slide 52 and to the detent member 53. The socket 62 is shown to be split to enable insertion of the head 59 to the position shown in FIG. 3.
Although the selector mechanism 45 is shown to be used in conjunction with wheels that print, this selector mechanism 45 could also be used in conjunction with wheels that drive print bands about a support as in U.S. Pat. No. 3,968,745 or in conjunction with wheels that drive print wheels, for example.
The wheels 32 are shown to be detented in any selected position by a detent mechanism generally indicated at 66. The support 29 also includes a recess 67 which extends in the lengthwise direction parallel to the axis of the wheels 32. The recess 67 is shown to open to the outer periphery of the support 29. The recess 67 receives a detent member in the form of a helical spring 68. The spring 68 is preferably of one-piece construction so that it contacts and is common to all the wheels 32. The recess 67 is contoured so that the spring 68 is contacted and supported in the recess at four locations 69, 70, 71 and 72 and extends beyond the periphery of the support 29. The spring 68 is essentially non-deformable, whereas the wheels 32 deform resiliently when indexed. The turns of the spring 68 are tightly wound as best shown in FIG. 3 and preferably the spring 68 is composed of metal, specifically small diameter wire. The wire diameter is less than the thickness of a wheel 32. The bases 32' of the wheels 32 are composed of plastics material which is resiliently deformable when a wheel 32 is indexed. The internal gear 56 has teeth 73 defined by pairs of converging surfaces 74. In a detented position as shown in FIGS. 7 and 10 for example, the spring 68 is shown to be in contact with both converging surfaces 74 of a pair. Each pair of converging recesses 74 provides a recess. When a wheel 32 is advanced, one pair of converging surfaces 74 leaves contact with the spring 68 and an adjacent pair of converging surfaces 74 are cammed into cooperation with the spring 68 by the spring 68 as the wheel returns to its original shape.
The reading wheel section 31 is shown to include a series of read wheels 75. The read wheels 75 have generally annular bases 76 about which bands 77 are wrapped. The bands 77 have human readable indicia 78 corresponding to the printing elements 34 on the wheels 32. The base 76 (FIG. 8) of each wheel 75 has a pair of sockets 79 and 80 for receiving respective lugs 81 and 82. A narrow gap 83 opens into the socket 79 and to the outer periphery of the base 76 and a narrow gap 84 opens into the socket 80 and into the outer periphery of the base 76. The gaps 83 and 84 are narrower than respective lugs 81 and 82 so that the lugs 81 and 82 are held captive in respective sockets 79 and 80. There is a continuous bevel 85 in the side of the base 76 adjacent the sockets 81 and 82 and the gaps 83 and 84 to facilitate insertion of the lugs 81 and 82. The bases 76 are shown to be rotatably mounted on a post or shaft 86. A gear 87 is connected to each wheel 75 and is preferably molded integrally with the base 76. Each gear 87 meshes with a gear 88 which is connected to a respective wheel 32. The gear 88 is preferably molded integrally with respective base 32'. When the selector shaft 46 is rotated, the gear 88 associated with the selected wheel 32 drives a meshing gear 87 of a respective read wheel 75. The user can observe which printing elements 34 are at the printing position P by looking through transparent portions or windows 89 of respective members 90. Each member 90 has a plurality of functions. Each member 90 is preferably molded from plastics material. The surface of each member 90 is matte or non-transparent except for the window 89, the outer surface of which is arched to provide a lens 89'. The lenses 89' provide some magnification of indicia 78 on the read wheels 75.
The members 90 have recesses 91 which have a depth substantially equal to the width or thickness of the gear 87 which they guide. The members 90 are arranged in a stack so that the gears 87 are trapped between adjacent members 90. Each member 90 has the same width (except for clearance) as an associated wheel 32 and it is apparent that the members 90 guide the gears 87 for rotation in respective paths in alignment with respective meshing gears 88. The members 90 also serve as shields to prevent damage to the gears 87 in the event the print head or the labeler or other printing apparatus of which it forms a part should be dropped or otherwise abused.
While the user can visually observe the printing elements which are at the printing position by peering through the window 89, the user is informed as to the particular wheel 32 with which the selector shaft 46 is coupled by means of the indicator mechanism 22. The indicator mechanism 22 is connected to the print head 21 by a connection generally indicated at 92 which enables the print head 21 to move into and out of printing cooperation with the platen 58, while an indicator 93 is only slidable relative to a fixed frame 94. The indicator 93 is slidable in a track parallel to the direction of shifting movement of the selector shaft 46. The indicator 93 includes a pair of opposed pointers 95 which are aligned with the gear 47 of the selector 45 and with the respective read wheel 75 at the window 89. The print head 21 is guided for back and forth movement by two pairs of opposed ball tracks 96 and 97, and 98 and 99. The ball tracks 97 and 99 are considered to be part of the frame 94. Ball bearing strips 100 and 101 are disposed between respective ball tracks 96 and 97, and 98 and 99. The connection 92 is more particularly a lost-motion connection. Specifically, the connection between the print head 21 and the indicator 93 includes a pair of telescoping members 102 and 103. The member 102 is connected to the selector shaft 46. A tubular projection 104 on the knob 48 extends into a hole 105 in the member 102. The screw 49 extends through the knob 48 and into its tubular projection 104 and is threadably received by a hole 106 in the selector shaft 46. The member 102 is free to pivot on the projection 104. The opposite sides of the member 102 are provided with guide members or lugs 107. The indicator 93 has a depending, essentially hollow member 108 having four spaced apart projections 109. The member 102 is telescopically received in the member 108. Each guide member 107 slides in slidable relationship between two respective pairs of the projections 109. The guide members 107 are in constant guided relationship with the projections 109 irrespective of whether the print head 21 is in the printing position or is in the non-printing position in which the print head 21 is spaced from the platen 58. Notwithstanding the fact that the print head 21 moves between the printing and non-printing positions, the indicator mechanism 22 remains coupled with the print head 21 and in particular remains coupled with the selector shaft 46.
The shaft 86 has an axially extending groove 110 which is shown to semi-circular, and each wheel base 76 has a groove or opening 110' which is shown to be semi-circular. When the grooves 110 and 110' are aligned they form a locating hole or opening 111. Each wheel has holes or openings 112 and 113 angularly spaced apart by other than 180°. In assembling the print head 21, the support 29 is connected to the side plate 23 by a screw 28. When the support 29 is connected to the side plate 23, arcuate projection 50', which partially surrounds the axis of the hole 50, fits snugly into a hole 23' in the side plate 23. Thereupon, side plate 23 is placed in a fixture F with pins A, B and C sticking through respective holes or openings 111', 112' and 113' in the side plate 23. The side plate 24 also has corresponding aligned holes 111', 112' and 113'. A wheel 32 and a corresponding read wheel 75 are assembled in pairs onto respective supports 29 and 86. The wheels 32 and 75 can only be assembled one way because of the pins A, B and C. Specifically the pin A extends through the holes 111' (in side plate 23) and 111, the pin B extends through holes 112' and 112, and pin C extends through holes 113' and 113. As indicated above, the printing members 33 can only be assembled onto the respective wheels 32 one way, and the bands 77 can only be assembed onto the respective bases 76 one way. Each wheel 76 could be provided with an additional aligning hole disposed at an angular position of other than 180° from the notch 110' but the same result can be obtained by observing that each gear 88 must be spaced from the adjacent gear or gears. Thus, if two gears 88 are in face-to-face contact, then one of the contacting gears 88 is turned the wrong way. When all the wheels 32 and 75 are properly aligned, the readable indicia 34 are all in a straight row showing blanks and the blank positions of labels 32 are at the printing position as shown in FIG. 2 for example. When all the wheels 32 and 75 are assembled, the selector shaft 46, coupled to the slide 52 and to the detent member 53, is inserted into the space within the wheels 32 with its end portion 46' extending a short distance through hole 23'. When thus positioning the selector shaft 46, the slide 52 is inserted through the end of the slideway 51. In this position of the selector shaft 46, the member 102 can be slid onto the projection 104 and the knob 48 can be slipped over the end portion 46' so that flat 46" complements a corresponding flat (not shown) on the knob 48. The knob 48 is thus non-rotatably connected to the shaft 46 and the screw 49 keeps the knob 48 from slipping off the shaft 46. The screw 49 also spreads the projection 104 which is split to prevent the connector 102 from shifting axially on the projection. Thereafter the side plate 24 is connected to the side plate 23 by the rest of the screws 28.
With the exception of the metal screws 28 and 49, the metal ball bearing strips 100 and 101, the metal spring 68, and the bands 33 and 77 which are composed of elastomeric material, the entire assembly 20 is composed of moldable plastics material. The one-piece element which comprises the slide 52, the detent member 53 and the socket 62 is constructed of a material that is sufficiently flexible and resilient to enable the arm 53' to flex as the selector shaft 46 is shifted axially and to enable the socket 62 to open to receive the head 59 during assembly. Also the entire shaft 46 and the gear 47 are molded as one piece.
While it is preferred to detent the selector 46 and the wheels 32 in the space within wheels 32, in another embodiment (not shown) the detenting of both the selector 46 and read wheels 75 is accomplished in the space within the read wheels 75.
Other embodiments and modifications of this invention will suggest themselves to those skilled in the art, and all such of these as come within the spirit of this invention are included within its scope as best defined by the appended claims. | The disclosure relates to a selective printing apparatus adapted to be used in a hand held labeler. The apparatus includes selectively settable printing members driven by wheels coupled by gearing with read wheels for indicating the selected data to be printed. The read and print wheels are driven by a manually movable, shiftable and rotatable selector shaft. The print wheels are detented and the selector shaft is detented within holes in the print wheels. An indicator slidably mounted by a stationary frame is coupled to the selector shaft through a lost-motion connection to enable the print head to move between printing and non-printing positions. | 1 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application Ser. No. 60/413,267, filed Sep. 23, 2002.
BACKGROUND OF THE INVENTION
[0002] This application relates to medical devices such as catheters that have sensors at their distal tips to which electrical wiring is connected.
[0003] Sensor catheters are used to gather information during medical procedures for diagnosing and treating patients. Ultrasonic imaging catheters, for example, may be used to gather ultrasonic images of a patient's blood vessels. Alternative imaging techniques also may be used, such as magnetic resonance imaging, optical coherence tomography and infrared imaging. During certain procedures, catheters may be used to gather a variety of physiological parameters such as temperature, pressure, pH, flow velocity and/or volumetric flow. Gradients or changes in physiological parameters across an area of interest may also be determined.
[0004] Sensor catheters are typically connected to control and analysis equipment, which may be used to generate images from raw imaging data and display physiological parameters. A number of wires must be run along the length of a typical catheter to connect the control and analysis equipment disposed at the catheter's proximal end to the sensor(s) disposed at the distal catheter tip.
[0005] In many instances, there are seven or more wires that convey power supply voltages, ground potential, drive signals, and raw sensor signals to and from the catheter sensors. These wires may be organized as a single cable bundle. However, cross-talk or noise among signal wires is a source of interference when using a sensor catheter to gather sensor measurements. This may adversely affect ringdown performance.
[0006] In view of the above, it would be desirable to provide an imaging catheter including improved wiring arrangements to reduce wire-to-wire cross-talk.
SUMMARY OF THE INVENTION
[0007] In view of the foregoing, it is an object of the present invention to provide a sensor catheter having improved wiring arrangements for reducing wire-to-wire cross-talk.
[0008] In accordance with the principles of the present invention, sensor catheters are provided having improved wiring arrangements that reduce wire-to-wire cross-talk. The wires are grouped in distinct subgroups such as pairs of wires or groups of three or more wires that carry related signals. Accordingly, a group of seven wires may be divided into two twisted wire pairs and one group of three twisted wires. In this manner, wire-to-wire cross-talk is reduced.
[0009] By way of example, in an ultrasonic imaging catheter, the two wires that carry sensor signals from the ultrasonic imaging catheter may be grouped together and twisted closely together as a pair. As a result, cross-talk between the two wires is reduced, especially when compared to wire arrangements in which all of the wires are arranged in a single bundle. In addition, wires associated with ultrasonic drive signals also may be grouped together as a pair. Likewise, wires carrying power supply and clock signals (e.g., for use by multiplexer circuits at the catheter's distal end) may be grouped together as a pair.
[0010] The above examples are merely illustrative arrangements. According to the present invention, sensor catheters having varying signaling needs and signal wires will require different wire subgroup arrangements. The resulting wire subgroup arrangements may be twisted together to form a single wire group formed of multiple wire subgroups.
[0011] Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above and other objects and advantages of the present invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
[0013] [0013]FIG. 1 is a side view of a previously known sensor catheter system;
[0014] [0014]FIG. 2 is a side-sectional view of the previously known sensor catheter of FIG. 1;
[0015] [0015]FIG. 3 is a cross-sectional view of a previously known wire bundle for a sensor catheter;
[0016] [0016]FIG. 4 is cross-sectional view of a first embodiment of a wiring arrangement for a sensor catheter constructed in accordance with the principles of the present invention;
[0017] [0017]FIG. 5 is cross-sectional view of a second embodiment of a wiring arrangement for a sensor catheter constructed in accordance with the principles of the present invention; and
[0018] [0018]FIG. 6 is cross-sectional view of a third embodiment of a wiring arrangement for a sensor catheter of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Referring to FIG. 1, a previously known sensor catheter system 10 comprises catheter 12 including proximal end 12 a attached to processing equipment 14 and distal end 12 b including sensor assembly 16 comprising one or more sensors. By way of example, sensor assembly 16 may includes a temperature sensor, a pressure sensor, a pH sensor, a flow velocity sensor and/or a volumetric flow sensor for measuring temperature, pressure, pH, flow velocity and flow volume. Of course, sensor assembly 16 may include sensors other than those listed above.
[0020] Sensor assembly 16 also may include an imaging sensor, such as an ultrasound, magnetic resonance, optical coherence tomography or infrared imaging sensor. Imaging sensors are typically used to gather images from locations inside a patient's body during surgical and diagnostic procedures. Catheter 12 may be configured to gather images from inside a patient's blood vessels during percutaneous procedures such as cardiological or peripheral intervention. An illustrative catheter that may be used for ultrasound applications is described in commonly assigned U.S. patent application Ser. No. 10/233,870, filed Aug. 29, 2002.
[0021] Referring to FIG. 2, signals from sensor 16 are transmitted to and from processing equipment 14 via wire bundle 18 including a plurality of wires. Sensor assembly 16 may include an ultrasound sensor that transmits signals to processing equipment 14 , which processes the signal data and displays the resulting images on a suitable display screen. Alternatively, sensor assembly 16 may include other sensors that transmit different signals to the processing equipment.
[0022] Processing equipment 14 also transmits signals that control the operation of sensor assembly 16 . For example, if catheter 12 is an ultrasound imaging catheter, processing equipment 14 transmits drive signals for one or more transducer elements disposed within the sensor assembly. These drive signals cause the transducer elements to emit acoustic vibrations directed towards a target area within the patient's body.
[0023] Power supply signals and clock signals (e.g., for synchronizing the timing of circuitry within sensor assembly 16 ) also may be transmitted to sensor assembly 16 from processing equipment 14 via wire bundle 18 . In order to improve overall system performance, it is desirable to reduce cross-talk between the different wires, regardless of the type of signal being transmitted.
[0024] Referring now to FIG. 3, a previously known wiring arrangement 20 for a sensor catheter comprises a single wire bundle having six individual wires 20 a radially surrounding central wire 20 b. Wiring arrangement further comprises outer sheath 21 for retaining the wires 20 a and 20 b. This arrangement has the advantage of being relatively compact, but suffers from a relatively high degree of wire-to-wire cross-talk.
[0025] Referring to FIG. 4, a first embodiment of a wiring arrangement for sensor catheter 12 constructed in accordance with the principles of the present invention is described. Wiring arrangement 22 comprises first wire bundle 24 contained within sheath 25 , second wire bundle 26 contained within sheath 27 and tird wire bundle 28 contained within sheath 29 . First wire bundle 24 includes wires 24 a and 24 b, which are twisted together to assist in electrically isolating the wires from the environment, thereby reducing electromagnetic signal interference among the individual wires. Similarly, second wire bundle 26 includes wires 26 a and 26 b that are twisted together; third wire bundle 28 includes wires 28 a, 28 b and 28 c that are twisted together. All three wire bundles 24 , 26 and 28 are twisted together to form wiring arrangement 22 and housed within outer sheath 30 .
[0026] Referring to FIG. 5, a second embodiment of a wiring arrangement for sensor catheter 12 constructed in accordance with the principles of the present invention is described. Wiring arrangement 32 comprises first wire bundle 34 contained within sheath 35 , second wire bundle 36 contained within sheath 37 and third wire bundle 38 contained within sheath 39 . First wire bundle 34 includes wires 34 a and 34 b, which are twisted together to assist in electrically isolating the wires from the environment, thereby reducing electromagnetic signal interference among the individual wires. Similarly, second wire bundle 36 includes wires 36 a and 36 b that are twisted together; third wire bundle 38 includes wires 38 a, 38 b and 38 c that are twisted together. Unlike the embodiment of FIG. 4, wire bundles 34 , 36 and 38 of the embodiment of FIG. 5 are not twisted and retained within an outer sheath.
[0027] Referring to FIG. 6, a third embodiment of a wiring arrangement for sensor catheter 12 of the present invention is described. Wiring arrangement 42 comprises first wire bundle 44 contained within sheath 45 , second wire bundle 46 contained within sheath 47 and third wire bundle 48 contained within sheath 49 . The first pair of wires includes wires 44 a, 44 b and 44 c, which are twisted together to assist in electrically isolating the wires from the environment, thereby reducing electromagnetic signal interference among the individual wires. Similarly, second wire bundle 46 includes wires 46 a, 46 b and 46 c that are twisted together; third wire bundle 48 includes wires 48 a, 48 b and 48 c that are twisted together. All three wire bundles 44 , 46 and 48 are twisted together to form wiring arrangement 42 and contained within an outer sheath 50 .
[0028] Twisting the wires in the wire bundles has been observed to reduce electromagnetic interference among the wires. In some embodiments, the wires are twisted in a clockwise direction, while in others the wires may be twisted in a counter-clockwise direction. Alternatively, wires within different bundles may be twisted in different directions depending upon the application of the sensor catheter. Moreover, multiple wire bundles may be twisted together to form a single wire group. When forming a single wire group from multiple wire bundles, the direction of wire bundle twisting preferably is opposite to the direction in which individual wires are twisted when forming the multiple wire bundles.
[0029] The wiring arrangements of FIGS. 4-6 are merely illustrative. As would be appreciated by those of skill in the art, many different wiring arrangements are possible without departing from the scope of the present invention. For example, the wiring arrangement may include 2 or more wire bundles, each wire bundle including two or more individual wires.
[0030] Although preferred illustrative embodiments of the present invention are described above, it will be evident to one skilled in the art that various changes and modifications may be made without departing from the invention. It is intended in the appended claims to cover all such changes and modifications that fall within the true spirit and scope of the invention. | Improved wiring arrangements for sensor catheters are provided to reduce wire-to-wire cross-talk wherein wires connecting the sensor of the sensor catheter to a processing unit are divided into a plurality of wire bundles contained within respective sheaths, with the wires in wire bundle twisted together reduce electromagnetic signal interference among the individual wires, or between wire bundles. | 0 |
BACKGROUND OF THE INVENTION
[0001] Embodiments of the invention relate generally to steel construction systems and methods. More specifically, embodiments of the invention relate to construction systems and methods that employ steel and foam in place of wood, primarily for residential structures.
[0002] The residential construction industry is heavily dependent on materials and techniques that have been in use for many years. The industry as a whole is resistant to change and is, therefore, ripe for improvements. For example, many have attempted to incorporate steel into residential construction as a replacement for wood framing. Unfortunately, however, many issues have prevented widespread acceptance of steel framing.
[0003] Steel is generally more expensive than wood. Hence, a direct replacement of steel for wood, without regard to cost differences, would likely raise the price of a home to a unacceptable level given today's price differentials.
[0004] Another problem is that steel conducts heat and cold much better than wood, thus making insulating a home much more difficult. Further, the temperature differential between a steel stud in an exterior wall and temperature of the inside of a home can cause visible artifacts to appear on the interior drywall at the studs.
[0005] Yet another issue is that craft workers such as electricians and plumbers are less familiar with steel frame construction. As a result, their prices for working in such structures tend to be higher.
[0006] For these and other reasons, improved steel frame construction techniques and systems are needed.
BRIEF SUMMARY OF THE INVENTION
[0007] Embodiments of the invention provide a wall stud. The wall stud has a steel member having a generally rectangular cross-sectional shape and having at least first, second and third sides, the first and second sides being opposite one another. The wall stud also includes a first foam member having a generally rectangular cross-sectional shape. The first foam member is affixed to the first side of the steel member. The wall stud also includes a second foam member having a generally rectangular cross-sectional shape. The second foam member is affixed to the second side of the steel member. The wall stud also has a ridged cap affixed to a side of the first foam member opposite the steel member.
[0008] In some embodiments, the steel member is two-inch square tubular steel having a wall thickness in the range of 14 to 16 gauge. The first and second foam members may be two-inch square closed cell structural foam having a density in the range 6 to 8 pounds per cubic foot. The wall stud may include an adhesive material affixing the first foam member and the second foam member to the steel member. The ridged cap may include tabs that extend along opposite sides of the first foam member.
[0009] Still other embodiments provide a wall panel. The wall panel includes a top plate having a generally rectangular cross-sectional shape, a bottom plate having a generally rectangular cross-sectional shape, and a plurality of studs affixed in a generally parallel configuration between the top plate and the bottom plate thereby forming a generally planer frame. Each stud, the top plate, and the bottom plate include a steel member having a generally rectangular cross-sectional shape and having at least first, second and third sides. The first and second sides are opposite one another. Each stud, the top plate, and the bottom plate also include a first foam member having a generally rectangular cross-sectional shape. The first foam member is affixed to the first side of the steel member. Each stud, the top plate, and the bottom plate also include a second foam member having a generally rectangular cross-sectional shape. The second foam member is affixed to the second side of the steel member. Each stud, the top plate, and the bottom plate also include a ridged cap affixed to a side of the first foam member opposite the steel member.
[0010] In some embodiments, the steel members comprises two-inch square tubular steel having a wall thickness in the range of 14 to 16 gauge. The first and second foam members may be two-inch square closed cell structural foam having a density in the range 6 to 8 pounds per cubic foot. The wall panel may include an adhesive material affixing the first foam members and the second foam members to the steel members. The wall panel may include sheeting adjacent the second foam member of each stud, the top plate, and the bottom plate. The sheeting may be a closed-cell, structural foam material. The sheeting, the top plate, the bottom plate, and the plurality of studs may form one or more cavities, in which case the wall panel may include insulating foam disposed within the cavities. The insulating foam may be a closed cell, spray-on foam.
[0011] Still other embodiments provide a method of constructing a wall panel. The method includes assembling a generally planer steel frame. The frame includes a top plate having a generally rectangular cross-sectional shape and at least first, second, and third sides. The first and second sides may be opposite one another. The frame also includes a bottom plate having a generally rectangular cross-sectional shape and at least first, second, and third sides. The first and second sides being opposite one another and generally co-planer with the first and second sides of the top plate. The panel also includes a plurality of steel members affixed in a generally parallel configuration between the top plate and the bottom plate. Each steel member has a generally rectangular cross-sectional shape and at least first, second, and third sides. The first and second sides are opposite one another and co-planer with the first and second sides of the top plate and the bottom plate. The method also includes affixing first foam members having a generally rectangular cross-sectional shape to the first sides of the top plate, the bottom plate, and the steel members. The method further includes affixing second foam members having a generally rectangular cross-sectional shape to the second sides of the top plate, the bottom plate, and the steel members and affixing sheeting to the top plate, the bottom plate, and the steel members. The sheeting is disposed adjacent the second foam members to thereby form cavities together with the top plate, the bottom plate, the steel members, the first foam members, and the second foam members. The method further includes affixing a rigid cap to a side of each first foam member opposite each steel member to which each first foam member is affixed. The method also includes applying insulating foam into the cavities.
[0012] In some embodiments, some operations take place at a first location and others take place at a second location. The first location may be a production facility and the second location may be a job site, in which case the method may include transporting the panel at least 0.25 miles between the production facility and the job site. The first location may include a controllable environment. Affixing first foam members may include using adhesive to affix the first foam member to the steel member. Affixing a rigid cap may include using fasteners to affix the ridged cap to the first foam member by penetrating the first foam member and anchoring the fastener into the steel member. The steel members may be two-inch square tubular steel having a wall thickness in the range of 14 to 16 gauge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings wherein like reference numerals are used throughout the several drawings to refer to similar components. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
[0014] FIG. 1 illustrates an exploded view of a stud according to embodiments of the invention.
[0015] FIG. 2 illustrates a wall panel according to embodiments of the invention, which panel incorporates studs as illustrated in FIG. 1 .
[0016] FIG. 3 illustrates a method of fabricating a wall panel such as the wall panel of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0017] Embodiments of the invention provide improved steel frame construction techniques and systems. Some embodiments provide wall studs having a combination of foam and steel that may be used in place of wood studs. Other embodiments employ such studs in pre-fabricated panels. Still other embodiments provide methods for constructing with steel and foam using a combination of off-site prefabrication and onsite installation.
[0018] Although embodiments of the present invention will be described herein with respect to residential construction, those skilled in the art will appreciate that the embodiments described herein may be applied to commercial construction.
[0019] Attention is directed to FIG. 1 , which illustrates an exploded view of a stud 100 according to embodiments of the invention. The stud 100 includes a steel member 102 having an exterior foam member 104 fastened to one side and an interior foam member 106 fastened to the opposite side. The stud 100 may include an interior cap 108 and/or an exterior cap 110 . Either cap 108 , 110 may be fastened to the stud with fasteners 112 . As will be described in greater detail below, the stud components may be fastened using other means such as tape, glue, and/or the like. In a specific embodiment, only the interior cap 110 is used.
[0020] The steel member 102 may be any of a variety of steel products. In a specific embodiment, the steel member 102 is 16 gauge, two-inch square, tubular steel. Other embodiments employ different gauge steel (e.g., 14 gauge) and/or different size tube (e.g., 2″× 3 ″). Some embodiments employ “C-channel” and/or track steel instead of or in combination with tubular steel. In either case, the steel member 102 may be galvanized and/or otherwise coated. A coating system used in some embodiments is the GATORSHIELD® system, a product of the Mechanical Tube Division of Allied Tube and Conduit of Harvey, Ill. The steel member 102 may be specified to be oil free, which enhances the effectiveness of some adhesive fastening systems, as will be explained in more detail hereinafter.
[0021] The interior foam member 106 and the exterior foam member 104 are two square-inch, six-pound, closed cell, structural foam strips in some embodiments. In other embodiments, eight-pound structural foam is used. In a specific embodiment the foam is LAST-A-FOAM® foam, a product of the General Plastics Manufacturing Company of Tacoma, Wash. The foam may be cut into strips from larger sheets. Other types and sizes of foam may be used. In some embodiments, the foam members 104 , 106 are made of a fireproof or fire resistant material. Either or both the interior foam member 106 and the exterior foam member 104 may be notched as shown. Notches 114 may be spaced at intervals such as 24″ to thereby improve the efficiency with which utilities may be installed in the final structure.
[0022] The exterior cap 110 (if used) and interior cap 108 are 25 gauge steel sheeting (i.e., sheet metal), which may be galvanized and specified to be oil free. Other sizes, generally in the range of 22-25 gauge, may be used. Other materials may be used, such as wood, fiberglass, and other, generally ridged materials. The caps 108 , 110 may be bent such that a tab 116 extends on either side of the foam members 104 , 106 . The tabs 116 may be, for example, three-eights inches, three-quarter inches, or the like. The tabs 116 provide a fastening point for utility items such as electrical boxes while the cap itself serves as a secure attachment point for dry wall, foam, OSD, or other interior or exterior sheeting.
[0023] The foam members 104 , 106 may be attached to the steel member 102 using tape, glue, or any acceptable adhesive (not shown) in some embodiments. In a specific embodiment, the foam members 104 , 106 are fastened to the steel member 102 using an adhesive transfer tape, such as 3M™ 6035. The caps 108 , 110 may be attached to the foam members 104 , 106 using a similar product. In some embodiments, fasteners 112 are used to secure the caps 108 , 110 to the steel member 102 . The fasteners 112 penetrate the foam members 104 , 106 and penetrate the steel member 102 , thereby securing the entire assembly. The fasteners may be, for example, grade 5 or better, galvanized, self-taping screws.
[0024] It should be appreciated that steel studs according to other embodiments do not necessarily include all the components illustrated and described here, as will be appreciated by those skilled in the art. Further, the stud 102 need not be fully assembled as shown before being integrated with other building materials as will become clear from the ensuing description of a wall panel 200 made using a plurality of steel studs such as the stud 102 .
[0025] As will be described in more detail hereinafter, exterior sheeting 118 may be applied to the completed stud.
[0026] Having described a stud 102 according to embodiments of the invention, attention is directed to FIGS. 2 and 3 which together illustrate and describe a wall panel 200 and a method of constructing one. The wall panel incorporates steel studs according to embodiments of the invention. For purposes of this description, the studs comprised by the wall panel 200 are the studs 102 , although other embodiments of panels according to the present invention may incorporate different steel stud embodiments.
[0027] FIG. 3 depicts a method 300 of constructing a wall panel and incorporating it into a structure according to embodiments of the invention. Those skilled in the art will appreciate that other embodiments of methods according to the present invention may include more, few, or different steps than those illustrated and described here. Further, the steps illustrated and described here may be traversed in different orders than depicted here.
[0028] The method 300 begins at block 302 at which point a steel frame 202 is assembled. Typically, steel members 204 are welded on two-foot centers to top 206 and bottom 208 plates of the same tubular steel material. Window openings 210 and doorway openings 212 are framed at this time. In some embodiments, this step takes place at a pre-fabrication facility in a controlled environment. To accommodate this construction methodology, the panel 200 is sized appropriately for transportation to the job site.
[0029] At block 304 , exterior foam members ( 104 from FIG. 1 ) are fastened to the steel members 204 using an adhesive system as previously described. The adhesive system may be glue, double-stick tape, and/or the like. In a specific embodiment, the adhesive is applied from a carrier that is rolled like tape. As the carrier is unrolled, a sticky surface is exposed that is applied to one of the surfaces (e.g., the steel members 204 ). Thereafter, the carrier is removed, thus exposing the second sticky surface to which the other surface (e.g., a foam member 104 ) is adhered. Having specified the steel components to be oil free improves the adherence properties of such adhesive systems. In some embodiments, pressure is mechanically applied to the assembly to improve the adherence of the foam members to the steel members 204 . The foam members typically are fastened to both vertical and horizontal steel members 204 .
[0030] At block 306 , exterior sheeting ( 118 from FIG. 1 ) is fastened to the panel 200 . The exterior sheeting may be OSB, hardboard, structural foam, DENSGLASS™, or other appropriate material. In a specific embodiment, the exterior sheeting is ten-pound, closed cell, foam and may be either structural or not. In some embodiments, the exterior sheeting is fireproof or fire resistant. The exterior sheeting may be glued, taped, or the like, and/or secured with mechanical fasteners (not shown). The sheeting may be installed without removing portions for doorway 212 and/or window openings 210 .
[0031] In some embodiments, insulating foam 218 is applied to the panel cavities 220 at block 308 . In addition to providing greater structural support, the foam enhances the insulating properties of the wall panel. For example, some embodiments have an R-8 per square inch rating and 3# density. The insulating foam 218 may be, for example, a two-part polyurethane foam such as those distributed by USCS of Phoenix, Ariz., or other appropriate foam material. In some embodiments, the insulating foam 218 is fireproof or fire resistant. The insulating foam 218 need not completely fill the panel cavities 220 . In some embodiments, the insulating foam 218 is not applied until the panel 200 is further along in the assembly process and, in some cases, is not applied until the panel 200 is erected at the job site.
[0032] In some embodiments, adhesive (not shown), if used, is applied to the interior side of the steel members 204 at block 310 . In other embodiments, this operation is not performed until the panel 200 is erected at the job site.
[0033] At block 312 , the panel 200 is shipped to the job site. Typically, several panels are shipped simultaneously. At block 314 , the panel is used along with other panels to assemble a structure. Panels 200 may be fastened together using screws, bolts or other mechanical fasteners. In some embodiments, the panels are welded together to form the structure. As is apparent, the panels may be assembled at other points in the process.
[0034] At block 316 , notched, interior foam members ( 106 from FIG. 1 ) are attached to the steel members 204 . The interior foam members may be attached as previously described using glue, tape, or other appropriate adhesive material. In embodiments wherein an adhesive material was applied at block 310 , a backing may be removed so that the interior foam members may be attached. The interior foam members typically are attached to both horizontal and vertical steel members 204 .
[0035] At block 318 , interior steel caps ( 108 from FIG. 1 ) are attached to the interior foam members. The interior steel caps may be attached using tape, glue, and/or other appropriate adhesive. In some embodiments, the caps are also or alternatively fastened using fasteners ( 112 from FIG. 1 ) that penetrate the interior foam members 220 and screw into the steel members 204 .
[0036] It should be noted that blocks 316 and 318 may be iteratively completed. In other words, it is not necessary that all interior foam members 220 be fastened to the panel 200 before any caps 222 are attached. In fact, as previously mentioned, the steps illustrated and described here may be completed in any of a variety of orders.
[0037] Is should also be noted that the insulating foam may be applied at any point in the process, either before or after the panel is shipped to the job site. Likewise, the sheeting covering the window openings 210 and doorways 212 may be removed at most any time, either before or after the panel 200 is shipped to the job site.
[0038] It should also be noted that the references to “interior” and “exterior” herein need not import meaning into the final orientation of the panel with respect to the inside and outside of a structure. In some embodiments, the side referred to herein as “interior” may in fact be oriented toward the exterior of the structure. Likewise with the term “exterior.” Further, a panel may be used on the interior of a structure, in which case the terms have no relevance to the finale orientation of the panel with respect to the interior and exterior of the structure.
[0039] The panels 200 may be placed on any appropriate foundation material, including concrete, structural foam footings, OSB floor sheeting, and/or the like. In some embodiments, steel floor and/or roof truss systems are employed to complete a structure that is essentially free of wood products. In some embodiments, similar panels are used in basement wall applications. In such applications, portions of the panel, especially buried exterior portions, may be coated with a material that prevents moisture intrusion. An exemplary coating is NITROCOAT 2595, a two-part coating product from UCSC or Phoenix, Ariz. Further still, in some embodiments, panels may include an orthogonal member for placement below grade to serve as a footing.
[0040] Having described several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the invention. Additionally, a number of well known processes and elements have not been described in order to avoid unnecessarily obscuring the present invention. Accordingly, the above description should not be taken as limiting the scope of the invention, which is defined in the following claims. | A wall stud includes a steel member having a generally rectangular cross-sectional shape and having at least first, second and third sides, the first and second sides being opposite one another. The wall stud also includes a first foam member having a generally rectangular cross-sectional shape. The first foam member is affixed to the first side of the steel member. The wall stud also includes a second foam member having a generally rectangular cross-sectional shape. The second foam member is affixed to the second side of the steel member. The wall stud also has a ridged cap affixed to a side of the first foam member opposite the steel member. | 4 |
FIELD
[0001] The present disclosure is related to voltage sensing and regulation in power gated CPU's. More specifically, a system and method for voltage sensing at the active power gated CPU cores is disclosed.
BACKGROUND
[0002] Voltage sensing and regulation become more complicated in a gated system. Power gating effectively closes off the leakage current path for CPU cores which are not active. In a power gated configuration, current travels into the CPU silicon at the power gate Controlled Collapse Chip Connection bumps (C4 bumps) on the ungated side, through power gating transistors, and into a gated power domain on the chip and package substrate. If the core's power gates are on, a conducting path exists between the ungated voltage domain and the gated domain. If the power gates are off, the gated CPU is isolated from the ungated supply.
[0003] Multi core systems make use of power gating to reduce leakage power on inactive cores, and utilize that power for faster and more efficient operation of the active cores. Any core may go into an inactive state and be gated, in which its voltage supply is cut off by the power gates, and the on core voltage will decay to 0V. In that state, the remaining active cores must be supplied with an appropriate voltage level.
[0004] Voltage sensing may be conducted through on die structures located in a variety of locations throughout the cores. An integrated on die regulator senses these locations and uses a digital algorithm to determine the correct regulation voltage. Power gating does not present a problem for this configuration, since the on die voltage regulator controller is able to logically determine the voltages to sense and those to ignore if power gating is enabled for some of the cores.
[0005] However, in most instances external VR11 operation may be desired. In this case, a voltage sense line from the die is routed to the regulator to monitor the voltage and use it for regulatory feedback. Complications arise when the voltage at any gated core could fall to 0V, while other cores need a stable voltage supply. The voltage regulator needs to somehow ignore the voltage at cores with power gates turned off, while continuing to monitor and adjust to voltage changes at the active cores.
[0006] Sensing the voltage upstream in the package ungated region is undesirable because the gated voltage is separated from this domain by package power routing, the power gates themselves, and any other parasitic impedance between the power gates and the core transistors. These series elements in the power path could account for up to 20-30 mV of voltage difference between the regulation point and the true core voltage. The loss in sensing accuracy of 2-4 MHz per mV is a problem which calls for an as yet unavailable means for voltage sensing at each core, which is able to comprehend the gating states to disable sensing at the gated cores.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic representation of the voltage domains on package and silicon for a typical power gated system according to the disclosure;
[0008] FIG. 2 is a circuit diagram of a power supply pathway and sensing network for a power gated system according to the disclosure using an off die voltage regulator controller;
[0009] FIG. 3 is a side view of a CPU mounting assembly according to the disclosure;
[0010] FIG. 4 is a power flow block diagram for the CPU of FIG. 3 ; and
[0011] FIG. 5 is a diagram of the power gate transistors for the CPU of FIG. 3 , having one pair of C4 bumps isolated for voltage sensing.
[0012] Although the following Detailed Description will proceed with reference being made to these illustrative embodiments, many alternatives, modifications, and variations thereof will be apparent to those skilled in the art. Accordingly, it is intended that the claimed subject matter be viewed broadly.
DETAILED DESCRIPTION
[0013] The disclosure of FIGS. 1 through 5 provides a power gated system 100 and method, with only a package substrate change, to enable voltage sensing at a point 162 in the active CPU cores for providing correct voltage regulation. Referring to FIG. 1 , Region A is the package substrate 102 . Region B is the Silicon Footprint 110 for a CPU having N cores, including Core- 1 106 A, Core- 2 106 B, Core- 3 106 C and so on, through Core-N 106 N. Region C is the ungated power region 108 , and Region D is the power gating region 104 for the CPU. In order to sense the voltages of the active cores of 106 A- 106 N and average them to provide an accurate regulation voltage, the power gates of Region D may be used along with a ‘wired OR’ in the package.
[0014] FIG. 2 shows the schematic for the sensing circuit 130 , along with the standard core current pathway 134 through the power gates 124 A to 124 N. FIG. 3 shows the mounting of CPU 152 of the disclosure to a typical CPU socket 154 of a typical motherboard 156 . The power gates 124 A- 124 N are shown as single devices for each gated power domain 110 , but are actually parallel sets of hundreds of devices to provide low resistance to current traveling through them. Current from the platform voltage regulator 150 enters the CPU silicon 152 through the ungated power supply section 108 .
[0015] Depending on the activity state of the cores 106 A through 106 D in the CPU, all, some, or none of the power gating transistors 124 A to 124 D will be in an on state and conducting current. For those power gates 124 A to 124 D that are conducting, current will flow through the power gate transistors in region 104 , and into the gated regions 106 A to 106 D to power the transistors on the chip. If a power gate 124 A for a core is on, the gated power domain 106 A must be regulated to a specified voltage to ensure functionality of the core. If a power gate 124 N is off, its corresponding gated power domain will fall to zero volts. Power gates which are in the on state may observe and regulate the voltage of the cores which are active. If a power gate is off, its power domain may be ignored, since a zero voltage may corrupt the correct sensing voltage for regulation.
[0016] FIG. 5 shows the isolation of one C4 bump pair ( 112 Ain/ 112 Aout) for voltage sensing, in the power gating of the disclosed CPU 152 of M bump pairs, 112 A through 112 M. Current enters the bump pairs 112 from ungated power region 108 region and exits though gated region 110 . To ensure that only the gated power domains in the on state are sensed, and to maintain design simplicity, one power gate 124 A per core may be allocated, or “sacrificed”, to a sensing pathway 160 . The power gates 124 A to 124 N are groupings of many parallel transistors that operate in unison. In the Bloomfield CPU design, there are approximately 150 individual pathways making up each power gate transistor represented in 124 A to 124 N. By isolating one power gating transistor 124 A from each group of 124 A to 124 N, and routing a sense line 160 through it, the problem of sensing only on state gated power domains is solved. If the power gate 124 A is turned off, the sensing voltage does not pass through the power gate. If the power gate 124 A is turned on, it passes the correct voltage from the gated power domain through the power gate.
[0017] A single C4 bump 112 A in the ungated region 108 and a single C4 bump 112 A in the gated region 110 for each core are sacrificed for voltage sensing and are designated as the voltage sense bump pair 112 A. The designated sense bump pair is no longer available as a current providing pathway, and is isolated from the ungated power region 108 in the package 152 and on silicon power bussing. Substrate level isolation allows the bump voltage at pair 112 A to be observed with no significant current passing through it. With no substantial current passing through bump pair 112 A and its associated power gating transistor 124 A, the true core voltage is observable at the sensing point 162 of system 100 .
[0018] Depending on design requirements, the voltage sensing point may be at C4 bump 112 A, or more commonly at an alternate location in the gated region 110 connected to C4 bump 112 A through a trace. Package traces 118 are routed from each of the designated sensing bumps 112 A for each core to a central point 162 in the package gating region 110 , and out of the package/socket through a merged trace 122 . The merging of the traces provides an adequate averaging function, so that the average voltage of active cores is observed. By averaging through merging, the regulation voltage will be appropriate for the loaded core and the unloaded core. The merged trace is routed to a high impedance amplifier input contained in voltage regulator 150 . The high impedance input implies that no significant current will flow through the sense line.
[0019] When one or more of the power gates 124 A through 124 N turn off to isolate an inactive core, co-functioning sacrificial gates 132 A through 132 N simultaneously cut off the sense bump voltage connection into the inactive core. This provides that only the active cores are monitored for voltage regulation. Sacrificing a single pair of C4 power bumps and converting them to dedicated sense bumps eliminates the need for added die complexity to facilitate the voltage sensing on gated/ungated cores.
[0020] Design simplicity is a key benefit of this invention. The necessary structures already exist on the power gated die to provide this capability. The package substrate is the simplest element to change in order to enable the off chip sensing capability. The sacrifice of the one C4 bump 112 for sensing in a 4-core package only reduces that path width by 0.6%, which is acceptable.
[0021] Providing a unified sensing mechanism at the socket level allows a well established and trusted voltage regulation technologies, such as VR11 to support the CPU. Otherwise, a typical on die regulator controller may be used for validation. But, when such an on die controller is nonfunctional or less than fully functional, the validation of the entire CPU may be at risk.
[0022] By implementing this simple package change, the system designer is able to regulate to the correct core voltage, and is freed from a requirement to determine the activity states of each core.
[0023] It should be understood that the above disclosures are merely representative and that there are many possible embodiments for the present invention, and that the scope of the invention should only be limited according to the following claims made thereto. | A system and method for voltage sensing at active power gated cores of a multi core CPU wherein a Controlled Collapse Chip Carrier bump in a gating region for an associated core is isolatable from an ungated power region by a power gate to allow voltage sensing at a designated location with substantially no current passing there through. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Patent Application Ser. No. 61/229,838, filed Jul. 30, 2009.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to the manufacture of light weight parts for assembly with other parts. Such parts are frequently used in airplanes and vehicles.
[0004] 2. Background Art
[0005] British Patent 686,428 issued in 1954 discloses riveting strips of steel sheet metal to elongated aluminum-magnesium alloy profiled bearers. Steel sheet metal is welded to the strips of steel sheet metal.
[0006] Mellis et al., U.S. Patent Application Publication No. 2007/0271793, published Nov. 29, 2007 discloses a suspension arm for use in a vehicle, in which a coupling for assembling the arm to other components of the vehicle is attached to a tubular member made of steel, aluminum or the like, using a cast-in-place technique, rather than conventional welding.
SUMMARY OF THE INVENTION
[0007] In the present invention, a light weight alloy part is molded in a mold containing at least one weldable metal insert, so that portions of portions of the alloy part lap portions of the insert to securely lock said weldable insert to the light weight alloy part. The resulting hybrid part is thus both light weight and weldable to other assemblies and sub-assemblies.
[0008] These and other objects, advantages and features of the invention will be more fully understood and appreciated by reference to the written specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective and relatively close-up view of a known steering column support bracket, with the bracket being stamped and MIG-welded to the tubular member of an instrument panel frame;
[0010] FIG. 2 is a perspective view of an embodiment of a hybrid assembly consisting of a steel instrument panel frame and steering column support bracket comprising a magnesium-casted part and a steel insert assembly;
[0011] FIG. 3 is a perspective view of the steering column support bracket illustrated in FIG. 2 ;
[0012] FIG. 4 is a perspective view of the steering column support bracket shown in FIG. 2 , and illustrating the location of the holes or forms within the steel stampings positioned below the magnesium line;
[0013] FIG. 5 is a perspective view showing the separate components of the steel inserts of the steel stampings of the steering column support bracket; and
[0014] FIG. 6 is a perspective and stand-alone view of the magnesium-casted component of the steering column support bracket.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The principles of a preferred embodiment are disclosed, by way of example, in a vehicle part 200 as described herein and illustrated in FIGS. 2-6 . The vehicle part 200 includes components comprised of steel and of magnesium, with the use of magnesium facilitating a relative reduction in weight. The structure of the vehicle part 200 and preferred processes for manufacturing the vehicle part 200 permit the use of welding processes, although magnesium components are known to be essentially unweldable to other parts.
[0016] FIG. 1 illustrates a known vehicle part 100 . The known vehicle part 100 can be characterized as an instrument panel reinforcement frame with a steering column support bracket. More specifically, the vehicle part 100 includes an instrument panel reinforcement frame or main frame 102 having a configuration as shown in part in FIG. 1 . A greater portion of the main frame 102 is illustrated in FIG. 2 as frame 202 , which incorporates the preferred embodiment and will be described in subsequent paragraphs herein. The main frame 102 includes a tubular member 104 which extends across the entirety of the upper portion of the main frame 102 .
[0017] Secured to the tubular member 104 of the main frame 102 is a steering column support bracket 106 . The known steering column support bracket 106 includes an upper or top plate 108 having a substantially rectangular configuration as illustrated in FIG. 1 . Extending downwardly from opposing sides of the upper plate 108 are a pair of downwardly extending flanges 110 . The downwardly extending flanges 110 can be integral with or otherwise secured to a pair of webs 112 . In turn, the webs 112 , at their edges opposing the edges adjacent the downwardly extending flanges 110 , are coupled to or are integral with a pair of wings 114 . For purposes of mating the steering column support bracket 106 to the tubular member 104 , the downwardly extending flanges 110 each include an arcuate cut 116 having a shape conforming to the curvature of the outer surface of the tubular member 104 . In addition, each of the wings 114 also includes an edge having an arcuate cut 118 . Again, the arcuate cuts 118 are shaped to as to conform to the curvature of the tubular member 104 . With the arcuate cuts 116 , 118 , the elements of the steering column support bracket 106 securely mate with the tubular member 104 of the main frame 102 . FIG. 1 also illustrates a pair of bolts 122 which can be used to secure the steering column support bracket 106 to other components of the steering column itself.
[0018] For purposes of securing the steering support bracket 106 to the tubular member 104 , the support bracket 106 can be directly welded to the tubular member 104 , through MIG welding and resistance welding processes. Weld lines for the support bracket 106 and the tubular member 104 are shown as lines 120 in FIG. 1 .
[0019] As previously described, the known vehicle part 100 includes the steering bracket support column 106 which is comprised of steel or steel alloys, and which are of relatively substantial weight. To reduce the weight and still permit the use of welding processes to secure a support bracket to a main frame in the manufacture of the vehicle part, the preferred embodiment 200 illustrated in FIGS. 2-6 provides for a relatively lighter weight steering column support bracket, while still permitting the use of welding processes in the manufacture of the entirety of the vehicle part.
[0020] The preferred embodiment comprised of the vehicle part 200 is specifically shown in FIGS. 2-6 . As apparent from subsequent description, a number of the components of the vehicle part 200 correspond to the components of the vehicle part 100 with respect to the main frame. In fact, one of the advantages of the preferred embodiment is the addition of a relatively lighter weight magnesium part into the assembly of the steering column support bracket and main frame, without substantial modification to the assembly process. That is, the steering column support bracket in accordance with the preferred embodiment will still be MIG welded to components of the main frame.
[0021] More specifically, and with respect to FIGS. 2-6 , the vehicle part 200 includes a main frame 202 , shown substantially in its entirety in FIG. 2 . The main frame 202 , in this particular embodiment, is shown as an instrument panel reinforcement frame. However, it should be emphasized that numerous parts can be manufactured in accordance with processes associated with the preferred embodiment, other than the specific main frame and steering column support bracket described herein.
[0022] The main frame 202 includes a tubular member 204 extending substantially along the entirety of the length of the main frame 202 . Secured to the tubular member 204 of the main frame 202 , through welding processes, is a steering column support bracket 206 . The steering column support bracket 206 , when assembled with the main frame 202 , performs the same functions as the steering column support bracket 106 previously described with respect to the vehicle part 100 . However, unlike the steering column support bracket 106 , the steering column support bracket 206 of the preferred embodiment comprises a magnesium part 208 which is molded to weldable steel inserts 210 . The magnesium part 208 is shown in a perspective and stand-alone configuration in FIG. 6 . In accordance with the preferred embodiment, the magnesium part 208 is of a relatively lighter weight than steel components, and is the principle part of the assembly, the weldable steel inserts being smaller. Yet, the weldable steel inserts are sufficiently large as to space the magnesium part 208 sufficiently far from the welder to avoid igniting the magnesium during the welding process.
[0023] In addition to the magnesium part 208 , the steering column support bracket 206 also includes steel inserts 210 . The steel inserts 210 are also shown in a perspective and stand-alone configuration in FIG. 5 . As illustrated therein, the steel inserts 210 can include three inserts. The inserts are shown as center insert 212 and a pair of opposing side inserts 214 .
[0024] With respect to the center insert 212 , and as shown particularly in FIGS. 3 , 4 and 5 , the insert 212 includes a substantially rectangular top plate 216 . A pair of extending flanges 218 extend downwardly from the top plate on opposing sides thereof. The downwardly extending flanges 218 each include an arcuate cut 220 having a shape and configuration as primarily shown in FIG. 5 . The shape and configuration of the arcuate cut 220 will conform to the curvature of the tubular member 204 for purposes of mating the components together.
[0025] Turning to the side inserts 214 , each side insert 214 is comprised of an outwardly extending steel wing 222 . The steel wings 222 are shown in detail primarily in FIG. 5 . Each of the outwardly extending steel wings 222 includes a downwardly extending flange 224 . Each downwardly extending flange 224 includes an arcuate cut 226 . The arcuate cuts 226 , as with the arcuate cuts 220 , are also shaped so as to conform to the curvature of the tubular member 204 . In addition, and as will be apparent from subsequent description herein, the shape and configuration of the downwardly extending flanges 218 and 224 will conform to shapes and configurations of elements of the magnesium part 208 described subsequently herein.
[0026] Reference is now made to FIGS. 4 and 5 , showing the elements of the steel inserts 210 . As shown therein, the center insert 212 and side inserts 214 all include a series of holes 228 positioned at various locations on the inserts 210 . More specifically, and primarily with reference to FIG. 5 , three holes 228 are shown within the top plate 216 . A pair of holes 228 are shown in a top portion of each of the outwardly extending steel wings 222 . Further, holes 228 are positioned through the downwardly extended flanges 218 of the center insert 212 , and the downwardly extending flanges 224 of the side inserts 214 . In manufacture of the vehicle part 200 , the holes 15 will allow molten magnesium to flow from one side of a steel insert 210 to the other side thereof. When the magnesium hardens, the hardening action will serve to lock the steel inserts 210 in place, with respect to the magnesium part 208 . Without this locking function, the magnesium, in view of its properties, would not bond to the steel of the steel inserts 210 to any significant degree.
[0027] Reference is now made primarily to FIG. 6 , showing a stand-alone configuration of the magnesium part 208 . The magnesium part 208 includes, in this particular embodiment, a center portion 230 and a series of plates 232 at various angled configurations relative to one another. Positioned outwardly relative to the center portion 230 are a pair of extending members 234 , which extend from a front to a rear of the steering column support bracket 206 . Each of the extending members 234 includes an inner and downwardly extending flange 236 which can be integral with the sides of the plates 232 . At the bottom of the inner downwardly extending flanges 236 is a lower section 238 which can be positioned substantially at a right angle with respect to the corresponding flange 236 . Positioned on the lower sections 238 are a set of strengthening ribs 240 which extend from the front to the rear of the magnesium part 208 . A series of webs 242 , again for strengthening purposes, are positioned transversely across the ribs 240 . Extending upwardly from the lower sections 238 are a pair of outer flanges 244 . The magnesium part 208 can also include a set of formed bushings 246 , for purposes of receiving connecting components for securing the steering column support bracket 206 to other components of the steering column.
[0028] FIG. 3 illustrates a stand-alone, perspective view of the entirety of the steering column support bracket 206 , specifically showing the magnesium part 208 and the steel inserts 210 . The steel inserts 210 can be formed through conventional stamping processes. The magnesium part 208 can be formed as a casting through injection molding processes. During the molding processes, the steel inserts 210 , appropriately positioned with respect to the magnesium part molding configuration, are insert molded and over-molded.
[0029] To appropriately secure the steel inserts 210 to the magnesium part 208 , the previously described holes 228 are positioned relative to the mold for the magnesium part 208 , so that the holes 228 in the top plate 216 and in the upper portions of the outwardly extending steel wings 222 are located below the center portion 230 and the outwardly extending wings 248 of the magnesium part 208 . When in these positions, and also with respect to the holes 228 located in the flanges 218 and 224 of the steel inserts 210 , the holes 228 will permit molten magnesium injected into the mold to flow from one side of each of the steel inserts 210 to the other side. When the molten magnesium hardens, the resultant steering column support bracket 206 will have the configuration as particularly shown in FIGS. 3 and 4 . As apparent from the relative positioning of the steel inserts 10 and the magnesium part 208 as shown in these drawings, the steel inserts 210 are essentially locked in place relative to the magnesium part 208 . This function permits the steel inserts 214 to be coupled to the magnesium part 208 , without any use of welding or other connecting processes which are difficult to achieve with magnesium and similar metals.
[0030] In addition to the advantageous functions of the holes 228 , another aspect of the preferred embodiment for the vertical part 200 is the use of a series of beads 250 . The beads 250 are particularly shown in FIGS. 3 and 5 and are located on the steel inserts 210 . More specifically, the beads 250 can be characterized as being located at each position where there is a junction between a portion of the magnesium part 208 and a portion of the steel inserts 210 of the support bracket 206 . When the steel inserts 210 are positioned in the injection mold, and the molten magnesium is injected into the mold, the beads 250 serve to substantially prevent any molten magnesium from covering surfaces of the steel inserts which need to be exposed for purposes of facilitating welding of the steel inserts to the tubular member 204 .
[0031] Certain other aspects of the preferred embodiment and other embodiments can also be described. With respect to the holes 228 , it should be noted that the holes 228 can take other shapes and configurations within the steel inserts 210 . Of primary importance is that the holes or other formations in the steel inserts are positioned below what could be characterized as the “magnesium line” so as to allow the magnesium to flow through the holes or other formations during the molding stage, for purposes of effectively locking the steel inserts 210 to the magnesium part 208 .
[0032] With the steel inserts 210 forming part of the steering column support bracket 206 , the support bracket 206 can still be welded to the tubular member 204 or other components of the main frame 202 . That is, although the preferred embodiment advantageously utilizes a magnesium part 208 for the support bracket 206 , the use of the steel inserts 210 still provide the capability of welding (such as by MIG welding or resistance welding) the bracket 206 to the main frame 202 . Accordingly, the general process of assembling the steering column support bracket 206 to the main frame 202 is not substantially changed in that the bracket 206 is still welded to the tubular member 204 .
[0033] It is also possible to achieve the advantages of the embodiment, while having a differing relative configuration of the steel inserts 210 and the magnesium part 208 . For example, at least part of the steel inserts 210 could be positioned in other locations relative to the magnesium part 208 and the entirety of the support bracket 206 . That is, at least part of the steel inserts 210 could be positioned in the middle of the entirety of the support bracket 206 , with openings positioned within the magnesium part 208 . Such a configuration would allow for the capability of more extensive welding positions.
[0034] The steel utilized for the steel inserts 210 can be one of a number of variations. For example, it is believed that any 1008-1020 hot rolled, cold rolled or plate steel may be utilized for the steel inserts 210 . It may also be possible to utilize aluminum. However, a potential difficulty with the use of aluminum is that distortion must be avoided.
[0035] Also, it should be emphasized that the preferred embodiment described herein is directed specifically to a main frame 202 and steering column support bracket 206 . It is clear from the foregoing description that the advantageous processes associated with the preferred embodiment may be used for various types of structural components, in vehicles and for other purposes.
[0036] It will be apparent to those skilled in the pertinent arts that other embodiments of hybrid parts and processes associated with manufacture thereof can be designed. That is, the principles of hybrid parts and processes for manufacture are not limited to the specific embodiment described herein. Accordingly, it will be apparent to those skilled in the art that modifications and other variations of the above-described illustrative embodiment may be effected without departing from the spirit and scope of the novel concepts of the embodiment. | A light weight alloy part is molded in a mold containing at least one weldable metal insert, so that portions of portions of the alloy part lap portions of the insert to securely lock the weldable insert to the light weight alloy part. The resulting hybrid part is thus both light weight and weldable to other assemblies and sub-assemblies. | 1 |
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