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The present application claims the benefit of U. S. Provisional Application Serial No. 60/188,967, filed Mar. 10, 2000, which application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to implantable electronic and electrochemical medical devices and systems, and more particularly to a movable contact locking connector system for use with such devices and systems. Such connector system provides easy lead insertion, a reliable means to retain an in-line lead in a connector and ensures effective electrical connection between lead and connector contacts. The connector system provides these features through a simple design avoiding complexity.
Implantable electronic medical devices and systems have been in use for the past 20 years or more. One of the earliest implantable medical devices to be implanted in a patient was the cardiac pacemaker. Other implantable electronic devices have included neurostimulators, i.e., electrical stimulators designed to stimulate nerves or other tissue, sensors for sensing various physiological parameters or physical status of a patient, and therapeutic-delivery devices, e.g., pumps for delivering controlled amounts of medication. In more recent years, a tiny implantable cochlear stimulator has been developed that allows patients who are profoundly deaf to experience the sensation of hearing. Other tiny implantable sensors and neuro-stimulators are under development that will enhance the ability of a patient who is a recipient of such sensors or stimulators to walk, or to see, or to experience the use of other lost or impaired body functions.
Most of the implantable medical devices and systems described above require that at least one electrical lead be connected thereto in order for the device or system to perform its intended function. Such lead typically includes a plurality of insulated conductors, or wires, through which electrical signals may be delivered or sensed. At an end distal from an implantable electronic device, each of the insulated conductors usually terminates in one or more electrodes designed to be in contact with body tissue. A Spinal Cord Stimulation (SCS) system, for example, has an electrode array adapted for insertion into the spinal column of the patient. Such electrode array typically employs a multiplicity of electrode contacts, each of which must be individually electrically connected to the pulse generator circuitry housed within an Implantable Pulse Generator (IPG). The lead associated with such spinal cord stimulator thus carries the individual conductors that electrically connect the respective electrodes, to the implantable pulse generator, thus making up the spinal cord stimulation system.
In-line leads are often chosen to connect an electrode array to an implantable electronic device. The contacts of an in-line lead are spaced-apart rings on one or more ends of the lead. An important benefit of such in-line lead is that when the lead is used with a ring type electrode array of similar diameter, the lead and array combination may be inserted into a patient's spinal column using a large gauge needle. However, the use of a lead with such in-line male connector with a simple push-in female connector is limited by the ability to push the lead into a female connector passageway. The problem of in-line lead insertion has been addressed by U.S. Pat. No. 5,843,141 issued Dec. 1, 1998 for “Medical Lead Connector System.” The '141 patent uses a tool to pull the lead end into the connector. However, the requirement to provide good electrical contact between the contacts on the lead and the contacts in the connector, and the need to provide a means for retaining the lead in the connector once inserted, work against easy insertion, and results in a requirement that the lead be sufficiently strong to resist tearing or stretching during insertion and extraction. Damaging a lead during the implanting or replacement of an implantable electronic device increases the complexity and medical risks associated with the required surgery. But, adding strengthening structure to the lead may be difficult and result in undesirable stiffening of the section of the lead where the lead exits the connector. What is therefore needed is an improved in-line connector system that allows easy insertion of an in-line lead into a connector, good retention of the lead once inserted, and reliable contact between the lead's contacts and the connector's contacts. Further, it is desirable that an improved in-line connector system, having these qualities, not compromise the beneficial properties which the lead would otherwise have.
SUMMARY OF THE INVENTION
The present invention addresses the above and other needs by providing a connector system with spaced-apart moveable contacts in the connector, and means for forcing the moveable connector contacts downward against spaced-apart lead contacts (for the purposes of this description, downward means toward the lead contacts, however, in actual use the connector may be arbitrarily rotated). The connector system may be integrated into the housing of an implanted device for the connection of a lead to the device. Advantageously, the connector system provides easy lead insertion, positive lead retention, and reliable electrical contact, without complexity.
In accordance with one aspect of the invention, there is provided a connector system including one or more spaced-apart moveable contacts in a connector, one or more spaced-apart lead contacts on an end of an in-line lead, and a means for applying downward force against the moveable contacts. When a lead in inserted fully into the connector passageway, the downward force causes the moveable contacts to move from a first position, wherein the moveable contacts are not pressing against the lead contacts, to a second position, wherein the moveable contacts are pressing against the lead contacts. When the movable contacts are in the second position, sufficient force is applied to the moveable contacts by the means for applying downward force, to both retain the lead in the connector, and to provide reliable electrical connection between the moveable contacts and the lead contacts.
It is also a feature of the present invention to provide a connector body made from a resilient material. One or more moveable contacts are molded into the resilient connector body so that, in the absence of force, the moveable contacts rest in a position which permits easy insertion and removal of the lead. When force is applied to the moveable contacts by the means for applying downward force, the moveable contacts press against the lead contacts, thus retaining the lead, and providing reliable electrical contact between the connector contacts and the lead contacts. When the downward force is no longer applied to the moveable contacts, the resilient nature of the connector body causes the moveable contacts to return to the first position, thus freeing the lead.
It is a further feature of the invention to provide a solid cam with solid lobes as a means for applying downward force. The cam may be rotated, and the solid lobes thereby apply force to the moveable contacts, which force results in the moveable contacts moving from the first position to the second position. A cam stop lug is provided on the cam that cooperates with a cam stop in the connector to limit the rotation of the cam. The positions of the cam lug and the cam stop are designed to allow the cam to rotate to a locked position slightly past centering the solid lobes on the moveable contacts. As the cam is rotated from an open position to a locked position, the cam solid lobe pushes down on the moveable contacts. As the cam solid lobes rotate downward and against the moveable contacts, the resisting force of the movable contacts against the cam solid lobes result in torque on the cam resisting the rotation from the open to the locked position. When the cam lobes are pointed directly down (i.e., towards the moveable contacts) the moveable contacts, the solid lobes, and the rotational axis of the cam are aligned. In this position there is no torque on the cam. When the cam is rotated slightly farther, the torque on the cam is reversed and is pushing the cam towards the locked position. A past center effect thus results that causes the cam to remain in the locked position until sufficient torque is applied to force the solid lobes past centering the solid lobes on the moveable contacts. In a preferred embodiment the cam is a straight shaft with solid lobes spaced along the shaft. In an alternative embodiment the cam is a simple wireform device.
In a first alternative embodiment of the means for applying downward force, a rod with bulged sections is inserted into the connector. When the rod is fully inserted, the bulged sections align with the moveable contacts, thus applying force to move the moveable contacts from the first position to the second position. Advantageously, the bulged sections may be radially symmetric which allows the rod to be inserted with arbitrary rotation. In a variation of this embodiment, the rod is captive with a first and second position, wherein the bulges are not aligned with the movable contacts in the first position, allowing easy lead insertion; and the bulges are aligned with the movable contacts in the second position, providing good lead retention.
In a second alternative embodiment of the means for applying downward force, a moveable actuator is captive within the connector. The actuator defines one or more bulges vertically aligned with the moveable contacts. The actuator is free to move vertically within the connector. A key is insertable into the connector through a key passageway above the actuator. When the key is inserted, a ramped surface on the bottom face of the key pushes downward against the actuator causing the actuator to move downward against the moveable contacts, and thus causing the moveable contacts to move from the first position downward to the second position.
In a third alternative embodiment of the means for applying downward force, the single actuator and moveable contacts combination is replaced by individual second actuators cooperating with each movable contact. When the key is inserted, the key's ramped bottom surface pushes against the second actuators, thus causing the second actuators to move downward and push downward on the moveable contacts. The force of the second actuators on the moveable contacts causes the moveable contacts to move from the first position to the second position. In an alterative to this embodiment, the second actuators and moveable contacts are combined to form second movable contacts. The base of the second movable contact is resiliently molded into the connector body to allow vertical movement of the second moveable contacts and to retain the second moveable contacts in the connector body.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
FIG. 1A shows a detailed view of a typical Spinal Cord Stimulation (SCS) system, the system comprising an electrical sensor/stimulator device connected to a lead having an electrical contact or an electrical array at its distal end;
FIG. 1B depicts the SCS system of FIG. 1 implanted in a patient;
FIG. 2 shows an in-line lead used with the present invention;
FIG. 3 illustrates a rotating lock connector system according to the present invention, integrated into an implantable device;
FIG. 3A provides a top view of a connector system;
FIG. 4 shows a cross-sectional view of the connector taken along line 4 A— 4 A of FIG. 3A, with moveable contacts in a first position;
FIG. 5 shows a second cross-sectional view of the connector taken along line 4 A— 4 A of FIG. 3A, with moveable contacts in a second position;
FIG. 6A shows a cross-sectional view of the connector taken along line 6 A— 6 A of FIG. 4;
FIG. 6B shows a cross-sectional view of the connector taken along line 6 B— 6 B of FIG. 5;
FIG. 6C shows a cross-sectional view of the connector taken along line 6 C— 6 C of FIG. 5;
FIG. 7 illustrates a second embodiment of a rotating lock, with a bent wire cam;
FIG. 8 depicts a first alternative embodiment of a means for applying a downward force;
FIG. 9 depicts a second alternative embodiment of a means for applying a downward force;
FIG. 10 depicts a third alternative embodiment of a means for applying a downward force;
FIG. 11A shows a cross-sectional view of the second alternative embodiment, taken along line 11 A— 11 A of FIG. 9;
FIG. 11B shows a cross-sectional view of the third alternative embodiment, taken along line 11 B— 11 B of FIG. 10; and
FIG. 11C shows a cross-sectional view of a variation of the third alternative embodiment, taken along line 11 B— 11 B of FIG. 10 .
Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
The connector system of the present invention provides a simple method for inserting, retaining, and ensuring reliable electrical contact for a multi-contact in-line lead and a connector. Such connector system is typically used in implanted medical devices, for example, in a Spinal Cord Stimulation (SCS) system 4 as shown in FIG. 1 A. An SCS system 4 typically includes an Implantable Pulse Generator 10 , a connector 12 , an in-line lead 14 , an in-line connector 16 , an electrode lead 20 , and an electrode array 18 . The IPG 10 generates stimulation current for implanted electrodes that make up the electrode array 18 . A connector 12 is either attached to the body of the IPG 10 , or integrated into the IPG 10 . The in-line lead 14 is removably connected to the connector 12 and either permanently or removably connected to the in-line connector 16 , at the end of the in-line connector 16 proximal to the IPG 10 , and the electrode lead 20 is removably connected to the end of the in-line connector 16 distal from the IPG 10 . The electrode array 18 is typically formed on an end of the electrode lead distal from the in-line connector 16 . The in-series combination of the in-line lead 14 , in-line connector 16 , and electrode lead 20 , carry the stimulation current from the IPG 10 to the electrode array 18 .
A view of the SCS system 4 described in FIG. 1A above is depicted implanted in a patient 6 in FIG. 1 B. The electrode array 18 (or sensors in other applications) is implanted at the site of nerves that is the target of stimulation, e.g., along the spinal column 8 . Due to the lack of space where the electrode lead 20 exits the spinal column, the IPG 10 is generally implanted in the abdomen or above the buttocks. The in-line lead 20 facilitates locating the IPG 10 distal from the electrode lead exit point. The connector system of the present invention is particularly well suited for use with an IPG 10 because a small diameter lead is easier to pull through tissue than a large diameter lead, and the present invention facilitates the use of such small diameter lead.
The connector system of the present invention may be employed with various other implantable devices. Sensing devices have similar electrodes, leads, and implantable electronics. Any medical device requiring leads to connect sensors or stimulators to implantable electronics may benefit from the improved connector system.
The present invention is directed to implantable connector systems using an in-line lead 14 as shown in greater detail in FIG. 2 . The in-line lead 14 typically has a constant diameter D, which enables the lead to be implanted through a large gauge needle. A constant or uniform diameter D is particularly useful for an electrode lead 20 attached to a ring type electrode array of an SCS system 4 . In such case, the entire electrode array and electrode lead assembly are the same diameter, thus permitting the entire assembly to be implanted through a large gauge needle.
As seen in FIG. 2, an in-line lead 14 comprises a lead body 22 , at least one conductor 26 carried within the lead body 22 , and at least one spaced-apart lead contact 24 on the lead body 22 . A lead end 23 in inserted into the connector 12 to electrically connect the in-line lead 14 to the connector 12 . It is through the lead contacts 24 that electrical connection is made between each of the conductors 26 that are carried within the in-line lead 14 and the electrical circuit in the IPG 10 , or with the conductors of the in-line connector 16 . The in-line lead 14 may have identical ends (only one of which is shown in FIG. 2) with spaced-apart lead contacts 24 , or may have one end as depicted in FIG. 2, and the opposite end may be a female connector. In other cases, as with the electrode lead 20 , one end is as depicted in FIG. 2 and the opposite end includes the electrode array/sensors.
While the implantable system depicted in FIGS. 1A and 1B comprises a separate lead 14 connecting the electrode lead 20 to the IPG 10 , a connector made according to the present invention would apply equally well to a system with an electrode lead connected directly to the IPG 10 .
The in-line lead 14 may be manufactured using conventional lead manufacturing techniques and materials, as are known and practiced in the implantable lead art.
Turning to FIG. 3, a connector according the present invention is shown integrated into the IPG 10 . The lead 14 is insertable through a connector port 30 . The rearward end of a solid cam 34 , which solid cam 34 serves as a means for locking the lead 14 into the connector 12 , protrudes from the connector 12 just above the connector port 30 . The solid cam 34 has a handle lug 36 attached to the rearward end, which handle lug 36 provides means to removably connect a key or handle to the solid cam 34 for the purpose of rotating the solid cam 34 , as indicated by the arrow 32 .
A top view of the connector 12 is shown in FIG. 3A for the purpose of defining cross-section 4 A— 4 A.
A cross-sectional view of the connector 12 taken at line 4 A— 4 A of FIG. 3A is shown in FIG. 4 . The in-line lead 14 is shown fully inserted through connector port 30 , shown in FIG. 3, into a cylindrically shaped passageway 44 . In the example shown, the in-line lead 14 has four spaced-apart lead contacts 24 . The actual number of contacts may vary and is not limited by this description. At least one spaced-apart movable contact as 48 a is molded into the portion of a connector body 42 a that forms the wall of the passageway 44 . The movable contacts 48 a are vertically aligned with the respective lead contacts 24 with which each of the moveable contacts 48 a cooperates. The connector body 42 a is made from a resilient material, preferable epoxy. The first moveable contacts 48 are molded into the connector body 42 a so that in the absence of a downward force (within this description “downward” means toward the lead contacts 24 ; however, in use, the connector may be arbitrarily rotated) upon the moveable contacts 48 , the in-line lead 14 may be easily inserted completely into the passageway 44 . When a downward force is applied to the moveable contacts 48 , the resilient connector body 42 a allows the moveable contacts 48 to be pushed against the lead contacts 24 . The solid cam 34 comprises a substantially straight shaft 39 and at least one solid lobe 40 . The solid cam 34 shown in FIG. 4 has the at least one solid lobe 40 pointing away from the movable contacts 48 a. As a result, the movable contacts 48 a are in a relaxed position, wherein they are not pressing against the lead contacts 24 , thus permitting easy insertion of the in-line lead 14 . The handle lug 36 is also shown pointing up. In this embodiment the handle lug 36 is aligned with the solid lobes 40 to provide an intuitive indication of the direction of the solid lobes 40 . While this is an advantageous alignment, the handle lug 36 may be aligned arbitrarily without departing from the scope of the invention.
In a preferred embodiment, the moveable contacts 48 are resiliently attached to the connector body 42 a in a manner to cause the moveable contacts 48 to retreat from the lead contacts 24 when no downward force is acting on the moveable contacts 48 . In such cases, the moveable contacts rest in a first cam position when no force is applied to them. When the downward force is applied to the moveable contacts 48 , the moveable contacts 48 move to a second cam position where they contact the lead contacts 24 . In other embodiments, the absence of a downward force upon the moveable contacts 48 may result in the moveable contacts touching but applying negligible force to the lead contacts 24 . In either case, the absence of a downward force applied to the movable contacts 48 a results in easy insertion and removal of the lead end 23 from the connector 12 .
In a preferred embodiment, the lead contacts 24 comprise rings that circle the lead body 22 as shown in FIG. 2 . The cross-sectional view of the lead contacts 24 shown in FIG. 4 shows the rectangular cross sections of the lead contacts 24 at the top and bottom of the in-line lead 14 . In other embodiments the cross-sectional view of the lead contacts 24 may be rounded or “D” shaped. These other cross-sections are intended to come within the scope of the present invention. Connector ridge seals 46 are molded into the passageway 44 to prevent conductive body fluids from readily passing between connectors and to thereby minimize current leakage between contacts. The connector seals 46 form a complete circle around the inner diameter of the passageway 44 , much like an o-ring, and make sufficient contact with the lead body 22 to prevent fluid and current leakage.
A second sectional view taken at line 4 A— 4 A of FIG. 3A is shown in FIG. 5 . This view is identical to the view in FIG. 4 with the exception that the solid cam 34 has been rotated approximately 180 degrees into a locking position. The handle lug 36 is in the down position. The solid lobes 40 are now pointing down and contacting the moveable contacts 48 . The moveable contacts 48 are pushed down and are contacting the lead contacts 24 . In this position, the in-line lead 14 is held in the passageway 44 by the friction resulting from the moveable contacts 48 pushing against the lead contacts 24 . A reliable electrical connection is created by the same cooperation of contacts. A cam stop lug 50 resides on the forward end of the solid cam 34 .
A cross sectional view taken at line 6 A— 6 A of FIG. 4 is shown in FIG. 6 A. The arced shape of the moveable contacts 48 is clearly visible. Additionally, the conductors 26 are shown within the lead body 22 . The solid lobes 40 are pointed up and are not in contact with the moveable contacts 48 . In the absence of downward force, the moveable contacts 48 are not touching the lead contacts 24 .
A cross sectional view taken at line 6 B— 6 B of FIG. 5 is shown in FIG. 6 B. The solid lobes 40 are pointed downward and are pushing the moveable contacts 48 firmly against the lead contacts 24 .
Another cross sectional view taken at line 6 C— 6 C of FIG. 5 is shown in FIG. 6 C. The solid cam 34 is depicted in the locked position (i.e., the solid lobes 40 are pointing downward towards the moveable contacts 48 as shown in FIG. 6B.) The cam stop lug 50 , on the forward end of the solid cam 34 , is resting against a second cam stop 60 b, thus providing a second rotational stop for the solid cam 34 and a closed position for the connector 12 . The cam stop lug 50 and cam stop 60 b are designed to allow the solid cam 34 to rotate slightly past the point where the solid lobes 40 are pointed directly at the moveable contacts 48 . By incorporating this “past center” position, the solid cam remains in the locked position once released. The solid cam 34 may be rotated so that the cam stop lug 50 cooperates with a first cam stop 60 a thus providing a first rotational stop for the solid cam 34 an open position for the connector 12 . While the cam stop lug 50 is shown at the forward end of the solid cam 34 , other locations for the cam stop lug 50 along the length of the solid cam 34 will provide an equivalent function, and are intended to come within the scope of the present invention.
Turning to FIG. 7, and alternative embodiment of a cam serving as a means for applying downward force on the moveable contacts is shown. A wireform cam 74 is inexpensively formed from wire. Wireform lobes 76 press down on the moveable contacts 48 to provide downward force. At least one cam support 72 in a second connector body 42 b is provided to rotatably support at least one straight section of the wireform cam 74 . The support provided by the at least one cam support 72 allows the wireform cam to be rotated about an axis substantially parallel with the passageway 44 . The handle lug 36 provides a means to turn the wireform cam 74 in the same manner as the handle lug 36 in FIG. 3. A cam stop lug 50 provides a positive rotational stop for the second solid cam as in the case of the solid cam 34 illustrated in FIG. 6 C. The wireform cam 74 functions substantially the same as the solid cam 34 described in FIGS. 4, 5 , and 6 .
An alternative to the solid cam 34 of FIG. 4 is shown in FIG. 8. A removable rod 84 is inserted into a rod passageway 82 in a third connector body 42 c as a means for applying downward force on the moveable contacts 48 . In a preferred embodiment, the removable rod 84 defines radially symmetric bulges 86 at the same spacing as the spaced-apart moveable contacts 48 . Advantageously, the symmetry of the bulges permits the removable rod to be inserted with an arbitrary rotation. Alternative embodiments may include asymmetric bulges, with a key way, or equivalent means, to align the asymmetric bulges with the moveable contacts 48 a. When the removable rod 84 is fully inserted into the rod passageway 82 , the symmetric bulges 86 are aligned with the moveable contacts 48 , and push the moveable contacts 48 downward against the lead contacts 24 . The resulting cooperation between contacts both retains the in-line lead 14 in the passageway 44 , and provides a reliable electronic connection between the contacts. A rod latch 88 is provided on a forward rod end opposite the exposed rearward end of the removable rod 84 . A cooperating latch receptacle 89 , constructed from the resilient connector body 42 c material, is molded into the rod passageway 82 . When the removable rod 84 is pushed fully into the rod passageway 82 , the rod latch 88 snaps into the latch receptacle 89 to latch the removable rod 82 into the connector body 42 c. A hook hole 87 is provided on an exposed rearward end of the removable rod 84 to provide means to pull the removable rod from the connector body 42 c. The latch described in FIG. 8 is one example of many equivalent means for providing retention of a rod in a rod cavity.
In another variation, the rod may be captive within the connector. The rod would require sufficient freedom to be moved from a first rod position where the bulges are not aligned with the moveable contacts, to a second rod position where the bulges are aligned with the moveable contacts. Such variations will be apparent to those skilled in the art and are intended to fall within the scope of the present invention.
A second alternative embodiment of the connector is shown in FIG. 9. A fourth connector body 42 d comprises the passageway 44 as shown in previously described embodiments, but further comprises an actuator cavity 92 and a key passageway 95 . A captive actuator 93 is positioned in the actuator cavity 92 above the moveable contacts 48 as a means for applying downward force on the moveable contacts. The captive actuator 93 defines bottom bulges 94 which are vertically aligned with the movable contacts 48 a. The captive actuator 93 is limited to vertical motion only. A removable key 96 is removably insertable into the key passageway 95 above the captive actuator 93 . A fully inserted removable key 96 has a rearward end that protrudes from the connector body 42 d, and a forward end opposite the rearward end. The bottom of the removable key 96 defines a short downward ramp 91 at the forward end followed by a straight section. When the forward end of the removable key 96 is first inserted into the key passageway 95 , the downward ramp 91 makes contact with the captive actuator 93 , and the captive actuator 93 is pushed down against the moveable contacts 48 . The resulting downward force of the moveable contacts 48 against the lead contacts 24 retains the in-line lead 14 in the passageway 44 , and provides a reliable electronic connection between the contacts. When the removable key 96 is fully inserted into the key passageway 95 , a key latch 98 on the forward end of the removable key 96 , snaps into a latch receptacle 99 to retain the removable key 96 in the key passageway 95 . A hook hole 97 is provided in the rearward end of the removable key 96 to facilitate the removal of the removable key.
A third alternative embodiment of the connector is shown in FIG. 10. A fifth connector body 42 e comprises the passageway 44 and the key passageway 95 as shown in FIG. 9, but further comprises at least one actuator guide 102 . At least one multi actuator 104 slidably resides in the actuator guides 102 . The multi actuators 104 preferably have a round or rectangular horizontal cross section, but variations of the cross section will be apparent to those skilled in the art and fall within the scope of the present invention. The actuator guides 102 allows vertical movement of the multi actuators 104 but limit horizontal movement. The multi actuators 104 are positioned directly above the movable contacts 48 a. The removable key 96 as described in FIG. 9 or equivalent, is insertable into the key passageway 95 above the multi actuators 104 as a means for applying a downward force on the multi actuators 104 . The bottom of the removable key 96 defines the downward ramp 91 followed by a straight section. The straight section is sufficiently long to cover all of the multi actuators 104 when the removable key 96 is fully inserted into the key passageway 95 . When the downward ramp 91 on the bottom of the removable key 96 makes contact with the multi actuators 104 , the multi actuators 104 are pushed down against the moveable contacts 48 . The moveable contacts 48 then are pushed down against the lead contacts 24 . The resulting downward force both retains the in-line lead 14 in the passageway 44 , and provides a reliable electronic connection between the contacts.
FIGS. 11A and 11B are cross sectional views taken along the lines 11 A— 1 A of FIG. 9 and the lines 11 B— 11 B of FIG. 10, respectively. FIG. 11A shows a second cross section of the second alternative embodiment of the means for applying downward force on the moveable contacts 48 . In this view, the removable key 96 is seen in the key passageway 95 . The captive actuator 93 , in the actuator cavity 92 , is just below the removable key 96 , and is forced downward by the removable key. The captive activator 93 forces the moveable contacts 48 downward. The moveable contacts 48 are thus pushed against the lead contacts 24 . The resulting downward force both retains the in-line lead 14 in the passageway 44 , and provides a reliable electronic connection between the contacts.
FIG. 11B is nearly identical to FIG. 11A with the exception that the captive actuator 93 in the actuator cavity 92 of FIG. 11A is replaced by the multi actuators 104 in the actuator guides 102 in FIG. 11 B. The actuator guides 102 position the multi actuators 104 above the movable contacts 48 a and limit the multi actuators 104 to vertical movement. The removably insertable removable key 96 applies a downward force on the multi actuators 104 . The multi actuators 104 push down on the moveable contacts 48 . The moveable contacts 48 are thus pushed against the lead contacts 24 . The resulting downward force both retains the in-line lead 14 in the passageway 44 , and provides a reliable electronic connection between the contacts.
A connector with a second at least one spaced-apart moveable contact 48 b is shown in FIG. 11 C. The moveable contacts 48 b replace both the multi actuators 104 and first moveable contacts 48 a shown in FIG. 11B described above. The moveable contacts 48 b are movably contained in contact guides 112 . The contact guides 112 are vertically aligned with the lead contacts 24 of a fully inserted lead end 23 . The moveable contacts 48 b are resiliently molded into a sixth connector body 42 f at the base of the moveable contacts 48 b . Such resilient molding allows the movable contacts 48 b to be pushed against the lead contact 24 by the insertion of the removable key 96 into the key passageway 95 , wherein the bottom key surface presses against at least one contact top surface, thereby retaining the lead end 23 in the connector body 42 f. The same resilience causes the moveable contacts 48 b to pull away from the lead end 23 when the removable key 96 is removed from the key passageway 95 , allowing easy removal of the lead end 23 from the connector body 42 f.
It is this seen that in each embodiment of the connector described herein, the moveable contacts are molded into the resilient connector body material to provide the correct positioning for the moveable contacts. A downward force moves the moveable contacts against the in-line lead. A resilient force moves the moveable contacts away from the in-line lead when no other force is acting upon the moveable contacts. This advantageously provides a simple connector, but alternative designs, for example using springs, would obtain the same functionality as that described here. Other means for positioning and restoring the moveable contacts will be apparent to those skilled in the art, and are intended to be within the scope of the present invention.
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. | A moveable contact connector system provides easy lead insertion, lead retention, and reliable electrical connection for implantable devices. The connector system may be used with in-line leads commonly found in such applications. Moveable contacts are provided in the connector, which contacts are placed in a first position for easy lead insertion, and in a second position for lead retention. The second position also provides a good electrical connection between the moveable connector contacts and the lead contacts. Multiple means for moving said at least one moveable contact between the first and second positions are described. A first embodiment uses a rotatable cam which is rotated to align the cam lodes with said at least one moveable contact, pushing the movable contacts against the lead contacts. The second and third embodiments use a sliding key to force said at least one moveable contact against the lead contacts. | 0 |
BACKGROUND TO THE INVENTION
1. Field of the Invention
This invention relates to castors and to vehicles which have castors. More particularly, the invention relates to a vehicle which has wheels by which the vehicle is propelled and steered, and castors which support a proportion of the vehicle's weight and which swivel to appropriate orientations in accordance with the direction of travel of the vehicle. Preferably the wheels are at the front of the vehicle and the castors at the rear.
It is to be appreciated that when we refer to a castor, we mean an assembly in which a ground-engaging wheel is supported not only for rotation but also for swivelling movement about an axis, herein called a swivel axis, which is substantially vertically oriented in use and which is offset from the rotational axis of the wheel.
The invention has been devised in relation to a vehicle which is intended to be occupied by one person, to give mobility to that person if he or she is disabled or infirm. Such a vehicle is commonly known as a wheelchair, and for convenience will herein be referred to thus.
2. Description of Prior Art
Wheelchairs are known in which the front wheels provide for driving of the wheelchair but do not take any part in the steering thereof, whilst rear castors have their swivelling controlled by a servomechanism in order to steer the wheelchair. The front wheels may be driven by a common motor and a transmission arrangement which includes a differential to permit the wheels to rotate at different speeds when the wheelchair is cornering. Such known wheelchairs have a disadvantage in that the angle to which the castors can be swivelled in order to steer the chair is limited; if the castors are swivelled to too great an angle the castor wheels just skid sideways and have little or no influence on the direction of travel of the wheelchair. Thus there is a limit on manoeuvrability of the wheelchair: to turn the chair to face in the opposite direction requires a "three (or more) point turn" to be executed.
It is known in wheelchairs generally to provide for steering by differential driving of the driving wheels of the wheelchair. For example, the driving wheels may have separate electric driving motors and the wheelchair may be provided with a control system which is arranged appropriately to control the supply of electrical power to the two motors for steering the wheelchair. If a wheelchair of this type had the driven wheels at the front and castor wheels at the back, the position of the centre of gravity of the wheelchair with its occupant, usually is such that when the vehicle is steered while travelling forwardly an "oversteer" condition tends to exist, in which the rear end of the vehicle, unconstrained by the castor wheels, swings outwardly on a corner relative to the front of the wheelchair. Further, the directional stability of the wheelchair is such that very careful operation of the controls is necessary for the vehicle to run straight ahead, as the rear castors do not contribute to the directional stability of the wheelchair. Nevertheless, steering by differential driving of front wheels which do not undergo any steering pivotal movement is advantageous, because driving one front wheel forwardly while the other either is not driven at all or possibly even is driven rearwardly enables the vehicle to be turned in little more than its own length.
Wheelchairs with wheels and castors are disclosed in U.S. Pat. No. 4,614,246 and GB-2,275,029. In the latter, the castors have their swivelling axes inclined for restraining their swivelling movement. A further wheelchair with wheels and castors is disclosed in U.S. Pat. No. 5,275,248. Castors with means for controlling or biasing their swivelling movement are disclosed in U.S. Pat. No. 3,924,292, EP-0,625,434 and DE-3,136,203, while a shock absorbing wheel suspension assembly is disclosed by U.S. Pat. No. 4,392,668.
SUMMARY OF THE INVENTION
It is broadly the object of the present invention to overcome the above described disadvantages associated with conventional wheelchairs of which the front wheels are driven. It is to be appreciated that, in meeting this objective, the invention is also applicable to vehicles of other types and configurations.
According to one aspect of the present invention, we provide a vehicle having wheels by which the vehicle is propelled and steered and castors, wherein at least one of the castors incorporates biasing means for providing resistance to swivelling movement thereof from a straight-ahead position.
Preferably the wheels are at the front of the vehicle and the castors at the rear thereof.
The means for resisting swivelling of the castor from the straight-ahead position may comprise cam and follower means associated with parts of the castor which undergo relative angular movement when the castor swivels, the cam and following means causing relative displacement between said parts in a direction other than the angular swivelling movement, which relative displacement is resisted so as to resist the swivelling movement.
The relative movement in the other direction may be resisted by spring means, and/or by the proportion of weight of the vehicle carried by the castor.
Whilst it would be within the scope of the invention for the castor at each side of the vehicle to incorporate means which resists swivelling of the castor in both directions from a straight-ahead position, preferably the castor at one side of the vehicle has biasing means which comes into effect when steering in one direction from the straight-ahead position whilst the castor at the other side of the vehicle has biasing means which comes into effect when steering in the other direction from the straight-ahead position.
Preferably the castor at the left hand side of the vehicle has biasing means which comes into effect when the vehicle is steering to the right, whilst the castor at the right hand side of the vehicle has biasing means which comes into effect when the vehicle is steering left.
With such an arrangement of the castors, when the vehicle is travelling straight ahead either one or the other castor will resist small directional deviations therefrom. When the vehicle is turning to the left, weight is transferred to the right hand side of the vehicle and the right hand castor accordingly has most effect. When it is the proportion of the weight of the vehicle carried by the castor which provides the biasing action of the castor, the biasing action is increased in accordance with the cornering speed of the vehicle. This is what is required to resist the oversteering effect above referred to.
The use of castors in accordance with the invention also improves stability of a vehicle such as a wheelchair when traversing inclined surfaces, on rough ground, or when reversing.
In order to ensure that the castors do swivel when the vehicle is being steered, preferably the offset of the swivel axis from the rotational axis of the wheel of each castor is relatively large, e.g. of the order of the radius of the wheel. This ensures that the torque produced by steering of the vehicle is sufficient to overcome the effect of the biasing means of the castor.
Preferably each castor incorporates suspension means, i.e. means providing for upwards and downwards displacement of the castor wheel relative to the structure of the vehicle.
Preferably the suspension means comprises a pivoted arm by which the wheel is carried, pivotal movement of the arm relative to a further part of the castor assembly being resisted by resilient means. The resilient means may comprise a rubber or rubber-like element which is compressed upon the pivotal movement of the arm such that the wheel moves upwards relative to the vehicle.
The pivoted arm by which the wheel of the castor is carried is preferably a trailing arm, i.e. the rotational axis of the wheel is disposed rearwardly of the axis about which the arm is pivoted in the normal direction of movement of the castor. Such a trailing arm arrangement assists the wheel of the castor to surmount obstacles.
According to another aspect of the invention, we provide a castor having biasing means for resisting swivelling movement of the castor in at least one sense from a predetermined position.
Preferably the biasing means operates immediately upon the swivelling of the castor in one sense from the predetermined position, but provides no resistance to some swivelling in the other sense from the predetermined position.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention also provides a castor having the suspension means above referred to.
The invention will now be described by way of example with reference to the accompanying drawings, of which:
FIG. 1 is a diagrammatic side elevation of part of a wheelchair in accordance with one aspect of the invention;
FIG. 2 is a diagrammatic plan view of the arrangement of the wheels of the wheelchair of FIG. 1;
FIG. 3 is a rear elevation of the two castors of the wheelchair, with some detail omitted;
FIG. 4 is a plan view of the two castors of the wheelchair, also with some detail omitted;
FIG. 5 is a side elevation, partly in section, of one of the castors;
FIG. 6 is a view as FIG. 5, of a modified embodiment of castor;
FIG. 7 is a side elevation, partly in section, of a further modified embodiment of castor.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring firstly to FIGS. 1 and 2 of the drawings, this shows diagrammatically, in side elevation, part of a wheelchair which has a chassis structure indicated generally at 10. The chassis structure carries a chair which has a seat cushion 11, backrest 12, and arm rests 13. The chair is readily detachable from the chassis 10, and further comprises a support indicated generally at 14 for the feet of an occupant of the chair.
The wheelchair has a pair of front wheels 15 and a pair of rear wheels 16. The front wheels are mounted to the chassis 10 of the wheelchair by respective pivoted arms one of which is indicated at 17 in FIG. 1, arranged so that the wheel is movable upwardly and downwardly in an arc relative to the chassis. Such movement of the wheel is controlled by a spring-damper unit 18. Each of the front wheels 15 has a respective electric drive motor 19 and reduction gearbox by which the wheel is able to be driven under the command of a suitable control system, electrical power being derived from a battery (not shown) carried by the wheelchair.
The rear wheels 16 of the vehicle comprise respective castors, the wheels being able to swivel about respective swivel axes 20 offset from the rotational axes 21 of the wheels. As shown in outline in FIG. 1, and described in greater detail hereafter, the wheel of each castor assembly is carried on an arm 22 which is itself pivotable relative to a swivelling body 23 of the castor, to provide for arcuate upwards and downwards movement of the castor wheel.
Referring now to FIG. 2 of the drawings, although the front wheels 15 of the wheelchair are able to move upwardly and downwardly relative to the chassis of the wheelchair they are not able to undergo any steering swivel movement. Steering of the wheelchair is effected by differentially controlling the power supply to the respective electric drive motors of the two front wheels so that one motor is, in effect, driven faster than the other when the vehicle is required to move other than in the straight ahead direction. When the wheelchair is steered in this manner, the castors at the rear of the wheelchair permit the rear wheels to swivel in accordance with the direction in which the wheelchair is being steered. FIG. 2 shows the condition wherein differential driving of the front wheels causes the vehicle to be steered to the right, as indicated by arrow 24. The position of the centre of gravity of the wheelchair is as indicated at 25, and it will be appreciated that when the vehicle is steered the effect of such disposition of the centre of gravity is that the rear of the vehicle tends to swing outwardly. The tendency is for the vehicle to oversteer, and for the rear wheels to swivel about their swivel axes 20 to a greater extent than would be necessary if there were no such oversteering tendency.
According to the present invention, therefore, the castors at the rear of the vehicle are provided with biasing means which causes such oversteering of the wheelchair to be resisted.
Referring now to FIGS. 3, 4 and 5 of the drawings, FIGS. 3 and 4 show both castors at the rear of the vehicle. The castors at left and right of the vehicle are mirror images of one another, and accordingly in the following description only one of such castors will be described in detail, and the description of the castor at the other side of the vehicle will be confined to the differences thereof.
The castor at the right hand side of the vehicle has its swivel body 23, which is a generally U-section steel pressing, provided with an upwardly extending swivel pin 27 pivotable within bushes 28 in a sleeve 29. The pin 27 extends above the top of the sleeve 29, and carries a relatively light compression spring 30 whose opposite ends abut against a bearing washer 31 at the top of the sleeve 29 and an abutment washer 32 secured by a bolt whose head is shown at 33. Thus the body 23 is held captive to the sleeve 29 and biased upwardly relative thereto. It will be appreciated that the arrangement is such that the proportion of the weight of the wheelchair which is carried by the wheel of the castor also urges the body 23 upwardly relative to the sleeve 29, and the force exerted by the spring 30 is relatively low compared with the weight which is supported by the castor.
A suspension arm 35 is pivotally mounted to the body 23 by means of a pin 36 which is welded to the arm 35 and extends laterally through the body 23 being retained by a nut 37 and washer 38 at the free end of the pin. At its opposite end, arm 35 has welded thereto a spindle 39 on which is rotatably mounted the wheel of the castor, indicated in outline in FIG. 5 at 40. The wheel is retained by a nut 41 and washer 42. Adjacent the end of the arm 35 where the pin 36 is provided, a bracket 43 extends laterally from the arm and this faces an abutment 44 fixed in the body 23. A bonded metal-rubber-metal bush 45 is disposed between the facing parts of the bracket 43 and abutment 44, the bush being secured to these facing parts by respective studs which are connected to the metal parts of the bush between which the rubber is sandwiched, and which carry nuts 46. Thus pivotal movement of the arm 35 which causes upwards arcuate movement of the wheel relative to the body 23 is resisted by compression of the rubber in the bush 45. This provides a resilient suspension for the wheel of the castor, which is operable independently of the biasing means described hereafter.
A cam ring 48 surrounds the sleeve 29, the cam ring being secured to the sleeve by three radially extending screws 49 which extend through the cam ring and engage screw-threaded openings in the sleeve 29. On its undersurface, the cam ring has a cam track including a flat portion 50 followed by, circumferentially of the cam ring, a relatively steeply inclined ramp portion 51, a further flat portion 52, and a shallowly inclined ramp portion 53 which leads back to the flat portion 50. The cam track is engaged by the peripheral surface of a roller 54 which is rotatably mounted on a pin 55 fixed to an upwardly extending bracket 56 secured to the body 23. The orientation of the pin 55 is radial with respect to the swivel axis of the castor. Thus the roller 54 engages appropriate parts of the cam track 50 to 53 according to the position to which the castor has swivelled.
The left hand castor is, as above referred to, and as shown in FIGS. 3 and 4, a mirror image of the right hand castor above described. In particular, the cam track provided on the cam ring of the left hand castor has portions 60, 61, 62, 63 corresponding to the parts 50, 51, 52, 53 of the cam track of the right hand castor, but following one another in the opposite direction circumferentially of the cam ring. Thus the relatively steeply inclined ramp portion 51 of the cam track of the right hand castor is engaged when the right hand castor swivels to the left, whilst the corresponding portion 61 of the cam track of the left hand castor is engaged when the left hand castor swivels to the right.
When a wheelchair provided with castors as above described is travelling straight ahead, any deviation from the straight ahead condition requires one or other of its castors to swivel such that the relatively steep ramp portion 51 or 52 of its cam track is engaged by the roller carried by its swivelling body. Since travel of the roller from the flat portion 50, 60 of the cam track to the flat portion 52, 62 by way of the ramp portion 51, 61 requires downward displacement of the swivel body 23 of the castor relative to the sleeve 29 which is carried by the chassis of the wheelchair, i.e. lifting of the chassis structure of the wheelchair relative to the swivel body of the castor, such movement is resisted. Thus the wheelchair has good directional stability. When the wheelchair is steered to left or right by differential driving of the driven front wheels thereof, which causes swivelling of the castors at the rear of the wheelchair, the castor which is outermost with regard to the direction in which the wheelchair is being steered has its swivelling resisted by travel of the roller up the ramp portion 51, 61 of the associated cam track. Thus excessive swivelling of that castor, which could cause the oversteer condition above referred to, is resisted.
Since when the wheelchair is travelling and is steered weight is, in effect, transferred to the outermost castor, the oversteer resistance is dependent on such weight transfer and thus to the cornering forces produced.
When the wheelchair is being manoeuvred at low speed and greater swivel angles of the castors are involved, the portions 50, 52, 53 and 60, 62, 63 of the cam tracks are engaged by the rollers of the castors. Thus such greater angles of swivelling are not resisted to any significant extent.
It will be noted that the offset of the swivel axis of each castor from the rotational axis of the wheel is relatively great. Thus when the wheelchair is being steered sufficient swivelling torque is created to enable the ramp portions of the cam tracks of the castors to be climbed.
It will be further noted that the pivot of the suspension arm 35 to the body 23 of each castor is situated beyond the swivel axis of the castor, so that the suspension arm is relatively long. This assists in the surmounting of obstacles by the castor wheel.
Referring now to FIG. 6 of the drawings, this shows part of a castor which differs in minor constructional details only from the castor shown in FIG. 5. The castor has a bracket 43 attached to its pivoted arm, and an abutment 44 fixed across the swivelling body of the castor, but instead of the bonded metal-rubber-metal bush 45 therebetween there is an annular element 70 of rubber therebetween. A bolt 71 extends from the bracket 43 towards and through an aperture in the abutment 44, and extends through the opening in the centre of the element 70 so that the latter is held captive in the required positions. The external surface of the resilient element 70 is appropriately configured, e.g. with frusto-conical end portions and an intermediate annular groove, to give it the required resilient characteristics when compressed between the bracket 43 and abutment 44. In use, the operation of the castor of FIG. 6 is exactly the same as that of the castor of FIG. 5.
Referring finally now to FIG. 7 of the drawings, this shows a further embodiment of castor which may be utilised in a vehicle such as a wheelchair in accordance with the invention. This castor has a swivel body 60 similar to that of the previously described castors, having a swivel pin 61 extending upwardly therefrom and pivotable within bushes in a sleeve 62. The swivel pin 61 extends above the top of the sleeve 62 and is retained by a retaining spring and washer assembly indicated generally at 63. A suspension arm 64 extends from a member 65 which is pivotable relative to the body 60 about a pivot pin 66. The body 65 engages an annular elastomeric element 67 extending across the swivel body 60 and held on a bolt 68.
There is also a coil compression spring 69 operative between the member 65 and the body 60. The spring is constrained by a guide member 70 on a bolt 71 secured to the body 60 and extending with a clearance through an opening in the member 65. The presence of coil spring 69 in addition to the elastomeric, e.g. rubber, element 67, overcomes any potential problem of the elastomeric elements suffering from creep.
Above the body 60 the swivel pin 61 carries a cam ring 72, the cam ring being secured by radially extending screws 73 to a boss 74 above the body. The cam ring has on its upwardly facing surface a cam track 75, engaged by the peripheral surface of a roller 76. As illustrated, the roller 76 is the outer race of a rolling element bearing whose inner race 77 is carried on a bolt 78 radially engaging the sleeve 62. The configuration of the cam tracks 75 is designed to provide the same operating characteristics as those above described in relation to the castor shown in FIGS. 3, 4 and 5 of the drawings, but as compared with the earlier castor the modified arrangement of cam track and cam follower reduces the risk of fouling between these two elements.
It is to be appreciated that castors as above described will be usable in vehicles of other configuration than wheelchairs as shown in FIG. 1. The castors may find application in vehicles which are not powered, e.g. trolleys or the like. | A vehicle such as a wheelchair having wheels by which the vehicle is propelled and steered and castors which support a proportion of the vehicle's weight, has its castors provided with biasing means which resists swivelling movement of the castors from the straight-ahead position thereby resisting an oversteer condition of the vehicle. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention claims priority under 35 U.S.C. 119 of U.S. provisional application 60/059,598 filed on Sep. 23, 1997, the contents of which are fully incorporated herein by reference.
FIELD OF THE INVENTION
The present invention provides novel compounds, novel compositions, methods of their use, and methods of their manufacture, where such compounds of Formula 1 and Formula 2 are pharmacologically useful inhibitors of Protein Tyrosine Phosphatases (PTPases) such as PTP1B, CD45, PTP1C, PTPα, LAR and HePTP or the like,
wherein W, X, Y, Z, R 1 , R 2 and R 3 are defined more fully below. It has been found that PTPases plays a major role in the intracellular modulation and regulation of fundamental cellular signaling mechanisms involved in metabolism, growth, proliferation and differentiation (Flint et al., The EMBO J. 12:1937-46 (1993); Fischer et al, Science 253:401-6 (1991)). Overexpression or altered activity of tyrosine phosphatases can also contribute to the symptoms and progression of various diseases (Wiener, et al., J. Natl. cancer Inst. 86:372-8 (1994); Hunter and Cooper, Ann. Rev. Biochem, 54:897-930 (1985)). Furthermore, there is increasing evidence which suggests that inhibition of these PTPases may help treat certain types of diseases such as diabetes type I and II, autoimmune disease, acute and chronic inflammation, osteoporosis and various forms of cancer.
BACKGROUND OF THE INVENTION
Protein phosphorylation is now well recognized as an important mechanism utilized by cells to transduce signals during different stages of cellular function (Fischer et al, Science 253:401-6 (1991); Flint et al., The EMBO J. 12:1937-46 (1993)). There are at least two major classes of phosphatases: (1) those that dephosphorylate proteins (or peptides) that contain a phosphate group(s) on a serine or threonine moiety (termed Ser/Thr phosphatases) and (2) those that remove a phosphate group(s) from the amino acid tyrosine (termed protein tyrosine phosphatases or PTPases).
The PTPases are a family of enzymes that can be classified into two groups: a) intracellular or nontransmembrane PTPases and b) receptor-type or transmembrane PTPases.
Intracellular PTPases: Most known intracellular type PTPases contain a single conserved catalytic phosphatase domain consisting of 220-240 amino acid residues. The regions outside the PTPase domains are believed to play important roles in localizing the intracellular PTPases subcellularly (Mauro, L. J. and Dixon, J. E. TIBS 19:151-155 (1994)). The first intracellular PTPase to be purified and characterized was PTP1B which was isolated from human placenta (Tonks et al., J. Biol. Chem. 263: 6722-6730 (1988)). Shortly after, PTP1B was cloned (Charbonneau et al., Proc. Natl. Acad. Sci. USA 86: 5252-5256 (1989); Chernoff et al., Proc. Natl. Acad. Sci. USA 87: 2735-2789 (1989)). Other examples of intracellular PTPases include (1) T-cell PTPase (Cool et al. Proc. Natl. Acad. Sci. USA 86: 5257-5261 (1989)), (2) rat brain PTPase (Guan et al., Proc. Natl. Acad. Sci. USA 87:1501-1502 (1990)), (3) neuronal phosphatase STEP (Lombroso et al., Proc. Natl. Acad Sci. USA 88: 7242-7246 (1991)), (4) ezrin-domain containing PTPases: PTPMEG1 (Guet al., Proc. Natl. Acad. Sci. USA 88: 5867-57871 (1991)), PTPH1 (Yang and Tonks, Proc. Natl. Acad. Sci. USA 88: 5949-5953 (1991)), PTPD1 and PTPD2 (Møller et al., Proc. Natl. Acad. Sci. USA 91: 7477-7481 (1994)), FAP-1/BAS (Sato et al., Science 268: 411-415 (1995); Banville et al., J. Biol. Chem. 269: 22320-22327 (1994); Maekawa et al., FEBS Letters 337: 200-206 (1994)), and SH2 domain containing PTPases: PTP1C/SH-PTP1/SHP-1 (Plutzky et al, Proc. Natl. Acad. Sci. USA 89:1123-1127 (1992); Shen et al., Nature Lond. 352: 736-739 (1991)) and PTPID/Syp/SH-PTP2/SHP-2 (Vogel et al., Science 259:1611-1614 (1993); Feng et al., Science 259:1607-1611 (1993); Bastein et al., Biochem. Biophys. Res. Comm. 196:124-133 (1993)).
Low molecular weight phosphotyrosine-protein phosphatase (LMW-PTPase) shows very little sequence identity to the intracellular PTPases described above. However, this enzyme belongs to the PTPase family due to the following characteristics: (i) it possesses the PTPase active site motif: Cys-Xxx-Xxo(-XXO(-Xxx-Xxx-Arg (Cirri et al., Eur. J. Biochem. 214: 647-657 (1993)); (ii) this Cys residue forms a phospho-intermediate during the catalytic reaction similar to the situation with ‘classical’ PTPases (Cirri et al., supra; Chiarugi et al., FEBS Lett. 310: 9-12 (1992)); (iii) the overall folding of the molecule shows a surprising degree of similarity to that of PTP1B and Yersinia PTP (Su et al., Nature 370: 575-578 (1994)).
Receptor-type PTPases consist of a) a putative ligand-binding extracellular domain, b) a transmembrane segment, and c) an intracellular catalytic region. The structures and sizes of the putative ligand-binding extracellular domains of receptor-type PTPases are quite divergent. In contrast, the intracellular catalytic regions of receptor-type PTPases are very homologous to each other and to the intracellular PTPases. Most receptor-type PTPases have two tandemly duplicated catalytic PTPase domains.
The first receptor-type PTPases to be identified were (1) CD45/LCA (Ralph, S. J., EMBO J. 6:1251-1257 (1987)) and (2) LAR (Streuli et al., J. Exp. Med. 168:1523-1530 (1988)) that were recognized to belong to this class of enzymes based on homology to PTP1B (Charbonneau et al., Proc. Natl. Acad. Sci. USA 86: 5252-5256 (1989)). CD45 is a family of high molecular weight glycoproteins and is one of the most abundant leukocyte cell surface glycoproteins and appears to be exclusively expressed upon cells of the hematopoietic system (Trowbridge and Thomas, Ann. Rev. Immunol. 12: 85-116 (1994)).
The identification of CD45 and LAR as members of the PTPase family was quickly followed by identification and cloning of several different members of the receptor-type PTPase group. Thus, 5 different PTPases, (3) PTPa, (4) PTPb, (5) PTPd, (6) PTPe, and (7) PTPz, were identified in one early study (Krueger et al., EMBO J. 9: 3241-3252 (1990)). Other examples of receptor-type PTPases include (8) PTPg (Barnea et al., Mol. Cell. Biol. 13: 1497-1506 (1995)) which, like PTPz (Krueger and Saito, Proc. Natl. Acad. Sci. USA 89: 7417-7421 (1992)) contains a carbonic anhydrase-like domain in the extracellular region, (9) PTPμ (Gebbink et al., FEBS Letters 290: 123-130 (1991)), (10) PTPk (Jiang et al., Mol. Cell. Biol. 13: 2942-2951 (1993)). Based on structural differences the receptor-type PTPases may be classified into subtypes (Fischer et al., Science 253: 401-406 (1991)): (I) CD45; (II) LAR, PTPd, (11) PTPs ; (III) PTPb, (12) SAP-1 (Matozaki et al., J. Biol. Chem. 269: 2075-2081 (1994)), (13) PTP-U2/GLEPP1 (Seimiya et al., Oncogene 10: 1731-1738 (1995); Thomas et al., J. Biol.Chem. 269: 19953-19962 (1994)), and (14) DEP-1; (IV) PTPa,_PTPe. All receptor-type PTPases except Type IV contain two PTPase domains. Novel PTPases are continuously identified, and it is anticipated that more than 500 different species will be found in the human genome, i.e. close to the predicted size of the protein tyrosine kinase superfamily (Hanks and Hunter, FASEB J. 9: 576-596 (1995)).
PTPases are the biological counterparts to protein tyrosine kinases (PTKs). Therefore, one important function of PTPases is to control, down-regulate, the activity of PTKs. However, a more complex picture of the function of PTPases now emerges. Several studies have shown that some PTPases may actually act as positive mediators of cellular signaling. As an example, the SH2 domain-containing PTP1D seems to act as a positive mediator in insulin-stimulated Ras activation (Noguchi et al., Mol. Cell. Biol. 14: 6674-6682 (1994)) and of growth factor-induced mitogenic signal transduction (Xiao et al., J. Biol. Chem. 269: 21244-21248 (1994)), whereas the homologous PTP1C seems to act as a negative regulator of growth factor-stimulated proliferation (Bignon and Siminovitch, Clin. Immunol. Immunopathol. 73:168-179 (1994)). Another example of PTPases as positive regulators has been provided by studies designed to define the activation of the Src-family of tyrosine kinases. In particular, several lines of evidence indicate that CD45 is positively regulating the activation of hematopoietic cells, possibly through dephosphorylation of the C-terminal tyrosine of Fyn and Lck (Chan et al., Annu. Rev. Immunol. 12: 555-592 (1994)).
Dual specificity protein tyrosine phosphatases (dsPTPases) define a subclass within the PTPases family that can hydrolyze phosphate from phosphortyrosine as well as from phosphor-serine/threonine. dsPTPases contain the signature sequence of PTPases: His-Cys-Axx-Xxx-Gly-Xxo-Xxx-Arg. At least three dsPTPases have been shown to dephosphorylate and inactivate extracellular signal-regulated kinase (ERKs)/mitogen-activated protein kinase (MAPK): MAPK phosphatase (CL100, 3CH134) (Charles et al, Proc. Natl. Acad. Sci. USA 90: 5292-296 (1993)); PAC-1 (Ward et al., Nature 367: 651-654 (1994)); rVH6 Mourey et al., J. Biol. Chem. 271: 3795-3802 (1996)). Transcription of sPTPases are induced by different stimuli, e.g. oxidative stress or heat hock (Ishibashi et al., J. Biol. Chem. 269: 29897-29902 (1994); Keyse and Emslie, Nature 359: 644-647 (1992)). Further, they may be involved in regulation of the cell cycle: cdc25 (Millar and Russell, Cell 68: 407-410 (1992)); KAP (Hannon et al., Proc. Natl. Acad. Sci. USA 91: 1731-1735 (1994)). Interestingly, tyrosine dephosphorylation of cdc2 by a dual specific phosphatase, cdc25, is required for induction of mitosis in yeast (review by Walton and Dixon, Annu. Rev. Biochem. 62: 101-120 (1993)).
PTPases were originally identified and purified from cell and tissue lysates using a variety of artificial substrates and therefore their natural function of dephosphorylation was not well known. Since tyrosine phosphorylation by tyrosine kinases is usually associated with cell proliferation, cell transformation and cell differentiation, it was assumed that PTPases were also associated with these events.
This association has now been proven to be the case with many PTPases. PTP1B, a phosphatase whose structure was recently elucidated (Barford et al., Science 263:1397-1404 (1994)) has been shown to be involved in insulin-induced oocyte maturation (Flint et al., The EMBO J. 12:1937-46 (1993)) and recently it has been suggested that the overexpression of this enzyme may be involved in p185 c-erb B2 -associated breast and ovarian cancers (Wiener, et al., J. Natl. Cancer Inst. 86:372-8 (1994); Weiner et al., Am. J. Obstet. Gynecol. 170:1177-883 (1994)). The insulin-induced oocyte maturation mechanism has been correlated with the ability of PTP1B to block activation of S6 kinase. The association with cancer is recent evidence which suggests that overexpression of PTP1B is statistically correlated with increased levels of p185 c-erb B2 in ovarian and breast cancer. The role of PTP1B in the etiology and progression of the disease has not yet been elucidated. Inhibitors of PTP1B may therefore help clarify the role of PTP1B in cancer and in some cases provide therapeutic treatment for certain forms of cancer.
The activity of a number of other newly discussed phosphatases are currently under investigation. Two of these: PTP1C and Syp/PTP1DISHPTP2/PTP2C have recently been implicated in the activation of Platelet Derived Growth Factor and Epidermal Growth Factor induced responses (Li et al., Mole. Cell. Biol. 14:509-17 (1994)). Since both growth factors are involved in normal cell processing as well as disease states such as cancer and artherosclerosis, it is hypothesized that inhibitors of these phosphatases would also show therapeutic efficacy. Accordingly, the compounds of the present invention which exhibit inhibitory activity against various PTPases, are indicated in the treatment or management of the foregoing diseases.
PTPases: the insulin receptor signaling pathway/diabetes
Insulin is an important regulator of different metabolic processes and plays a key role in the control of blood glucose. Defects related to its synthesis or signaling lead to diabetes mellitus. Binding of insulin to its receptor causes rapid (auto)phosphorylation of several tyrosine residues in the intracellular part of the b-subunit. Three closely positioned tyrosine residues (the tyrosine-1150 domain) must all be phosphorylated to obtain full activity of the insulin receptor tyrosine kinase (IRTK) which transmits the signal further downstream by tyrosine phosphorylation of other cellular substrates, including insulin receptor substrate-1 (IRS-1) (Wilden et al., J. Biol. Chem. 267: 16660-16668 (1992); Myers and White, Diabetes 42: 643-650 (1993); Lee and Pilch, Am. J. Physiol. 266: C319-C334 (1994); White et al., J. Biol. Chem. 263: 2969-2980 (1988)). The structural basis for the function of the tyrosine-triplet has been provided by recent X-ray crystallographic studies of IRTK that showed tyrosine-1150 to be autoinhibitory in its unphosphorylated state (Hubbard et al., Nature 372: 746-754 (1994)).
Several studies clearly indicate that the activity of the auto-phosphorylated IRTK can be reversed by dephosphorylation in vitro (reviewed in Goldstein, Receptor 3: 1-15 (1993); Mooney and Anderson, J. Biol.Chem. 264: 6850-6857 (1989)), with the tri-phosphorylated tyrosine-1150 domain being the most sensitive target for protein-tyrosine phosphatases (PTPases) as compared to the di- and mono- phosphorylated forms (King et al., Biochem. J. 275: 413-418 (1991)). It is, therefore, tempting to speculate that this tyrosine-triplet functions as a control switch of IRTK activity. Indeed, the IRTK appears to be tightly regulated by PTP-mediated dephosphorylation in vivo (Khan et al., J. Biol. Chem. 264: 12931-12940 (1989); Faure et al., J. Biol. Chem. 267: 11215-11221 (1992); Rothenberg et al., J. Biol. Chem. 266: 8302-8311 (1991)). The intimate coupling of PTPases to the insulin signaling pathway is further evidenced by the finding that insulin differentially regulates PTPase activity in rat hepatoma cells (Meyerovitch et al., Biochemistry 31: 10338-10344 (1992)) and in livers from alloxan diabetic rats (Boylan et al., J. Clin. Invest. 90: 174-179 (1992)).
Relatively little is known about the identity of the PTPases involved in IRTK regulation. However, the existence of PTPases with activity towards the insulin receptor can be demonstrated as indicated above. Further, when the strong PTPase-inhibitor pervanadate is added to whole cells an almost full insulin response can be obtained in adipocytes (Fantus et al., Biochemistry 28: 8864-8871 (1989); Eriksson et al., Diabetologia 39: 235-242 (1995)) and skeletal muscle (Leighton et al., Biochem. J. 276: 289-292 (1991)). In addition, recent studies show that a new class of peroxovanadium compounds act as potent hypoglycemic compounds in vivo (Posner et al.,supra). Two of these compounds were demonstrated to be more potent inhibitors of dephosphorylation of the insulin receptor than of the EGF-receptor.
It was recently found that the ubiquitously expressed SH2 domain containing PTPase, PTP1D (Vogel et al., 1993, supra), associates with and dephosphorylates IRS-1, but apparently not the IR itself (Kuhn{acute over (e)} et al., J. Biol. Chem. 268: 11479-11481 (1993); (Kuhn{acute over (e)} et al., J. Biol. Chem. 269:15833-15837 (1994)).
Previous studies suggest that the PTPases responsible for IRTK regulation belong to the class of membrane-associated (Faure et al., J. Biol. Chem. 267:11215-11221 (1992)) and glycosylated molecules (H{umlaut over (a)}ring et al., Biochemistry 23: 3298-3306 (1984); Sale, Adv. Prot. Phosphatases 6:159-186 (1991)). Hashimoto et al. have proposed that LAR might play a role in the physiological regulation of insulin receptors in intact cells (Hashimoto et al., J. Biol.Chem. 267: 13811-13814 (1992)). Their conclusion was reached by comparing the rate of dephosphorylationlinactivation of purified IR using recombinant PTP1B as well as the cytoplasmic domains of LAR and PTPa. Antisense inhibition was recently used to study the effect of LAR on insulin signaling in a rat hepatoma cell line (Kulas et al., J. Biol. Chem. 270: 2435-2438 (1995)). A suppression of LAR protein levels by about 60 percent was paralleled by an approximately 150 percent increase in insulin-induced auto-phosphorylation. However, only a modest 35 percent increase in IRTK activity was observed, whereas the insulin-dependent phosphatidylinositol 3-kinase (PI 3-kinase) activity was significantly increased by 350 percent. Reduced LAR levels did not alter the basal level of IRTK tyrosine phosphorylation or activity. The authors speculate that LAR could specifically dephosphorylate tyrosine residues that are critical for PI 3-kinase activation either on the insulin receptor itself or on a downstream substrate. While previous reports indicate a role of PTPa in signal transduction through src activation (Zheng et al., Nature 359: 336-339 (1992); den Hertog et al., EMBO J. 12: 3789-3798 (1993)) and interaction with GRB-2 (den Hertog et al., EMBO J. 13: 3020-3032 (1994); Su et a., J. Biol. Chem. 269: 18731-18734 (1994)), a recent study suggests a function for this phosphatase and its close relative PTPe as negative regulators of the insulin receptor signal (Møller et al., 1995 supra). This study also indicates that receptor-like PTPases play a significant role in regulating the IRTK, whereas intracellular PTPases seem to have little, if any, activity towards the insulin receptor. While it appears that the target of the negative regulatory activity of PTPases a and e is the receptor itself, the downmodulating effect of the intracellular TC-PTP seems to be due to a downstream function in the IR-activated signal. Although PTP1B and TC-PTP are closely related, PTP1B had only little influence on the phosphorylation pattern of insulin-treated cells. Both PTPases have distinct structural features that determine their subcellular localization and thereby their access to defined cellular substrates (Frangione et al., Cell 68: 545-560 (1992); Faure and Posner, Glia 9: 311-314 (1993)). Therefore, the lack of activity of PTP1B and TC-PTP towards the IRTK may, at least in part, be explained by the fact that they do not co-localize with the activated insulin receptor. In support of this view, PTP1B and TC-PTP have been excluded as candidates for the IR-associated PTPases in hepatocytes based on subcellular localization studies (Faure et al., J. Biol. Chem. 267: 11215-11221 (1992)).
The transmembrane PTPase CD45, which is believed to be hematopoietic cell-specific, was in a recent study found to negatively regulate the insulin receptor tyrosine kinase in the human multiple myeloma cell line U266 (Kulas et al., J. Biol.Chem. 271: 755-760 (1996)).
PTPases: somatostatin
Somatostatin inhibits several biological functions including cellular proliferation (Lamberts et al., Molec. Endocrinol. 8: 1289-1297 (1994)). While part of the antiproliferative activities of somatostatin are secondary to its inhibition of hormone and growth factor secretion (e.g. growth hormone and epidermal growth factor), other antiproliferative effects of somatostatin are due to a direct effect on the target cells. As an example, somatostatin analogs inhibit the growth of pancreatic cancer presumably via stimulation of a single PTPase, or a subset of PTPases, rather than a general activation of PTPase levels in the cells (Liebow et al., Proc. Natl. Acad. Sci. USA 86: 2003-2007 (1989); Colas et al., Eur. J. Biochem. 207: 1017-1024 (1992)). In a recent study it was found that somatostatin stimulation of somatostatin receptors SSTR1, but not SSTR2, stably expressed in CHO-K1 cells can stimulate PTPase activity and that this stimulation is pertussis toxin-sensitive. Whether the inhibitory effect of somatostatin on hormone and growth factor secretion is caused by a similar stimulation of PTPase activity in hormone producing cells remains to be determined.
PTPases: the immune system/autoimmunity
Several studies suggest that the receptor-type PTPase CD45 plays a critical role not only for initiation of T cell activation, but also for maintaining the T cell receptor-mediated signaling cascade. These studies are reviewed in: (Weiss A., Ann. Rev. Genet 25: 487-510 (1991); Chan et al., Annu. Rev. Immunol 12: 555-592 (1994); Trowbridge and Thomas, Annu. Rev. Immunol. 12: 85-116 (1994)). CD45 is one of the most abundant of the cell surface glycoproteins and is expressed exclusively on hemopoetic cells. In T cells, it has been shown that CD45 is one of the critical components of the signal transduction machinery of lymphocytes. In particular, evidence has suggested that CD45 phosphatase plays a pivotal role in antigen-stimulated proliferation of T lymphocytes after an antigen has bound to the T cell receptor (Trowbridge, Ann. Rev. immunol, 12:85-116 (1994)). Several studies suggest that the PTPase activity of CD45 plays a role in the activation of Lck, a lymphocyte-specific member of the Src family protein-tyrosine kinase (Mustelin etal., Proc. Natl. Acad. Sci. USA 86: 6302-6306 (1989); Ostergaard et al., Proc. Natl. Acad. Sci. USA 86: 8959-8963 (1989)). These authors hypothesized that the phosphatase activity of CD45 activates Lck by dephosphorylation of a C-terminal tyrosine residue, which may, in turn, be related to T-cell activation. In a recent study it was found that recombinant p56lck specifically associates with recombinant CD45 cytoplasmic domain protein, but not to the cytoplasmic domain of the related PTPa (Ng et al., J. Biol. Chem. 271: 1295-1300 (1996)). The p56lck-CD45 interaction seems to be mediated via a nonconventional SH2 domain interaction not requiring phosphotyrosine. In immature B cells, another member of the Src family protein-tyrosine kinases, Fyn, seems to be a selective substrate for CD45 compared to Lck and Syk (Katagiri et al., J. Biol. Chem. 270: 27987-27990 (1995)).
Studies using transgenic mice with a mutation for the CD45-exon6 exhibited lacked mature T cells. These mice did not respond to an antigenic challenge with the typical T cell mediated response (Kishihara et al., Cell 74:143-56 (1993)). Inhibitors of CD45 phosphatase would therefore be very effective therapeutic agents in conditions that are associated with autoimmune disease.
CD45 has also been shown to be essential for the antibody mediated degranulation of mast cells (Berger et al., J. Exp. Med. 180:471-6 (1994)). These studies were also done with mice that were CD45-deficient. In this case, an IgE-mediated degranulation was demonstrated in wild type but not CD45-deficient T cells from mice. These data suggest that CD45 inhibitors could also play a role in the symptomatic or therapeutic treatment of allergic disorders.
Another recently discovered PTPase, an inducible lymphoid-specific protein tyrosine phosphatase (HePTP) has also been implicated in the immune response. This phosphatase is expressed in both resting T and B lymphocytes, but not non-hemopoetic cells. Upon stimulation of these cells, mRNA levels from the HePTP gene increase 10-15 fold (Zanke et al., Eur. J. Immunol. 22:235-239 (1992)). In both T and B cells HePTP may function during sustained stimulation to modulate the immune response through dephosphorylation of specific residues. Its exact role, however remains to be defined.
Likewise, the hematopoietic cell specific PTP1C seems to act as a negative regulator and play an essential role in immune cell development. In accordance with the above-mentioned important function of CD45, HePTP and PTP1C, selective PTPase inhibitors may be attractive drug candidates both as immunosuppressors and as immunostimulants. One recent study illustrates the potential of PTPase inhibitors as immunmodulators by demonstrating the capacity of the vanadium-based PTPase inhibitor, BMLOV, to induce apparent B cell selective apoptosis compared to T cells (Schieven et al., J. Biol. Chem. 270: 20824-20831 (1995)).
PTPases: cell-cell interactions/cancer
Focal adhesion plaques, an in vitro phenomenon in which specific contact points are formed when fibroblasts grow on appropriate substrates, seem to mimic, at least in part, cells and their natural surroundings. Several focal adhesion proteins are phosphorylated on tyrosine residues when fibroblasts adhere to and spread on extracellular matrix (Gumbiner, Neuron 11, 551-564 (1993)). However, aberrant tyrosine phosphorylation of these proteins can lead to cellular transformation. The intimate association between PTPases and focal adhesions is supported by the finding of several intracellular PTPases with ezrin-like N-terminal domains, e.g. PTPMEGI (Gu et al., Proc. Natl. Acad. Sci. USA 88: 5867-5871 (1991)), PTPH1 (Yang and Tonks, Proc. Natl. Acad. Sci. USA 88: 5949-5953 (1991)) and PTPD1 (Møller et al., Proc. Natl. Acad. Sci. USA 91: 7477-7481 (1994)). The ezrin-like domain show similarity to several proteins that are believed to act as links between the cell membrane and the cytoskeleton. PTPD1 was found to be phosphorylated by and associated with c-src in vitro and is hypothesized to be involved in the regulation of phosphorylation of focal adhesions (Møller et al., supra).
PTPases may oppose the action of tyrosine kinases, including those responsible for phosphorylation of focal adhesion proteins, and may therefore function as natural inhibitors of transformation. TC-PTP, and especially the truncated form of this enzyme (Cool et al., Proc. Natl. Acad. Sci. USA 87: 7280-7284 (1990)), can inhibit the transforming activity of v-erb and v-fms (Lammers et al., J. Biol. Chem. 268: 22456-22462 (1993); Zander et al., Orcogene 8: 1175-1182 (1993)). Moreover, it was found that transformation by the oncogenic form of the HER2/neu gene was suppressed in NIH 3T3 fribroblasts overexpressing PTP1B (Brown-Shimer et al., Cancer Res. 52: 478-482 (1992)).
The expression level of PTP1B was found to be increased in a mammary cell line transformed with neu (Zhay et al., Cancer Res. 53: 2272-2278 (1993)). The intimate relationship between tyrosine kinases and PTPases in the development of cancer is further evidenced by the recent finding that PTPe is highly expressed in murine mammary tumors in transgenic mice over-expressing c-neu and v-Ha-ras, but not c-myc or int-2 (Elson and Leder, J. Biol. Chem. 270:26116-26122 (1995)). Further, the human gene encoding PTPg was mapped to 3p21, a chromosomal region which is frequently deleted in renal and lung carcinomas (LaForgia et a[., Proc. Natl. Acad. Sci. USA 88: 5036-5040 (1991)).
In this context, it seems significant that PTPases appear to be involved in controlling the growth of fibroblasts. In a recent study it was found that Swiss 3T3 cells harvested at high density contain a membrane-associated PTPase whose activity on an average is 8-fold higher than that of cells harvested at low or medium density (Pallen and Tong, Proc. Natl. Acad. Sci. USA 88: 6996-7000 (1991)). It was hypothesized by the authors that density-dependent inhibition of cell growth involves the regulated elevation of the activity of the PTPase(s) in question. In accordance with this view, a novel membrane-bound, receptor-type PTPase, DEP-1, showed enhanced (>=10-fold) expression levels with increasing cell density of WI-38 human embryonic lung fibroblasts and in the AG1518 fibroblast cell line ({umlaut over (O)}stman et al., Proc. Natl. Acad. Sci. USA 91: 9680-9684 (1994)).
Two closely related receptor-type PTPases, PTPk and PTPμ, can mediate homophilic cell-cell interaction when expressed in non-adherent insect cells, suggesting that these PTPases might have a normal physiological function in cell-to-cell signaling (Gebbink et at., J. Biol.Chem. 268: 16101-16104 (1993); Brady-Kalnay et al., J. Cell Biol. 122: 961-972 (1993); Sap et al., Mol. Cell. Biol. 14: 1-9 (1994)). Interestingly, PTPk and PTPμ do not interact with each other, despite their structural similarity (Zondag et al., J. Biol.Chem. 270: 14247-14250 (1995)). From the studies described above it is apparent that PTPases may play an important role in regulating normal cell growth. However, as pointed out above, recent studies indicate that PTPases may also function as positive mediators of intracellular signaling and thereby induce or enhance mitogenic responses. Increased activity of certain PTPases might therefore result in cellular transformation and tumor formation. Indeed, in one study over-expression of PTPa was found to lead to transformation of rat embryo fibroblasts (Zheng, supra). In addition, a novel PTP, SAP-1, was found to be highly expressed in pancreatic and colorectal cancer cells. SAP-1 is mapped to chromosome 19 region q13.4 and might be related to carcinoembryonic antigen mapped to 19q 13.2 (Uchida et al., J. Biol.Chem. 269: 12220-12228 (1994)). Further, the dsPTPase, cdc25, dephosphorylates cdc2 at Thr14/Tyr-15 and thereby functions as positive regulator of mitosis (reviewed by Hunter, Cell 80: 225-236 (1995)). Inhibitors of specific PTPases are therefore likely to be of significant therapeutic value in the treatment of certain forms of cancer.
PTPases: platelet aggregation
Recent studies indicate that PTPases are centrally involved in platelet aggregation. Agonist-induced platelet activation results in calpain-catalyzed cleavage of PTP1B with a concomitant 2-fold stimulation of PTPase activity (Frangioni et al., EMBO J. 12:48434856 (1993)). The cleavage of PTP1B leads to subcellular relocation of the enzyme and correlates with the transition from reversible to irreversible platelet aggregation in platelet-rich plasma. In addition, the SH2 domain containing PTPase, PTP1C/SH-PTP1, was found to translocate to the cytoskeleton in platelets after thrombin stimulation in an aggregation-dependent manner (Li et al., FEBS Lett. 343: 89-93 (1994)).
Although some details in the above two studies were recently questioned there is over-all agreement that PTP1B and PTP1C play significant functional roles in platelet aggregation (Ezumi et al., J. Biol. Chem. 270:11927-11934 (1995)). In accordance with these observations, treatment of platelets with the PTPase inhibitor pervanadate leads to significant increase in tyrosine phosphorylation, secretion and aggregation (Pumiglia et al., Biochem. J. 286: 441-449 (1992)).
PTPases: osteoporosis
The rate of bone formation is determined by the number and the activity of osteoblasts, which in term are determined by the rate of proliferation and differentiation of osteoblas progenitor cells, respectively. Histomorphometric studies indicate that the osteoblast number is the primary determinant of the rate of bone formation in humans (Gruber et al., Mineral Electrolyte Metab. 12: 246-254 (1987); reviewed in Lau et al., Biochem. J. 257: 23-36 (1989)). Acid phosphatases/PTPases may be involved in negative regulation of osteoblast proliferation. Thus, fluoride, which has phosphatase inhibitory activity, has been found to increase spinal bone density in osteoporotics by increasing osteoblast proliferation (Lau et al., supra). Consistent with this observation, an osteoblastic acid phosphatase with PTPase activity was found to be highly sensitive to mitogenic concentrations of fluoride (Lau et al., J. Biol. Chem. 260: 4653-4660 (1985); Lau et al., J. Biol. Chem. 262: 1389-1397 (1987); Lau et al., Adv. Protein Phosphatases 4:165-198 (1987)). Interestingly, it was recently found that the level of membrane-bound PTPase activity was increased dramatically when the osteoblast-like cell line UMR 106.06 was grown on collagen type-l matrix compared to uncoated tissue culture plates. Since a significant increase in PTPase activity was observed in density-dependent growth arrested fibroblasts (Pallen and Tong, Proc. Natl. Acad. Sci. 88: 6996-7000 (1991)), it might be speculated that the increased PTPase activity directly inhibits cell growth. The mitogenic action of fluoride and other phosphatase inhibitors (molybdate and vanadate) may thus be explained by their inhibition of acid phosphatases/PTPases that negatively regulate the cell proliferation of osteoblasts. The complex nature of the involvement of PTPases in bone formation is further suggested by the recent identification of a novel parathyroid regulated, receptor-like PTPase, OST-PTP, expressed in bone and testis (Mauro et al., J. Biol. Chem. 269: 30659-30667 (1994)). OST-PTP is up-regulated following differentiation and matrix formation of primary osteoblasts and subsequently down-regulated in the osteoblasts which are actively mineralizing bone in culture. It may be hypothesized that PTPase inhibitors may prevent differentiation via inhibition of OST-PTP or other PTPases thereby leading to continued proliferation. This would be in agreement with the above-mentioned effects of fluoride and the observation that the tyrosine phosphatase inhibitor orthovanadate appears to enhance osteoblast proliferation and matrix formation (Lau et al., Endocrinology 116: 2463-2468 (1988)). In addition, it was recently observed that vanadate, vanadyl and pervanadate all increased the growth of the osteoblast-like cell line UMR106. Vanadyl and pervanadate were stronger stimulators of cell growth than vanadate. Only vanadate was able to regulate the cell differentiation as measured by cell alkaline phosphatase activity (Cortizo et al., Mol. Cell. Biochem. 145: 97-102 (1995)).
PTPases: microorganisms
Dixon and coworkers have called attention to the fact that PTPases may be a key element in the pathogenic properties of Yersinia (reviewed in Clemens et al. Molecular Microbiology 5: 2617-2620 (1991)). This finding was rather surprising since tyrosine phosphate is thought to be absent in bacteria. The genus Yersinia comprises 3 species: Y. pestis (responsible for the bubonic plague), Y. pseudoturberculosis and Y. enterocolitica (causing enteritis and mesenteric lymphadenitis). Interestingly, a dual-specificity phosphatase, VH1, has been identified in Vaccinia virus (Guan et al., Nature 350: 359-263 (1991)). These observations indicate that PTPases may play critical roles in microbial and parasitic infections, and they further point to PTPase inhibitors as a novel, putative treatment principle of infectious diseases.
DESCRIPTION OF THE INVENTION
The present invention relates to compounds of Formula 1 and Formula 2, wherein W, X, Y, Z, R 1 , R 2 , R 3 are defined below.
In the above Formula 1 and Formula 2,
X is O, NH, S, SO or SO 2 ;
Y is O or S;
R 1 is NO 2 , NH 2 or NHR 4 wherein R 4 is SO 2 CF 3 , C 1 -C 6 alkyl or C 1 -C 6 alkylaryl, wherein the alkyl and aryl groups may be optionally substituted;
R 2 is hydrogen, nitro, halo, cyano, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, COOH, carboxyC 1 -C 6 alkyl, C 1 -C 6 alkyloxycarbonyl, aryloxycarbonyl, arylC 1 -C 6 alkyloxycarbonyl or CONR 6 R 7 , wherein R 6 and R 7 are independently selected from hydrogen, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, C 1 -C 6 alkylcarbonyl, arylcarbonyl, arylC 1 -C 6 alkylcarbonyl, C 1 -C 6 alkylcarboxy or arylC 1 -C 6 alkylcarboxy wherein the alkyl and aryl groups are optionally substituted; or
R 6 and R 7 are taken together with the nitrogen to which they are attached forming a cyclic or bicyclic system containing 3 to 11 carbon atoms and 0 to 2 additional heteroatoms selected from nitrogen, oxygen or sulfur, the ring system can optionally be substituted with at least one C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, hydroxy, C 1 -C 6 alkyloxy, arylC 1 -C 6 alkyloxy, C 1 -C 6 alkyloxyC 1 -C 6 alkyl, NR 9 R 10 or C 1 -C 6 alkylaminoC 1 -C 6 alkyl, wherein R 9 and R 10 are independently selected from hydrogen, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, C 1 -C 6 alkyl-carbonyl, arylcarbonyl, arylC 1 -C 6 alkylcarbonyl, C 1 -C 6 alkyl-carboxy or arylC 1 -C 6 alkylcarboxy wherein the alkyl and aryl groups are optionally substituted; or
R 6 and R 7 are independently a saturated or partial saturated cyclic 5,6 or 7 membered amine or lactam;
R 3 is hydrogen, cyano, hydroxy, thiol, C 1 -C 6 alkylthio, SOC 1 -C 6 alkyl, SO 2 C 1 -C 6 alkyl, COOR 5 , C 1 -C 6 alkyl, C 1 -C 6 alkyloxy, NR 6 R 7 , aryl, arylC 1 -C 6 alkyl, C 1 -C 6 alkyloxycarbonylC 1 -C 6 alkyl, arylC 1 -C 6 alkyloxy-carbonylC 1 -C 6 alkyl, CONR 6 R 7 , -carbonylNR 6 C 1 -C 6 alkylCOR 8 , wherein R 5 is selected from hydrogen, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, C 1 -C 6 alkylcarbonyl, arylcarbonyl, arylC 1 -C 6 alkylcarbonyl, C 1 -C 6 alkylcarboxy, C 1 -C 6 alkyloxycarbonylC 1 -C 6 alkyl, arylC 1 -C 6 alkyloxy-carbonylC 1 -C 6 alkyl; wherein the alkyl and aryl groups are optionally substituted as defined below and R 6 and R 7 are defined as above;
R 8 is hydroxy, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, C 1 -C 6 alkyloxy, aryloxy, arylC 1 -C 6 alkyloxy or NR 6 R 7 ; wherein R 6 and R 7 are defined as above;
W is N and Z is NR 11 or CR 11 R 12 ;
or
W is CR 11 and Z is O or NR 11 ;
wherein R 11 and R 12 are independently selected from hydrogen, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, wherein the alkyl and aryl groups are optionally substituted;
In formula 2; the aryl group is an unsubstituted, mono-, di- or trisubstituted monocyclic, polycyclic, biaryl or heterocyclic aromatic fused group optionally substituted as outlined below under the definition section.
Definitions
As used herein, the term “attached” or “-” (e.g. —COR 8 which indicates that the carbonyl is attached to the scaffold) signifies a stable covalent bond, certain preferred points of attachment being apparent to those skilled in the art.
The terms “halogen” or “halo” include fluorine, chlorine, bromine, and iodine.
The term “alkyl” includes C 1 -C 6 straight chain saturated and C 2 -C 6 unsaturated aliphatic hydrocarbon groups, C 1 -C 6 branched saturated and C 2 -C 6 unsaturated aliphatic hydrocarbon groups, C 3 -C 6 cyclic saturated and C 5 -C 6 unsaturated aliphatic hydrocarbon groups, and C 1 -C 6 straight chain or branched saturated and C 2 -C 6 straight chain or branched unsaturated aliphatic hydrocarbon groups substituted with C 3 -C 6 cyclic saturated and unsaturated aliphatic hydrocarbon groups having the specified number of carbon atoms. For example, this definition shall include but is not limited to methyl (Me), ethyl (Et), propyl (Pr), butyl (Bu), pentyl, hexyl, heptyl, ethenyl, propenyl, butenyl, penentyl, hexenyl, isopropyl (i-Pr), isobutyl (i-Bu), tert-butyl (t-Bu), sec-butyl (s-Bu), isopentyl, neopentyl, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cyclopentenyl, cyclohexenyl, methylcyclopropyl, ethylcyclohexenyl, butenylcyclopentyl, and the like.
The term “substituted alkyl” represents an alkyl group as defined above wherein the substitutents are independently selected from halo, cyano, nitro, trihalomethyl, carbamoyl, hydroxy, COOR 5 , C 1 -C 6 alkyloxy, aryloxy, arylC 1 -C 6 alkyloxy, thio, C 1 -C 6 alkylthio, arylthio, arylC 1 -C 6 alkylthio, NR 6 R 7 , C 1 -C 6 alkylamino, arylamino, arylC 1 -C 6 alkylamino, di(arylC 1 -C 6 alkyl)amino, C 1 -C 6 alkylcarbonyl, arylC 1 -C 6 alkylcarbonyl, C 1 -C 6 alkyl-carboxy, arylC 1 -C 6 alkylcarboxy, C 1 -C 6 alkylcarbonylamino, -C 1 -C 6 alkyl-aminoCOR 8 , arylC 1 -C 6 alkylcarbonylamino, tetrahydrofuryl, morpholinyl, piperazinyl, hydroxypyranyl, —COR 8 , —CONR 6 R 7 , -C 1 -C 6 alkylCONR 6 R 7 wherein R 5 , R 6 , R 7 and R 8 are defined as above.
The term “alkyloxy” (e.g. methoxy, ethoxy, propyloxy, allyloxy, cyclohexyloxy) represents an “alkyl” group as defined above having the indicated number of carbon atoms attached through an oxygen bridge. The term “alkyloxyalkyl” represents an “alkyloxy” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “aryloxy” (e.g. phenoxy, naphthyloxy and the like) represents an aryl group as defined below attached through an oxygen bridge. The term “arylalkyloxy” (e.g. phenethyloxy, naphthylmethyloxy and the like) represents an “arylalkyl” group as defined below attached through an oxygen bridge.
The term “arylalkyloxyalkyl” represents an “arylalkyloxy” group as defined above attached through an “alkyl” group defined above having the indicated number of carbon atoms.
The term “arylthio” (e.g. phenylthio, naphthylthio and the like) represents an “aryl” group as defined below attached through an sulfur bridge.
The term “alkyloxycarbonyl” (e.g. methylformiat, ethylformiat and the like) represents an “alkyloxy” group as defined above attached through a carbonyl group.
The term “aryloxycarbonyl” (e.g. phenylformiat, 2-thiazolylformiat and the like) represents an “aryloxy” group as defined above attached through a carbonyl group.
The term “arylalkyloxycarbonyl” (e.g. benzylformiat, phenyletylformiat and the like) represents an “arylalkyloxy” group as defined above attached through a carbonyl group.
The term “alkyloxycarbonylalkyl” represents an “alkyloxycarbonyl” group as defined above attached through an “alkyl” group as defined above having the indicated number of carbon atoms.
The term “arylalkyloxycarbonylalkyl” represents an “arylalkyloxycarbonyl” group as defined above attached through an “alkyl” group as defined above having the indicated number of carbon atoms.
The term “alkylthio” (e.g. methylthio, ethylthio, propylthio, cyclohexenylthio and the like) represents an “alkyl” group as defined above having the indicated number of carbon atoms attached through a sulfur bridge.
The term “arylalkylthio” (e.g. phenylmethylthio, phenylethylthio, and the like) represents an “arylalkyl” group as defined above having the indicated number of carbon atoms attached through a sulfur bridge.
The term “alkylthioalkyl” represents an “alkylthio” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “arylalkylthioalkyl” represents an “arylalkylthio” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “alkylamino” (e.g. methylamino, diethylamino, butylamino, N-propyl-N-hexylamino, (2-cyclopentyl)propylamino, hexenylamino, pyrrolidinyl, piperidinyl and the like) represents one or two “alkyl” groups as defined above having the indicated number of carbon atoms attached through an amine bridge. The two alkyl groups may be taken together with the nitrogen to which they are attached forming a cyclic or bicyclic system containing 3 to 11 carbon atoms and 0 to 2 additional heteroatoms selected from nitrogen, oxygen or sulfur, the ring system can optionally be substituted with at least one C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, hydroxy, C 1 -C 6 alkyloxy, C 1 -C 6 alkyloxyC 1 -C 6 alkyl, NR 9 R 10 , C 1 -C 6 alkylaminoC 1 -C 6 alkyl substituent wherein the alkyl and aryl groups are optionally substituted as defined in the definition section and R 9 and R 10 are defined as above.
The term “arylalkylamino” (e.g. benzylamino, diphenylethylamino and the like) represents one or two “arylalkyl” groups as defined above having the indicated number of carbon atoms attached through an amine bridge. The two “arylalkyl” groups may be taken together with the nitrogen to which they are attached forming a cyclic or bicyclic system containing 3 to 11 carbon atoms and 0 to 2 additional heteroatoms selected from nitrogen, oxygen or sulfur, the ring system can optionally be substituted with at least one C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, hydroxy, C 1 -C 6 alkyloxy, C 1 -C 6 alkyloxyC 1 -C 6 alkyl, NR 9 R 10 , C 1 -C 6 alkylaminoC 1 -C 6 alkyl substituent wherein the alkyl and aryl groups are optionally substituted as defined in the definition section and R 9 and R 10 are defined as above.
The term “alkylaminoalkyl” represents an “alkylamino” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “arylalkylaminoalkyl” represents an “arylalkylamino” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “arylalkyl” (e.g. benzyl, phenylethyl) represents an “aryl” group as defined below attached through an alkyl having the indicated number of carbon atoms or substituted alkyl group as defined above. The term “alkylcarbonyl” (e.g. cyclooctylcarbonyl, pentylcarbonyl, 3-hexenylcarbonyl) represents an “alkyl” group as defined above having the indicated number of carbon atoms attached through a carbonyl group.
The term “arylalkylcarbonyl” (e.g. phenylcyclopropylcarbonyl, phenylethylcarbonyl and the like) represents an “arylalkyl” group as defined above having the indicated number of carbon atoms attached through a carbonyl group.
The term “alkylcarbonylalkyl” represents an “alkylcarbonyl” group attached through an “alkyl” group as defined above having the indicated number of carbon atoms.
The term “arylalkylcarbonylalkyl” represents an “arylalkylcarbonyl” group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “alkylcarboxy” (e.g. heptylcarboxy, cyclopropylcarboxy, 3-pentenylcarboxy) represents an “alkylcarbonyl” group as defined above wherein the carbonyl is in turn attached through an oxygen bridge.
The term “arylalkylcarboxy” (e.g. benzylcarboxy, phenylcyclopropylcarboxy and the like) represents an “arylalkylcarbonyl” group as defined above wherein the carbonyl is in turn attached through an oxygen bridge.
The term “alkylcarboxyalkyl” represents an “alkylcarboxy” group attached through an “alkyl” group as defined above having the indicated number of carbon atoms.
The term “arylalkylcarboxyalkyl” represents an “arylalkylcarboxy” group attached through an “alkyl” group as defined above having the indicated number of carbon atoms.
The term “alkylcarbonylamino” (e.g. hexylcarbonylamino, cyclopentylcarbonyl-aminomethyl, methylcarbonylaminophenyl) represents an “alkylcarbonyl” group as defined above wherein the carbonyl is in turn attached through the nitrogen atom of an amino group. The nitrogen atom may itself be substituted with an alkyl or aryl group.
The term “arylalkylcarbonylamino” (e.g. benzylcarbonylamino and the like) represents an “arylalkylcarbonyl” group as defined above wherein the carbonyl is in turn attached through the nitrogen atom of an amino group. The nitrogen atom may itself be substituted with an alkyl or aryl group.
The term “alkylcarbonylaminoalkyl” represents an “alkylcarbonylamino” group attached through an “alkyl” group as defined above having the indicated number of carbon atoms. The nitrogen atom may itself be substituted with an alkyl or aryl group.
The term “arylalkylcarbonylaminoalkyl” represents an “arylalkylcarbonylamino” group attached through an “alkyl” group as defined above having the indicated number of carbon atoms. The nitrogen atom may itself be substituted with an alkyl or aryl group.
The term “alkylcarbonylaminoalkylcarbonyl” represents an alkylcarbonylaminoalkyl group attached through a carbonyl group. The nitrogen atom may be further substituted with an “alkyl” or “aryl” group.
The term “aryl” represents an unsubstituted, mono-, di- or trisubstituted monocyclic, polycyclic, biaryl and heterocyclic aromatic groups covalently attached at any ring position capable of forming a stable covalent bond, certain preferred points of attachment being apparent to those skilled in the art (e.g., 3-indolyl, 4-imidazolyl). The aryl substituents are independently selected from the group consisting of halo, nitro, cyano, trihalomethyl, hydroxypyranyl, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, hydroxy, COOR 5 , C 1 -C 6 alkyloxy, C 1 -C 6 alkyloxyC 1 -C 6 alkyl, aryloxy, arylC 1 -C 6 alkyloxy, arylC 1 -C 6 alkyloxyC 1 -C 6 alkyl, thio, C 1 -C 6 alkylthio, C 1 -C 6 alkyl-thioC 1 -C 6 alkyl, arylthio, arylC 1 -C 6 alkylthio, arylC 1 -C 6 alkylthioC 1 -C 6 alkyl, NR 6 R 7 , C 1 -C 6 alkylamino, C 1 -C 6 alkylaminoC 1 -C 6 alkyl, arylamino, arylC 1 -C 6 alkylamino, arylC 1 -C 6 alkylaminoC 1 -C 6 alkyl, di(arylC 1 -C 6 alkyl)-aminoC 1 -C 6 alkyl, C 1 -C 6 alkylcarbonyl, C 1 -C 6 alkylcarbonylC 1 -C 6 alkyl, arylC 1 -C 6 alkyl-carbonyl, arylC 1 -C 6 alkylcarbonylC 1 -C 6 alkyl, C 1 -C 6 alkylcarboxy, C 1 -C 6 alkylcarboxyC 1 -C 6 alkyl, arylC 1 -C 6 alkylcarboxy, arylC 1 -C 6 alkyl-carboxyC 1 -C 6 alkyl, C 1 -C 6 alkylcarbonylamino, C 1 -C 6 alkylcarbonylaminoC 1 -C 6 alkyl, -carbonylNR 6 C 1 -C 6 alkylCOR 8 , arylC 1 -C 6 alkyl-carbonylamino, arylC 1 -C 6 alkylcarbonylaminoC 1 -C 6 alkyl, —CONR 6 R 7 , or -C 1 -C 6 alkyl-CONR 6 R 7 ;
wherein R 5 , R 6 , R 7 and R 8 are defined as above and the alkyl and aryl groups are optionally substituted as defined in the definition section;
The definition of aryl includes but is not limited to phenyl, biphenyl, indenyl, fluorenyl, naphthyl (1-naphthyl, 2-naphthyl), pyrrolyl (2-pyrrolyl), pyrazolyl (3-pyrazolyl), imidazolyl (1-imidazolyl, 2-imidazolyl, 4-imidazolyl, 5-imidazolyl), triazolyl (1,2,3-triazol-1-yl, 1,2,3-triazol-2-yl 1,2,3-triazol-4-yl, 1,2,4-triazol-3-yl), oxazolyl (2-oxazolyl, 4-oxazolyl, 5-oxazolyl), isoxazolyl (3-isoxazolyl, 4-isoxazolyl, 5-isoxazolyl), thiazolyl (2-thiazolyl, 4-thiazolyl, 5-thiazolyl), 1,3,4-oxadiazol-2-yl, 1,3,4-thiadiazol-2-yl, tetrazol-5-yl, thiophenyl (2-thiophenyl, 3-thiophenyl), pyridyl (2-pyridyl, 3-pyridyl, 4-pyridyl), pyrimidinyl (2-pyrimidinyl, 4-pyrimidinyl, 5-pyrimidinyl, 6-pyrimidinyl), pyrazinyl, pyridazinyl (3-pyridazinyl, 4-pyridazinyl, 5-pyridazinyl), quinolyl (2-quinolyl, 3-quinolyl, 4-quinolyl, 5-quinolyl, 6-quinolyl, 7-quinolyl, 8-quinolyl), isoquinolyl (1-isoquinolyl, 3-isoquinolyl, 4-isoquinolyl, 5-isoquinolyl, 6-isoquinolyl, 7-isoquinolyl, 8-isoquinolyl), benzo[b]furanyl (2-benzo[b]furanyl, 3-benzo[b]furanyl, 4-benzo[b]furanyl, 5-benzo[b]furanyl, 6-benzo[b]furanyl, 7-benzo[b]furanyl), 2,3-dihydro-benzo[b]furanyl (2-(2,3-dihydro-benzo[b]furanyl), 3-(2,3-dihydro-benzo[b]furanyl), 4-(2,3-dihydro-benzo[b]furanyl), 5-(2,3-dihydro-benzo[b]furanyl), 6-(2,3-dihydro-benzo[b]furanyl), 7-(2,3-dihydro-benzo[b]furanyl), benzo[b]thiophenyl (2-benzo[b]thiophenyl, 3-benzo[b]thiophenyl, 4-benzo[b]thiophenyl, 5-benzo[b]thiophenyl, 6-benzo[b]thiophenyl, 7-benzo[b]thiophenyl), 2,3-dihydro-benzo[b]-thiophenyl (2-(2,3-dihydro-benzo[b]thiophenyl), 3-(2,3-dihydro-benzo[b]-thiophenyl), 4-(2,3-dihydro-benzo[b]thiophenyl), 5-(2,3-dihydro-benzo[b]-thiophenyl), 6-(2,3-dihydro-benzo[b]thiophenyl), 7-(2,3-dihydro-benzo[b]-thiophenyl), indolyl (1-indolyl, 2-indolyl, 3-indolyl, 4-indolyl, 5-indolyl, 6-indolyl, 7-indolyl), indazole (1-indazolyl, 3-indazolyl, 4-indazolyl, 5-indazolyl, 6-indazolyl, 7-indazolyl), benzimidazolyl (1-benzimidazolyl, 2-benzimidazolyl, 4-benzimidazolyl, 5-benzimidazolyl, 6-benzimidazolyl, 7-benzimidazolyl, 8-benzimidazolyl), benzoxazolyl (1-benzoxazolyl, 2-benzoxazolyl), benzothiazolyl (1-benzothiazolyl, 2-benzothiazolyl, 4-benzothiazolyl, 5-benzothiazolyl, 6-benzothiazolyl, 7-benzothiazolyl), carbazolyl (1-carbazolyl, 2-carbazolyl, 3-carbazolyl, 4-carbazolyl), 5H-dibenz[b,f]azepine (5H-dibenz[b,f]azepin-1-yl, 5H-dibenz[b,f]azepine-2-yl, 5H-dibenz[b,f]azepine-3-yl, 5H-dibenz[b,f]azepine-4-yl, 5H-dibenz[b,f]-azepine-5-yl), 10,11-dihydro-5H-dibenz[b,f]azepine (10,11-dihydro-5H-dibenz[b,f]azepine-1-yl, 10,11-dihydro-5H-dibenz[b,f]azepine-2-yl, 10,11-dihydro-5H-dibenz[b,f]azepine-3-yl, 10,11-dihydro-5H-dibenz[b,f]azepine-4-yl, 10,11-dihydro-5H-dibenz[b,f]azepine-5-yl), piperidinyl (2-piperidinyl, 3-piperidinyl, 4-piperidinyl), pyrrolidinyl (1-pyrrolidinyl, 2-pyrrolidinyl, 3-pyrrolidinyl), phenylpyridyl (2-phenylpyridyl, 3-phenylpyridyl, 4-phenylpyridyl), phenylpyrimidinyl (2-phenylpyrimidinyl, 4-phenyl-pyrimidinyl, 5-phenylpyrimidinyl, 6-phenylpyrimidinyl), phenylpyrazinyl, phenylpyridazinyl (3-phenyl-pyridazinyl, 4-phenylpyridazinyl, 5-phenyl-pyridazinyl).
The term “arylcarbonyl” (e.g. 2-thiophenylcarbonyl, 3-methoxyanthrylcarbonyl, oxazolylcarbonyl) represents an “aryl” group as defined above attached through a carbonyl group.
The term “arylalkylcarbonyl” (e.g. (2,3-dimethoxyphenyl)-propylcarbonyl, (2-chloronaphthyl)pentenylcarbonyl, imidazolylcyclo-pentylcarbonyl) represents an “arylalkyl” group as defined above wherein the “alkyl” group is in turn attached through a carbonyl.
The compounds of the present invention have asymmetric centers and may occur as racemates, racemic mixtures, and as individual enantiomers or diastereoisomers, with all isomeric forms being included in the present invention as well as mixtures thereof.
Pharmaceutically acceptable salts of the compounds of formula 1 and formula 2, where a basic or acidic group is present in the structure, are also included within the scope of this invention. When an acidic substituent is present, such as —COOH or —P(O)(OH) 2 , there can be formed the ammonium, morpholinium, sodium, potassium, barium, calcium salt, and the like, for use as the dosage form. When a basic group is present, such as amino or a basic heteroaryl radical, such as pyridyl, an acidic salt, such as hydrochloride, hydrobromide, acetate, oxalate, maleate, fumarate, citrate, palmoate, methanesulfonate, p-toluenesulfonate, and the like, can be used as the dosage form.
Also, in the case of the —COOH or —P(O)(OH) 2 being present, pharmaceutically acceptable esters can be employed, e.g., methyl, tert-butyl, pivaloyloxymethyl, and the like, and those esters known in the art for modifying solubility or hydrolysis characteristics for use as sustained release or prodrug formulations.
In addition, some of the compounds of the instant invention may form solvates with water or common organic solvents. Such solvates are encompassed within the scope of the invention.
The term “therapeutically effective amount” shall mean that amount of drug or pharmaceutical agent that will elicit the biological or medical response of a tissue, system, animal, or human that is being sought by a researcher, veterinarian, medical doctor or other.
DETAILED DESCRIPTION
A preferred embodiment of this application relates to compounds having the structures shown in Formula 3 and Formula 4:
wherein
(i) R 2 , X and W are defined as above,
(ii) R 26 is OR 21 , NR 22 R 23 , wherein R 21 , R 22 and R 23 are independently selected from hydrogen, hydroxy, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, C 1 -C 6 alkylcarbonyl, arylcarbonyl, arylC 1 -C 6 alkylcarbonyl, C 1 -C 6 alkylcarboxy, arylC 1 -C 6 alkylcarboxy, C 1 -C 6 alkyloxycarbonylC 1 -C 6 alkyl, aryIC 1 -C 6 alkyloxy-carbonylC 1 -C 6 alkyl, C 1 -C 6 alkyloxycarbonylarylC 1 -C 6 alkyl; wherein the alkyl and aryl groups are optionally substituted or R 22 and R 23 are independently a saturated or partial saturated cyclic 5,6 or 7 membered amine or lactam; wherein the alkyl and aryl groups are optionally substituted or
R 22 and R 23 are taken together with the nitrogen to which they are attached forming a cyclic or bicyclic system containing 3 to 11 carbon atoms and 0 to 2 additional heteroatoms selected from nitrogen, oxygen or sulfur, the ring system can optionally be substituted with at least one C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, hydroxy, C 1 -C 6 alkyloxy, C 1 -C 6 alkyloxyC 1 -C 6 alkyl, NR 9 R 10 or C 1 -C 6 alkylaminoC 1 -C 6 alkyl substituent; wherein R 9 and R 10 are defined as above and the alkyl and aryl groups are optionally substituted or
R 22 and R 23 are independently -C 1 -C 6 alkylCONR 6 R 7 wherein R 6 and R 7 are defined as above and the alkyl and aryl groups are optionally substituted or
R 26 is selected from
wherein R 6 , R 22 and R 23 are defined as above;
(iii) A is selected from hydrogen, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl or from
wherein Ar is aryl and R 21 , R 22 , R 23 , and R 25 are independently selected from the group consisting of hydrogen, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, wherein the alkyl and aryl groups are optionally substituted as defined above and
(iv) B is selected from hydrogen, halo, nitro, cyano, COOH, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl, C 1 -C 6 alkyloxy, C 1 -C 6 alkyloxyC 1 -C 6 alkyl, C 1 -C 6 alkylthio, C 1 -C 6 alkylthioC 1 -C 6 alkyl, COR 8 , C 1 -C 6 alkylamino, C 1 -C 6 alkylaminoC 1 -C 6 alkyl, —CONR 6 R 7 C 1 -C 6 alkylcarbonyl, C 1 -C 6 alkylcarbonylC 1 -C 6 alkyl, C 1 -C 6 alkyl-carbonylamino, C 1 -C 6 alkylcarbonylaminoC 1 -C 6 alkyl, arylcarbonyl, arylC 1 -C 6 alkylcarbonyl, or B is selected from
wherein R 6 , R 21 , R 22 , R 23 , and R 25 are defined as above and (*) indicates the point of attachment of B.
The following compounds are preferred:
7-Amino-4-ethylsulfanyl-2-(4-methoxy-phenyl)thieno[3,4-d]pyridazin-1(2H)-one;
3-Amino-4H-naphtho[2,1-b]thieno[3,4-d]pyran-4-one;
3-Amino-8-methoxy-4H-thieno[3,4-c]chromen-4-one;
3-Amino-7-fluoro-4H-thieno[3,4-c]chromen-4-one;
5-Amino-3-(4-carboxy-phenyl)-4-oxo-3 ,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
3-Amino-7-methoxy-4H-thieno[3,4-c]chromen-4-one;
3-Amino-4H-thieno[3,4-c]chromen-4-one;
7-Amino-4-ethylsulfanyl-2-phenyl-thieno[3,4-d]pyridazin-1 (2H)-one;
5-Amino-3-(3-carboxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
5-Amino-7-bromo-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
3-Amino-7-morpholin-4-yl-4H-thieno[3,4-c]chromen-4-one;
5-Amino-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carbothioic acid amide;
7-Amino-4-cyano-2-(2-methoxy-phenyl)-1-oxo-1,2-dihydro-thieno[3,4-d]pyridazine-5-carboxylic acid ethyl ester;
3-Amino-9-methoxy-4H-thieno[3,4-c]chromen-4-one;
3-Amino-4H-naphtho[2,1-b]thieno[3,4-d]pyran-4-one;
3-Amino-1-bromo-4H-thieno[3,4-c]chromen-4-one;
5-Amino-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carbonitrile;
5-Amino-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylicacid hydrazide;
5-Amino-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
5-Amino-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid;
5-Amino-3-(3-methoxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
3-Amino-8-bromo-4H-thieno[3,4-c]chromen-4-one;
3-Amino-8-chloro-4H-thieno[3,4-c]chromen-4-one;
3-Amino-4H-thieno[3,4-c]chromen-4-one-8-carboxylic acid ethyl ester;
5-Amino-3-(4-((1-benzylcarbamoyl-pentyl)isopropyl-carbamoyl)phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
5-Amino-3-(4-((1-benzylcarbamoyl-pentylcarbamoyl)phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
5-Amino-3-(4-((1-(5-carboxy-pentylcarbamoyl)-pentyl)isopropyl-carbamoyl)phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
5-Amino-3-(4-chloro-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
5-Amino-7-bromo-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
5-Amino-3-(4-iodo-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
5-Amino-3-(3-iodo-phenyl)4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester;
5-Amino-3-(4-benzyloxycarbonyl-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester; 5-Amino-3-(3-methoxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid;
7-Amino-4-ethanesulfinyl-2-phenyl-2H-thieno[3,4-d]pyridazin-1-one;
7-Amino-4-ethanesulfonyl-2-phenyl-2H-thieno[3,4-d]pyridazin-1-one;
(7-Amino-4-methyl-1-oxo-1H-thieno[3,4-d]pyridazin-2-yl)acetic acid ethyl ester;
7-Amino-4-(5-oxo-4,5-dihydro[1,3,4]oxadiazol-2-yl)-2-phenyl-2H-thieno[3,4-d]pyridazin-1-one;
[5-Amino-3-(4-methoxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazin-1-yl]carbamic acid tert-butyl ester; and
4,7-Diamino-2-(4-methoxy-phenyl)-2H-thieno[3,4-d]pyridazin-1-one;
or a pharmaceutically acceptable salt thereof.
These compounds were evaluated for biological activity with a truncated form of PTP1B (corresponding to the first 321 amino acids), which was expressed in E. coli and purified to apparent homogeneity using published procedures well-known to those skilled in the art. The enzyme reactions were carried out using standard conditions essentially as described by Burke et al. ( Biochemistry 35; 15989-15996 (1996)). The assay conditions were as follows. Appropriate concentrations of the compounds of the invention were added to the reaction mixtures containing different concentrations of the substrate, p-nitrophenyl phosphate (range: 0.16 to 10 mM—final assay concentration). The buffer used was 100 mM sodium acetate pH 5.5, 50 mM sodium chloride, 0.1% (w/v) bovine serum albumin and 5 mM dithiothreitol (total volume 100 ml). The reaction was started by addition of the enzyme and carried out in microliter plates at 25° C. for 60 minutes. The reactions were stopped by addition of NaOH. The enzyme activity was determined by measurement of the absorbance at 405 nm with appropriate corrections for absorbance at 405 nm of the compounds and p-nitrophenyl phosphate. The data were analyzed using nonlinear regression fit to classical Michaelis Menten enzyme kinetic models. Inhibition is expressed as K i values in μM. The results of representative experiments are shown in Table 1
TABLE 1
Inhibition of classical PTP1B by compounds of the invention
PTP1B
Example no.
K 1 values (μM)
2
2
3
4
THE SYNTHESIS OF THE COMPOUNDS
In accordance with one aspect of the invention, the compounds of the invention are prepared as illustrated in the following reaction scheme:
By allowing a diazonium salt (I) to react with a ketone (II), and subsequently cyclising the intermediate (III) with ethyl cyanoacetate (IV), and by allowing the intermediate (V) to react with sulfur wherein Ar and R 2 are defined as above and EWG is CN, COOR 5 , CONR 5 R 7 , COR 8 wherein R 5 , R 6 , R 7 and R 8 are defined as above.
By allowing a hydrazone of formula (VI) prepared as above in Method A to react with tert-butyl hypochloride followed by deacetylation with methanol, and by allowing intermediate (VII) to react with a nucleophile (IX), and subsequently cyclising the intermediate (X) with ethyl cyanoacetate (IV) followed by cyclisation by allowing the intermediate to react with sulfur wherein Ar, R 2 are defined as above and X is sulfur and R 5 is C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl wherein the alkyl and aryl groups are optionally substituted as defined above.
By allowing an aryl ketone (XI) to react with ethyl cyanoacetate (IV), and by subsequently cyclising the intermediate (XII) with sulfur wherein Z, R 2 and B are defined as above.
By allowing a carboxylic acid (XIII), a primary amine (XIV) and an aldehyde (XV) to react with a isocyanide (XVI) wherein R 6 , R 26 , R 27 , and R 28 are independently selected from the group consisting of hydrogen, C 1 -C 6 alkyl, aryl, arylC 1 -C 6 alkyl as defined above and the alkyl and aryl groups are optionally substituted defined as above.
In a preferred method, the above described four component Ugi reaction can be carried out by attaching any one of the components to a solid support. Hence, the synthesis can be accomplished in a combinatorial chemistry fashion.
By allowing a carboxylic acid (XIII), a primary amine (XIV) and a ketoaldehyde (XVII) to react with a isocyanide (XVI) and by subsequently cyclising the intermediate (XVIII) with ammonium acetate wherein R 6 , R 26 , R 27 , and R 28 defined as above.
In a preferred method, the above described four component Ugi reaction can be carried out by attaching any one of the components to a solid support. Hence, the synthesis can be accomplished in a combinatorial chemistry fashion.
The present invention also has the objective of providing suitable topical, oral, and parenteral pharmaceutical formulations for use in the novel methods of treatment of the present invention. The compounds of the present invention may be administered orally as tablets, aqueous or oily suspensions, lozenges, troches, powders, granules, emulsions, capsules, syrups or elixirs. The composition for oral use may contain one or more agents selected from the group of sweetening agents, flavoring agents, coloring agents and preserving agents in order to produce pharmaceutically elegant and palatable preparations. The tablets contain the acting ingredient in admixture with non-toxic pharmaceutically acceptable excipients which are suitable for the manufacture of tablets. These excipients may be, for example, (1) inert diluents, such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents, such as corn starch or alginic acid; (3) binding agents, such as starch, gelatin or acacia; and (4) lubricating agents, such as magnesium stearate, stearic acid or talc. These tablets may be uncoated or coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed. Coating may also be performed using techniques described in the U.S. Pat. Nos. 4,256,108; 4,160,452; and 4,265,874 to form osmotic therapeutic tablets for control release.
Formulations for oral use may be in the form of hard gelatin capsules wherein the active ingredient is mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the active ingredient is mixed with water or an oil medium, such as peanut oil, liquid paraffin or olive oil.
Aqueous suspensions normally contain the active materials in admixture with excipients suitable for the manufacture of aqueous suspension. Such expicients may be (1) suspending agent such as sodium carboxymethyl cellulose, methyl cellulose, hydroxypropylmethyl-cellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia; (2) dispersing or wetting agents which may be (a) naturally occurring phosphatide such as lecithin; (b) a condensation product of an alkylene oxide with a fatty acid, for example, polyoxyethylene stearate; (c) a condensation product of ethylene oxide with a long chain aliphatic alcohol, for example, heptadecaethylen-oxycetanol; (d) a condensation product of ethylene oxide with a partial ester derived from a fatty acid and hexitol such as polyoxyethylene sorbitol monooleate, or (e) a condensation product of ethylene oxide with a partial ester derived from fatty acids and hexitol anhydrides, for example polyoxyethylene sorbitan monooleate.
The pharmaceutical compositions may be in the form of a sterile injectable aqueous or oleagenous suspension. This suspension may be formulated according to known methods using those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation may also a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution, and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose, any bland fixed oil may be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid find use in the preparation of injectables.
The Compounds of the invention may also be administered in the form of suppositories for rectal administration. These compositions can be prepared by mixing the drug with a suitable non-rritating excipient which is solid at ordinary temperature but liquid at the rectal temperature and will therefore melt in the rectum to release the drug. Such materials are cocoa butter and polyethylene glycols.
The compounds of the present invention may 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, stearylamine, or phosphatidyl-cholines.
For topical use, creams, ointments, jellies, solutions or suspensions, etc., containing the compounds of Formula 1 are employed.
Dosage levels of the compounds of the present invention are of the order of about 0.5 mg to about 100 mg per kilogram body weight, with a preferred dosage range between about 20 mg to about 50 mg per kilogram body weight per day (from about 25 mg to about 5 g's per patient per day). The amount of active ingredient that may be combined with the carrier materials to produce a single dosage will vary depending upon the host treated and the particular mode of administration. For example, a formulation intended for oral administration to humans may contain 5 mg to 1 g of an active compound with an appropriate and convenient amount of carrier material which may vary from about 5 to about 95 percent of the total composition. Dosage unit forms will generally contain between from about 5 mg to about 500 mg of active ingredient.
It will be understood, however, that the specific dose level for any particular patient will depend upon a variety of factors including the activity of the specific compound employed, the age, body weight, general health, gender, diet, time of administration, route of administration, rate of excretion, drug combination and the severity of the particular disease undergoing therapy. The dosage needs to be individualized by the clinician.
EXAMPLES
The process for preparing compounds of Formula 1, Formula 2 Formula 3 and Formula 4 and preparations containing them is further illustrated in the following examples, which, however, are not to be construed as limiting.
Hereinafter, TLC is thin layer chromatography, CDCl 3 is deuterio chloroform and DMSO-d 6 is hexadeuterio dimethylsulfoxide. The structures of the compounds are confirmed by either elemental analysis or NMR, where peaks assigned to characteristic protons in the title compounds are presented where appropriate. 1 H NMR shifts (δ H ) are given in parts per million (ppm) downfield from tetramethylsilane (TMS) as internal reference standard. M.p.: is melting point and is given in °C. and is not corrected. Column chromatography/silica gel purification was carried out using the technique described by W. C. Still et al., J. Org. Chem. 43: 2923 (1978) on Merck silica gel 60 (Art. 9385). HPLC analyses were performed using 5 μm C 18 4×250 mm column eluted with various mixtures of water and acetonitrile, flow=1 ml/min, as described in the experimental section.
Compounds used as starting material are either known compounds or compounds which can readily be prepared by methods known per se.
Example 1
5-Amino-3-(4-carboxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester, morpholinium salt
4-Amino-benzoic acid (40 g, 0.28 mol) was dissolved in a mixture of concentrated hydrochloric acid (84 ml) and water (84 ml). To the resulting mixture was added dropwise at 5° C. a solution of sodium nitrite (21.5 g, 0.31 mol) in water (100 ml). The resulting diazonium salt was added to a mixture of sodium acetate (116 g, 0.85 mol), ethanol (300 ml) and ethyl acetoacetate (36.5 ml, 0.28 mol) at room temperature. The resulting mixture was diluted with a 50% aqueous ethanol (1 l) and stirred for 1 h at room temperature. The precipitate was filtered off and washed with water (1 l), 50% aqueous ethanol (1 l) and heptane (2×300 ml) and dried in vacuo at 50 ° C. for 48 h affording 77 g (98%) of 4-[N′-(1-ethoxycarbonyl-2-oxo-propylidene)-hydrazino]-benzoic acid as a solid.
A mixture of the above hydrazon (40 g, 0.14 mol), ethyl cyanoacetate (37 ml) and ammonium acetate (22.2 g, 0.29 mol) was heated at reflux (105° C.) for 3 h. 50% aqueous ethanol (100 ml) was added at 60° C. and the resulting mixture was cooled to 10° C. The precipitate was filtered off and washed with 50% aqueous ethanol (4×50 ml) and heptane (3×50 ml) and dried in vacuo at 50° C. for 18 h affording 17.8 g (38%). The aqueous phase was acidified to pH=2.5 with concentrated hydrochloric acid and the precipitate was filtered off and washed with 50% aqueous ethanol (2×100 ml) and heptane (1×100 ml) and dried in vacuo at 50° C. for 18 h affording 13.8 g (29%).
A total of 31.6 g (67%) of 1-(4-carboxy-phenyl)-5-cyano-4-methyl-6-oxo-1,6-dihydro-pyridazine-3-carboxylic acid ethyl ester as a solid was isolated.
To a mixture of the above pyridazine (17.00 g, 51.94 mmol) in ethanol (45 ml) was added sulfur (1.75 g, 54.53 mmol) and morpholin (10.2 ml). The resulting mixture was heated at 60° C. for 3 h. The cooled reaction mixture was left over night and diluted with ethanol (10 ml). The precipitate was filtered off and washed with a mixture of ethanol and diethyl ether (1:1) (3×60 ml) and with diethyl ether (3×50 ml), dried in vacuo at 50° C. for 6 h afforded 22.11 g (95%) of the title compound as a solid.
Calculated for C 20 H 22 N 4 O 6 S 1 ; C, 53.80%; H, 4.97%; N, 12.55%. Found: C, 54.05%; H, 5.35%; N, 12.32%.
Example 2
7-Amino-4-ethylsulfanyl-2-(4-methoxy-phenyl)thieno[3,4-d]pyridazin-1(2H)-one
4-Amino-anisole (15 g, 0.12 mol) was dissolved in a mixture of concentrated hydrochloric acid (36 ml) and water (36 ml). To the resulting mixture was added dropwise at 5° C. a solution of sodium nitrite (9.2 g, 0.13 mol) in water (45 ml). The resulting diazonium salt was added to a mixture of sodium acetate (30 g, 0.37 mol), ethanol (125 ml) and pentane-2,4-dione (12.2 g, 0.12 mol) at room temperature. The resulting mixture was stirred for 1 h at room temperature. The precipitate was filtered off and washed with water (2×150 ml), ethanol (2×50 ml) and dried in vacuo at 50° C. for 18 h affording 17 g (60%) of 3-[(4-methoxy-phenyl)-hydrazono]-pentane-2,4-dione as a solid.
To a solution of the above hydrazon (15 g, 0.064 mol) in chloroform (50 ml) cooled in a ice bath was added dropwise t-butylhypochlorit (7.6 g, 0.070 mol). The resulting mixture was stirred at room temperature for 1 h. The volatiles were evaporated in vacuo affording crude (17.2 g) of 3-chloro-3-[(4-methoxy-phenyl)hydrazono]pentane-2,4-dione as an oil. The crude oil (17.2 g) was dissolved in methanol (100 ml) and heated at reflux temperature for 5 min. The volatiles were evaporated in vacuo affording crude 11.6 g (80%) of pyruvoyl chloride 1-(4-methoxyphenylhydrazone) as a solid.
To a mixture of sodium ethoxide (50 ml; prepared from 0.51 g sodium and 50 ml ethanol) and ethyl mercaptane (1.7 ml, 23 mmol) was added in small portion the above pyruvoyl chloride (5 g, 22 mmol). The resulting mixture was stirred at room temperature for 18 h and diluted with water (100 ml) and extracted with diethyl ether (2×75 ml). The combined organic extracts were washed with water (2×50 ml) saturated aqueous sodium chloride (50 ml), dried (MgSO 4 ), filtered and evaporated in vacuo affording 5.1 g (92%) of 1-ethylsulfanyl-1,2-propanedione-1-(4-methoxyphenylhydrazone) as a solid.
A mixture of the above ethylsulfanyl (5.1 g, 20.2 mmol), ethyl cyanoacetate (2.4 g, 21.2 mmol) and ammonium acetate (3.1 g, 40.4 mmol) was heated at reflux (105° C.) for 1.5 h. 75% aqueous ethanol (75 ml) was added at 60° C. and the resulting mixture was cooled to 10° C. The precipitate was filtered off and washed with 50% aqueous ethanol (4×50 ml) and dried in vacuo at 50° C. for 18 h affording 4.2 g (69%) of 6-ethylsulfanyl-2-(4-methoxy-phenyl)-5-methyl-3-oxo-2,3-dihydro-pyridazine-4-carbonitrile as a solid.
To a mixture of the above pyridazine (4.0 g, 13.8 mmol) in ethanol (20 ml) was added sulfur (442 mg, 13.8 mmol) and morpholin (2 ml). The resulting mixture was heated at reflux temperature for 2 h. The reaction mixture was cooled and the precipitate was filtered off and washed with water (2×20 ml) and diethyl ether (2×25 ml), dried in vacuo at 50° C. for 18 h which afforded 2.2 g (50%) of the title compound as a solid.
Calculated for C 15 H 15 N 3 O 2 S 2 ; C, 53.31%; H, 4.62%; N, 12.43%. Found: C, 53.47%; H, 4.28%; N, 12.03%.
Example 3
3-Amino4H-naphtho[2,1 -b]thieno[3,4-d]pyran-4-one
To a mixture of sodium ethoxide (100 ml; prepared from 1.38 g sodium and 100 ml ethanol) and 2-hydroxy-1-acetonaphthone (11.29 g, 0.06 mol) was added ethyl cyanoacetate (11.1 ml, 0.1 mol). The resulting mixture was stirred at reflux temperature for 2 h. The reaction mixture was cooled in a ice bath and the precipitate was filtered off and washed with water (20 ml) and cold ethanol (3×20 ml), dried in vacuo at 50° C. for 18 h which afforded (9 g) of crude product. The crude product (9 g) was recrystallised from a mixture of acetone (1 l) and water (25 ml) affording 5.33 g (38%) of 1-methyl-3-oxo-3H-benzo[f]chromene-2-carbonitrile as a solid.
In a screw cap ampoule was added to a mixture of the above benzo[f]chromene (2.35 g, 10 mmol) in ethanol (20 ml), sulfur (321 mg, 10 mmol) and morpholin (1.3 ml). The resulting mixture was heated at 80° C. for 18 h. The reaction mixture was cooled and the precipitate was filtered off and washed with ethanol (2×20 ml) and carbon disulfide (2×20 ml), dried in vacuo at 50° C. for 18 h which afforded 1.82 g (68%) of the title compound as a solid.
M.p.: 221-222° C.
1 H NMR (300 MHz, DMSO-d 6 ) δ H 7.36 (s, 1H, thiophen); 7.43 (d, 1H); 7.57 (t, 1H); 7.71 (t, 1H); 7.89-8.03 (m, 4H, NH 2 and 2 aromatic protons); 8.71 (d, 1H).
Calculated for C 15 H 9 NO 2 S, 0.5 H 2 O; C, 65.20%; H, 3.65%; N, 5.07%. Found: C, 65.27%; H, 3.32%; N, 5.19%.
The following compounds were prepared in a similar way as described in example 3.
Example 4
3-Amino-4H-thieno[3,4-c]chromen-4-one
Calculated for C 11 H 7 NO 2 S; C, 60.82%; H, 3.25%; N, 6.45%. Found: C, 61.22%; H, 3.24%; N, 6.38%.
Example 5
3-Amino-7-methoxy-4H-thieno[3,4-c]chromen-4-one
Calculated for C 12 H 9 NO 3 S; C, 58.29%; H, 3.67%; N, 5.66%. Found: C, 58.10%; H, 3.7%; N, 5.8%.
Example 6
3-Amino-8-methoxy-4H-thieno[3,4-c]chromen-4-one
Calculated for C 12 H 9 NO 3 S; C, 58.29%; H, 3.67%; N, 5.66%. Found: C, 58.39%; H, 3.73%; N, 5.70%.
Example 7
3-Amino-9-methoxy-4H-thieno[3,4-c]chromen-4-one
1 H NMR (300 MHz, DMSO-d 6 ) δ H 3.95 (s, 3H), 6.83 (d, 1H), 6.90 (d, 1H), 6.95 (s, 1H, thiophen); 7.30 (t, 1H); 7.75 (bs, 2H, NH 2 ).
Example 8
3-Amino-7-morpholin-4-yl-4H-thieno[3,4-c]chromen-4-one
1 H NMR (300 MHz, DMSO-d 6 ) δ H 3.18 (m, 4H), 3.73 (m, 4H), 6.61 (s, 1H, thiophen); 6.70 (d, 1H); 6.85 (dd, 1H); 7.58-7.76 (m, 3H, NH 2 and one aromat).
Example 9
3-Amino-7-fluoro-4H-thieno[3,4-c]chromen4-one
1 H NMR (300 MHz, DMSO-d 6 ) δ H 6.86 (s, 1H, thiophen); 7.05-7.21 (m, 2H); 7.81 (bs, 2H, NH 2 ); 7.92 (dd, 1H).
Example 10
3-Amino-8-bromo-4H-thieno[3,4-c]chromen-4-one
Calculated for C 11 H 6 NBrO 2 S; C, 44.61%; H, 2.04%; N, 4.73%. Found: C,44.60%; H, 1.97%; N, 4.62%.
Example 11
3-Amino-8-chloro-4H-thieno[3,4-c]chromen-4-one
Calculated for C 11 H 6 NClO 2 S; C, 52.49%; H, 2.40%; N, 5.57%. Found: C, 52.72%; H, 2.40%; N, 5.50%.
Example 12
3-Amino-4H-thieno[3,4-c]chromen-4-one-8-carboxylic acid ethyl ester
Calculated for C 14 H 11 NO 4 S; C, 58.12%; H, 3.83%; N, 4.84%. Found: C, 58.09%; H, 3.85%; N, 4.81%.
Example 13
5-Amino-3-(4-((1-benzylcarbamoyl-pentyl)isopropyl-carbamoyl)phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester
To a solution of 5-amino-3-(4-carboxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester (9.0 mg, 0.025 mmol) in a mixture of methanol and tetrahydrofuran (200 ml, 1:1) was added isopropyl amine (25 μl, 0.025 mmol, 1.0 M in tetrahydrofuran), valeraldehyde (25 μl, 0.025 mmol, 1.0 M in tetrahydrofuran) and benzyl isocyanide (25 μl, 0.025 mmol, 1.0 M in tetrahydrofuran). The mixture was stirred at 45° C. for 64 h. After dilution with dichloromethane (1 ml), the mixture was purified on a preparative TLC plate using a mixture of methanol/ethyl acetate/hexane (1:4:4) as eluent. Spot eluting with R f =0.66 was collected which afforded 6.3 mg (42%) of the title compound.
Example 14
5-Amino-3-(4-((1-benzylcarbamoyl-pentylcarbamoyl)phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester
To 100 mg Rink resin (0.22 mmol/g, 0.022 mmol) was added 5-amino-3-(4-carboxy-phenyl)4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester (1 ml, 0.01 mmol, 0.1 M in methanol/tetrahydrofuran (⅓)), valeraldehyde (200 ml, 0.2 mmol, 1.0 M in tetrahydrofuran) and benzyl isocyanide (200 ml, 0.2 mmol, 1.0 M in methanol). The mixture was stirred at 45° C. for 72 h followed by filtration and washing with tetrahydrofuran (5×100 ml), triethylamine (3×50 ml), tetrahydrofuran (5×50 ml), methanol (5×50 ml) and dichloromethane (5×50 ml). The resin was dried and then treated with 20% TFA in dichloromethane for 30 min. After filtration and washing with dichloromethane (5×50 ml), the filtrate was concentrated in vacuo and directly loaded onto a preparative TLC plate using a mixture of methanol/ethyl acetate/hexane (1:4:4) as eluent. Spot eluting with R f =0.70 was collected which afforded 4.4 mg (36%) of the title compound as a solid.
1 H NMR (400 MHz, CD 3 OD): δ 8 H 0.88 (t, 3H, J =6.4 Hz), 1.25-1.36 (m, 7H), 1.79 (m, 1H), 1.87 (m, 1H), 4.33-4.39 (m, 4H), 4.50-4.55 (m, 1 H), 7.13 (s, 1H), 7.20 (m, 1H), 7.26 (m, 4H), 7.69 (d, 2H, J 8.8 Hz), 7.92 (d, 2H, J =8.8 Hz).
MS (ES + ); Calculated 561.20; Found 562.03.
Example 15
5-Amino-3-(4-((1-(5-carboxy-pentylcarbamoyl)-pentyl)isopropyl-carbamoyl)phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester
6-Aminocaproic acid (100 g, 0.76 mol) was suspended in a mixture of ethylformate and N,N-dimethylformamide (1 l, 1:1) and heated at 100° C. for 18 h. The volatiles were evaporated in vacuo and the residue treated with ethyl acetate. The solid matter was filtered off and washed with ethyl acetate and air dried which afforded 115 g (95%) of 6-formyl hexanoic acid.
Diisopropylcarbondiimide (60 g, 0.48 mol) was added to a mixture of 6-formyl hexanoic acid (80 g, 0.5 mol), 4-N,N-dimethylaminopyridin (4 g, 33 mmol) and Wang-resin (140 g, 1.12 mmol/g) in dry tetrahydrofuran (1 l) under an atmosphere of nitrogen. The reaction mixture was sonicated for 6 h and then stirred at room temperature for 18 h. The resin was filtered off and washed with dichloromethane, methanol (repeatedly) and then dried in a vacuum desiccator for 18 h.
To a stirred mixture of the above 6-formyl hexanoic acid Wang-resin ester (165 g, 0.16 mol) in dichloromethane (3.2 l) was added triethylamine (222 ml, 1.6 mol), tetrachloromethane (155 ml, 1.6 mol) and triphenylphosphine (168 g, 0.64 mol). The resulting mixture was stirred at room temperature for 16 h under an atmosphere of nitrogen. The resin was filtered off and washed with N,N-dimethylformamide, dichloromethane, methanol, dichloromethane and dried in a vacuum desiccator for 18 h which afforded 6-isocyano-hexanoic acid Wang-resin ester.
To 24 mg of the above isocyanide resin (0.84 mmol/g, 0.02 mmol) was added 5-amino-3-(4-carboxy-phenyl)4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester (1,0 ml, 0.01 mmol, 0.1 M in methanolltetrahydrofuran (1:3)), valeraldehyde (200 ml, 0.2 mmol, 1.0 M in tetrahydrofuran) and isopropyl amine (200 ml, 0.2 mmol, 1.0 M in tetrahydrofuran). The mixture was stirred at 45° C. for 72 h followed by filtration and washing with tetrahydrofuran (5×50 ml), triethylamine (3×50 ml), tetrahydrofuran (5×50 ml), methanol (5×50 ml) and dichloromethane (5×50 ml). The resin was dried and then treated with 20% TFA in dichloromethane for 30 min. After filtration and washing with dichloromethane (5×50 ml), the filtrate was concentrated in vacuo and the residue loaded onto a preparative TLC using a mixture of methanol/ethyl acetate/hexane (1:4:4) as eluent. Spot eluting with R f =0.57 was collected which afforded 6.0 mg (48%) of the title compound as a solid.
MS (ES + ); Calculated 627.27; Found 628.07
The following compounds were prepared in a similar way as described in example 1.
Example 16
5-Amino-3-(4-chloro-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester
M.p.: 187-189° C.;
Calculated for C 15 H 12 N 3 O 3 S; C, 51.51%; H, 3.46%; N, 12.01%. Found: C, 51.78%; H, 3.43%; N, 12.09%.
Example 17
5-Amino-7-bromo-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester
M.p.: 112-114° C.;
Calculated for C 15 H 12 BrN 3 O 3 S; C, 45.70%; H, 3.07%; N, 10.66%. Found: C, 45.91%; H, 3.07%; N, 10.41%.
Example 18
5-Amino-4-oxo-3-phenyl-3,4-dihydro-thieno[3 ,4-d]pyridazine-1-carboxylic acid hydrazide
To a solution of 5-Amino-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester (20 g, 0.063 mol, prepared as described in example 25) in ethanol (400 ml) was added hydrazine hydrate (3.3 g, 0.066 mol). The reaction mixture was stirred at reflux temperature for 6 h at which time an additional portion of hydrazine hydrate (3.3 g, 0.066 mol) was added and the resulting mixture was stirred for an additional 66 h at reflux temperature. An additional portion of hydrazine hydrate (1.5 g, 0.03 mol) was added and the reaction mixture was stirred for an additional 16 h at reflux temperature. The reaction mixture was cooled and the precipitated was filtered off, washed with small portions of ethanol and dried in vacuo at 50° C. for 18 h which afforded 17.9 g (94%) of the title compound as a solid.
1 H NMR (300 MHz, DMSO-d 6 ) δ H 4.51 (bs, 2H, H 2 NNHCO), 7.09 (s, 1 H, thiophen), 7.31 (t, 1 H), 7.43 (t, 2H), 7.57 (bs, 2H, NH 2 ), 7.65 (d, 1H), 9.58 (s, 1 H, H 2 N-NHCO).
Example 19
5-Amino-3-(3-carboxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester, morpholinium salt
Calculated for C 20 H 22 N 4 O 6 S; C, 53.80%; H, 4.97%; N, 12.55%. Found: C, 53.74%; H, 5.23%; N, 12.40%.
Example 20
5-Amino-3-(4-iodo-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester
M.p.: 198-200° C.;
Calculated for C 15 H 12 IN 3 O 3 S, 1×H 2 O; C, 39.23%; H, 3.07%; N, 9.15%. Found: C, 39.41%; H, 2.79%; N, 9.15%.
Example 21
5-Amino-3-(3-iodo-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester
M.p.: 186-187° C.;
Calculated for C 16 H 12 IN 3 O 3 S; C, 40.83%; H, 2.74%; N, 9.52%. Found: C, 40.76%; H, 2.71%; N, 9.54%.
Example 22
5-Amino-3-(4-benzyloxycarbonyl-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester
M.p.: 130-133° C.
Calculated for C 23 H 19 N 3 O 5 S; C, 61.46%; H, 4.26%; N, 9.35%. Found: C, 61.24%; H, 4.04%; N, 9.37%.
Example 23
5-Amino-3-(4-methoxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester
M.p.: 165-167° C.
Calculated for C 16 H 15 N 3 O 4 S; C, 55.64%; H, 4.38%; N, 12.17%. Found: C, 55.99%; H, 4.36%; N, 11.94%.
Example 24
5-Amino-3-(3-methoxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester
M.p.: 123-125° C.
Calculated for C 16 H 15 N 3 O 4 S, 0.25 H 2 O; C, 54.93%; H, 4.47%; N, 12.01%. Found: C, 55.25%; H, 4.47%; N, 12.02%.
Example 25
5-Amino-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester
Calculated for C 15 H 13 N 3 O 3 S; C, 57.13%; H, 4.16%; N, 13.32%.Found: C, 57.54%; H, 4.15%; N, 13.16%.
Example 26
5-Amino-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid
To a solution of the above pyridazine-1-carboxylic acid ethyl ester (3 g, 9.51 mmol) in a mixture of ethanol (50 ml) and water (25 ml) was added sodium hydroxide (0.46 g, 11.41 mmol). The resulting reaction mixture was stirred for 2.5 h at room temperature. Water (100 ml) was added, the aqueous phase was washed with ethyl acetate (50 ml), pH of the aqueous phase was adjusted to pH=3 by addition of concentrated hydrochloric acid. The precipitate was filtered off and washed with water (2×50 ml), heptane (2×50 ml) and dried in vacuo at 50° C. for 18 h affording 2.5 g (91%) of the title compound as a solid.
Calculated for C 13 H 9 N 3 O 3 S; C, 54.35%; H, 3.16%; N, 14.63%. Found: C, 57.52%; H, 3.29%; N, 14.23%.
Example 27
5-Amino-3-(3-methoxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid
To a solution of 5-amino-3-(4-methoxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid ethyl ester (3 g, 8.69 mmol, prepared in example 23) in a mixture of ethanol (50 ml) and water (25 ml) was added sodium hydroxide (0.38 g, 9.55 mmol). The resulting reaction mixture was stirred for 2.5 h at room temperature. Water (150 ml) was added, undissolved matter was filtered off. The aqueous phase was washed with diethyl ether (2×100 ml), pH was adjusted to pH=4 by addition of concentrated hydrochloric acid. The precipitate was filtered off and washed with water (2×50 ml), heptane (2×50 ml) and dried in vacuo at 50° C. for 18 h affording 2.3 g (83%) of the title compound as a solid.
M.p.: 227-229° C.
Calculated for C 13 H 9 N 3 O 3 S, 0.25×H 2 O; C, 52.25%; H, 3.60%; N, 13.06%. Found: C, 52.43%; H, 3.54%; N, 12.94%.
The following compound was prepared in a similar way as described in example 2.
Example 28
7-Amino-4-ethylsulfanyl-2-phenyl-thieno[3,4-d]pyridazin-1 (2H)-one
Calculated for C 14 H 13 N 3 OS 2 ; C, 55.42%; H, 4.32%; N, 13.85%. Found: C, 55.46%; H, 4.40%; N, 13.73%.
Example 29
7-Amino-4-ethanesulfinyl-2-phenyl-2H-thieno[3,4-d]pyridazin-1-one
Aniline (20 g, 0.215 mol) was dissolved in a mixture of concentrated hydrochloric acid (64 ml) and water (64 ml). To the resulting mixture was added dropwise at 0° C. a solution of sodium nitrite (16.3 g, 0.24 mol) in water (80 ml). The resulting diazonium salt was added to a mixture of sodium acetate (53 g, 0.64 mol), ethanol (225 ml) and pentane-2,4-dione (21.5 g, 0.22 mol) at room temperature. The resulting mixture was stirred for 1 h at room temperature. The precipitate was filtered off and washed with water (2×150 ml), 50% aqueous ethanol (2×50 ml), heptane (50 ml) and dried in vacuo at 50° C. for 18 h affording 39.3 g (90%) of 3-(phenylhydrazono)-pentane-2,4-dione as a solid.
To a solution of the above hydrazon (20 g, 0.103 mol) in chloroform (75 ml) cooled in a ice bath was added dropwise t-butylhypochlorit (15 g, 0.103 mol). The resulting mixture was stirred at room temperature for 3 h. The volatiles were evaporated in vacuo affording crude 3-chloro-3-(phenylhydrazono)-pentane-2,4-dione as an oil.
The crude oil was dissolved in methanol (125 ml) and heated at reflux temperature for 5 min. The reaction mixture was cooled, the precipitate was filtered off, washed with a small portion of heptane and dried in vacuo at 50° C. for 18 h affording 10.3 g (51%) of pyruvoyl chloride 1-(phenyihydrazone) as a solid.
To a mixture of sodium ethoxide (100 ml; prepared from 1.2 g sodium and 100 ml ethanol) and ethyl mercaptane (4.1 ml, 0.055 mol) was added in small portion the above pyruvoyl chloride (10.3 g, 0.052 mol). The resulting mixture was stirred at room temperature for 66 h, diluted with water (200 ml) and extracted with diethyl ether (2×100 ml). The combined organic extracts were washed with water (2×100 ml), saturated aqueous sodium chloride (100 ml), dried (MgSO 4 ), filtered and evaporated in vacuo affording 11.1 g (95%) of 1-ethylsulfanyl-1,2-propanedione-1-(phenylhydrazone) as an oil.
A mixture of the above ethylsulfanyl (10.0 g, 0.045 mol), ethyl cyanoacetate (5.3 g, 0.047 mol) and ammonium acetate (6.9 g, 0.090 mol) was heated at reflux (105° C.) for 1.5 h. 75% aqueous ethanol (25 ml) was added at 60° C. and the resulting mixture was cooled to 10° C. The precipitate was filtered off and washed with water (4×50 ml), heptane (50 ml), a diethyl ether (25 ml) and dried in vacuo at 50° C. for 18 h affording 7.5 g (61%) of 6-ethylsulfanyl-5-methyl-3-oxo-2-phenyl-2,3-dihydro-pyridazine-4-carbonitrile as a solid.
The above pyridazine (1.5 g, 5.5 mmol) was dissolved in 40% peroxyacetic acid (30 ml) and the resulting mixture was stirred at room temperature for 18 h. Water (200 ml) was added and the precipitate was filtered off. The aqueous phase was extracted with ethyl acetate (2×100 ml), the combined organic phases were washed with water (3×100 ml), saturated aqueous sodium chloride (100 ml), dried (MgSO 4 ), filtered and evaporated in vacuo affording 1.3 g (82%) of 6-ethanesulfinyl-5-methyl-3-oxo-2-phenyl-2,3-dihydro-pyridazine-4-carbonitrile as a solid.
To a mixture of the above ethanesulfinyl pyridazine (1.1 g, 3.83 mmol) in ethanol (50 ml) was added sulfur (130 mg, 4.0 mmol) and morpholin (1 ml). The resulting mixture was heated at reflux temperature for 2 h. The reaction mixture was cooled and the volatiles were evaporated in vacuo. The residue was suspended in water (100 ml) and extracted with ethyl acetate (2×100 ml). The combined organic phases were washed with saturated aqueous sodium chloride (100 ml), dried (MgSO 4 ), filtered and evaporated in vacuo affording crude 0.65 g of the title compound which was purified on silica gel (500 ml) using a mixture of ethyl acetate and heptane (1:2) as eluent. Pure fractions were collected and the solvent evaporated in vacuo affording 0.5 g (41%) of the title compound as a solid.
M.p.: 204-205° C.
Calculated for C 14 H 13 N 3 O 2 S 2 ; C, 52.65%; H, 4.10%; N, 13.16%. Found: C, 52.75%; H, 4.14%; N, 12.94%.
Example 30
7-Amino-4-ethanesulfonyl-2-phenyl-2H-thieno[3,4-d]pyridazin-1-one
6-Ethanesulfinyl-5-methyl-3-oxo-2-phenyl-2,3-dihydro-pyridazine-4-carbonitrile (4.0 g, 15 mmol, prepared as described in example 29) was dissolved in 40% peroxyacetic acid (75 ml) and the resulting mixture was stirred at 60° C. for 4 h and at room temperature for 2 h. Water (300 ml) was added and the precipitate was filtered off. The aqueous phase was extracted with ethyl acetate (2×300 ml), the combined organic phases were washed with water (3×300 ml), saturated aqueous sodium chloride (100 ml), dried (MgSO 4 ), filtered and evaporated in vacuo affording 2.1 g of crude 6-ethanesulfinyl-5-methyl-3-oxo-2-phenyl-2,3-dihydro-pyridazine-4-carbonitrile. To the crude ethanesulfinyl (2.1 g) dissolved in dichloromethane (50 ml) was added 3-chloroperoxybenzoic acid (1.2 g) and the resulting reaction mixture was stirred at reflux temperature for 16 h. The cooled reaction was washed with water (50 ml), dried (MgSO 4 ), filtered and evaporated in vacuo which afforded crude 3.2 g. The crude product (3.2 g) was suspended in diethyl ether (50 ml), stirred for 2 h, filtered off, washed with diethyl ether (2×25 ml) and dried in vacuo at 50° C. affording 1.3 g (29%) of 6-ethanesulfonyl-5-methyl-3-oxo-2-phenyl-2,3-dihydro-pyridazine-4-carbonitrile as a solid. To a mixture of the above ethanesulfonyl pyridazine (0.5 g, 1.64 mmol) in ethanol (20 ml) was added sulfur (55 mg, 1.72 mmol) and morpholin (0.4 ml). The resulting mixture was heated at reflux temperature for 2 h. The reaction mixture was cooled and the precipitate was filtered off and washed with water (2×25 ml), heptane (25 ml) and dried in vacuo at 50° C. for 16 h affording 0.4 g (73%) of the title compound as a solid.
M.p.: 190-191° C.
Calculated for C 14 H 13 N 3 O 3 S 2 ; C, 50.14%; H, 3.91%; N, 12.53%. Found: C, 49.87%; H, 3.86%; N, 12.24%.
Example 31
(7-Amino-4-methyl-1-oxo-1H-thieno[3,4-d]pyridazin-2-yl)acetic acid ethyl ester
To a solution of diacetyl (17.78 g, 0.20 mol) in water (300 ml) was added cyanoacetohydrazide (20.86 g, 0.20 mol). After stirring the resulting reaction mixture at room temperature for 2 h the precipitate was filtered off and washed with water (2×75 ml), a mixture of diethyl ether and ethanol (2×75 ml, 2:1) and dried in vacuo at 50° C. for 16 h which afforded 22.58 g (68%) of 2,3-butandione-2-(cyanoaetohydrazone) as a solid.
To a stirred solution of sodium ethoxide (350 ml, prepared from sodium hydride (18.17 g, 0.48 mol, 60% in mineral oil) and ethanol (350 ml) ) was added the above cyanoaetohydrazone (39.61 g, 0.24 mol) at 40° C. The resulting reaction mixture was heated at reflux temperature for 3 h, cooled to room temperature and poured onto ice (600 ml). pH of the solution was adjusted to pH=4 by addition of concentrated hydrochloric acid and the precipitate filtered off. The aqueous phase was evaporated in vacuo to {fraction (1/10)} of its volume and the precipitate was filtered off. The combined filter cakes were washed with water (2×50 ml), a mixture of ethanol and diethyl ether (3×80 ml, 1:1) and dried in vacuo at 50° C. for 16 h which afforded 19.65 g (56%) of 5,6-dimethyl-3-oxo-2,3-dihydro-pyridazine-4-carbonitrile as a solid.
To a solution of the above pyridazine (5.0 g, 33.52 mmol) in dry dimethylsulfoxide (50 ml) was added sodium hydride (900 mg, 38.55 mmol, 60% in mineral oil) the reaction mixture was stirred at room temperature until gas evolution was ceased at which time at solution of bromo ethyl acetate (5.6 ml, 50.28 mmol) in dry dimethylsulfoxide (20 ml) was added dropwise. The reaction mixture was stirred at room temperature for 16 h, poured into a mixture of water (250 ml) and saturated aqueous sodium carbonate (50 ml) and extracted with dichloromethane (3×120 ml). The combined organic extracts were washed with water (100 ml), dried (MgSO4), filtered and evaporated in vacuo. The residue was treated with heptane (2×10 ml) and evaporated in vacuo at 60° C. which afforded 7.16 g (91%) of 6-cyano-4,5-dimethyl-1-oxo-pyridazin-2-yl)acetic acid ethyl ester as an oil.
TLC: R f =0.41 (ethyl acetate/heptane 1:1)
1 H NMR (300 MHz, DMSO-d 6 ) δ H 1.31 (t, 3H), 2.35 (s, 3H), 2.46 (s, 3H), 4.24 (q, 2H), 4.85 (s, 2H).
To a mixture of the above pyridazine (6.0 g, 25.5 mmol) in ethanol (20 ml) was added sulfur (860 mg, 26.8 mmol) and morpholin (5 ml). The resulting mixture was heated at 50° C. for 6 h. The reaction mixture was cooled and the precipitate was filtered off and washed with water (2×25 ml), heptane (25 ml) and dried in vacuo at 50° C. for 16 h affording 2.04 g (30%) of the title compound as a solid.
1 H NMR (300 MHz, DMSO-d 6 ) δ H 1.20 (t, 3H), 2.21 (s, 3H), 4.12 (q, 2H), 4.60 (s, 2H), 6.70 (s, 1 H, thiophen), 7.35 (bs, 2H, NH 2 ).
Example 32
7-Amino-4-(5-oxo-4,5-dihydro[1,3,4]oxadiazol-2-yl)-2-phenyl-2H-thieno[3,4-d]pyridazin-1-one
To a ice cooled solution of 5-amino-4-oxo-3-phenyl-3,4-dihydro-thieno[3,4-d]pyridazine-1-carboxylic acid hydrazide (2.0 g, 6.64 mmol), triethylamine (0.67 g, 6.64 mmol) in dry tetrahydrofuran (50 ml) was added 1,1′-carbonyidiimidazole (1.3 g, 8.30 mmol). The resulting reaction mixture was stirred at 0° C. for 1 h and at room temperature for 2 h. Water (100 ml) was added and the precipitate was filtered off and washed with water (2×25 ml), diethyl ether (20 ml) and dried in vacuo at 50° C. for 16 h affording 1.7 g (78%) of the title compound as a solid.
M.p.:>250° C.
Calculated for C 14 H 9 N 5 O 3 S; C, 50.00%; H, 3.00%; N, 20.82%. Found: C, 49.98%; H, 2.98%; N, 20.62%.
Example 33
[5-Amino-3-(4-methoxy-phenyl)-4-oxo-3,4-dihydrothieno[3,4-d]pyridazin-1-yl]carbamic acid tert-butyl ester
To a solution of 5-cyano-4-methyl-1-(4-methoxy-phenyl)-6-oxo-1,6-dihydro-pyridazine-3-carboxylic acid ethyl ester (15 g, 0.048 mol, prepared as described in example 23) in a mixture of ethanol (250 ml) and water (100 ml) was added sodium hydroxide (2.1 g, 0.053 mol). The reaction mixture was stirred at room temperature for 16 h, the volatiles were evaporated and the residue diluted with water (200 ml). The aqueous phase was washed with ethyl acetate (250 ml) and pH was adjusted to pH=2 by addition of concentrated hydrochloric acid. The precipitate was filtered off and washed with water (2×80 ml) and dried in vacuo at 50° C. for 16 h which afforded 12.3 g (90%) of 5-cyano-1-(4-methoxy-phenyl)-4-methyl-6-oxo-1,6-dihydro-pyridazine-3-carboxylic acid as a solid.
To a solution of the above carboxylic acid (5.0 g, 0.018 mol) in dry N,N-dimethylformamide (150 ml) was added triethylamine (2.1 g, 0.021 mol) and potassium tert-butoxide (1.6 g, 0.021 mol). The resulting mixture was cooled to 0° C. and diphenylphosphoryl azide (5.8 g, 0.021 mol) was added. Stirring was continued at 0° C. for 3 h and at room temperature for 16 h at which time water (300 ml) was added. The precipitate was filtered off and redissolved in ethyl acetate (250 ml) and filtered through a path of silica gel. The organic phase was washed with water (2×100 ml), saturated aqueous ammonium chloride (100 ml), dried (MgSO 4 ), filtered and evaporated in vacuo which afforded 2.2 g of the intermediate carboxylic acid azide (NMR). To a solution of potassium tert-butoxide (1.6 g) in tert-butanol (100 ml) was added the above crud carboxylic acid azide (2.2 g). The reaction mixture was stirred at reflux temperature for 16 h, the volatiles were evaporated in vacuo and the residue purified on silica gel (800 ml) using a mixture of ethyl acetate and heptane (1:1) as eluent. Pure fractions were collected and evaporated in vacuo affording 0.9 g (14%) of [5-cyano-1-(4-methoxy-phenyl)-4-methyl-6-oxo-1,6-dihydro-pyridazin-3-yl]carbamic acid tert-butyl ester as a solid.
TLC: R f =0.44 (ethyl acetatelheptane 1:1)
1 H NMR (300 MHz, CDCl 3 ) δ H 1.51 (s, 9H), 2.53 (s, 3H), 3.87 (s, 3H), 6.47 (bs, 1 H, —OCONH—), 6.95 (d, 2H), 7.50 (d, 2H).
To a mixture of the above pyridazine (0.5 g, 1.4 mmol) in ethanol (30 ml) was added sulfur (43 mg, 1.5 mmol) and morpholin (0.5 ml). The resulting mixture was heated at 50° C. for 16 h. The volatiles were evaporated in vacuo, the residue was dissolved in ethyl acetate (100 ml) and washed with water (2×50 ml), dried (MgSO4), filtered and evaporated in vacuo. The residue 0.5 g was purified on silica gel (500 ml) using a mixture of ethyl acetate and heptane (1:1) as eluent. Pure fractions were collected and evaporated in vacuo affording 160 mg (29%) of the title compound as a solid.
M.p.: 99-101° C.
SP/MS(EI) Calculated 388.4, Found 388.1 (12%), 288.1 (48%).
1 H NMR (300 MHz, CDCl 3 ) δ H 1.50 (s, 9H), 3.82 (s, 3H), 6.11 (bs, 2H, NH 2 ), 6.56 (bs, 1 H, —OCONH—), 6.93 (d, 2H), 7.24 (s, 1H, thiophen), 7.43 (d, 2H).
Example 34
4,7-Diamino-2-(4-methoxy-phenyl)-2H-thieno[3,4-d]pyridazin-1-one
To a solution of [5-amino-3-(4-methoxy-phenyl)-4-oxo-3,4-dihydro-thieno[3,4-d]pyridazin-1-yl]carbamic acid tert-butyl ester (140 mg, 0.36 mmol, prepared as described in example 33) in dichloromethane (20 ml) was added trifluoroacetic acid (5 ml) and the reaction mixture was stirred at room temperature for 1 h. The volatiles were evaporated in vacuo and the residue was dissolved in ethanol and evaporated in vacuo. The semi solid residue was treated with diethyl ether (25 ml) for 16 h, the precipitate was filtered off and dried in vacuo at 50° C. for 16 h affording 30 mg crude title compound. The diethyl ether phase was evaporated and the residue was purified on silica gel (200 ml) using a mixture of ethyl acetate and heptane (3:1) as eluent. Pure fractions were collected and the solvent evaporated in vacuo affording 20 mg (19%) of the title compound as a solid.
SP/MS(EI) Calculated 288.4, Found 288.1 (100%).
1 H NMR (300 MHz, DMSO-d 6 ) δ H 3.75 (s, 3H), 5.84 (bs, 2H, NH 2 ), 6.79 (s, 1H, thiophen), 6.90 (d, 2H), 7.35 (bs, 2H, NH 2 ), 7.39 (d, 2H). | The present invention provides novel compounds of Formula 1 or Formula 2 and compositions thereof, methods of their use, and methods of their manufacture,
wherein X, Y, Z, W, R 1 , R 2 and R 3 are defined more fully in the description. These compounds are useful in the treatment of type I diabetes, type II diabetes, impaired glucose tolerance, insulin resistance, obesity, and a number of other diseases. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/686,573 filed on Jun. 2, 2005, the entire disclosure of which is incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] The Government of the United States has rights in this invention pursuant to Contract No. DE-FC26-95EE50425, awarded by the U.S. Department of Energy.
BACKGROUND
[0003] The present inventions relate to batteries and battery systems. More specifically, the present inventions relate to lithium batteries (e.g., lithium-ion batteries, lithium-polymer batteries, etc.) and systems using such batteries that include systems for managing one or more batteries, battery modules, or battery cells when predetermined conditions have been met.
[0004] It is known to provide batteries for use in vehicles such as automobiles. For example, lead-acid batteries have been used in starting, lighting, and ignition applications. More recently, hybrid vehicles have been produced which utilize a battery (e.g., a nickel-metal-hydride battery) in combination with other systems (e.g., an internal combustion engine) to provide power for the vehicle.
[0005] It is generally known that lithium batteries perform differently than nickel-metal-hydride batteries. In some applications, it may be desirable to obtain the enhanced power/performance of a lithium battery. However, the application of lithium battery technology may present design and engineering challenges beyond those typically presented in the application of conventional nickel-metal-hydride battery technology.
[0006] The design and management of a lithium battery system that can be advantageously utilized in a hybrid vehicle may involve considerations such as electrical performance monitoring, thermal management, and containment of effluent (e.g., gases that may be vented from a battery cell). For example, it may be desirable to monitor the temperature of individual battery cells within a lithium battery system to ensure that thermal runaway conditions are not met. When predetermined conditions are met, it may be desirable to provide a system for managing one or more batteries, battery modules, or battery cells. It may be further desirable for this battery management system to balance the cells or modules until conditions change. It may also be desirable to provide a system for disconnecting a battery, battery module, or cell from the system when a battery cell approaches a predetermined temperature threshold.
SUMMARY
[0007] It would be desirable to provide a battery system of a type disclosed in the present application that includes any one or more of these or other advantageous features:
[0008] A battery system that utilizes lithium batteries or cells (e.g., lithium-ion batteries, lithium-polymer batteries, etc.) to provide power for a vehicle.
[0009] A lithium battery system for use in vehicles that includes a device or mechanism for monitoring the temperature of one or more batteries in the battery system.
[0010] A lithium battery system for use in vehicles that includes a device or mechanism for balancing one or more battery cells of a circuit in the event that a predetermined condition has been met.
[0011] A lithium battery system for use in vehicles that includes a device or mechanism for removing one or more battery cells from a circuit in the event that a predetermined condition has been met.
[0012] A lithium battery system for use in vehicles that includes a device or mechanism for balancing one or more batteries, battery modules, or cells of a circuit in the event that the temperature of such batteries exceeds a predetermined threshold value.
[0013] A lithium battery system for use in vehicles that includes a device or mechanism for disconnecting one or more batteries, battery modules, or cells from a circuit in the event that the temperature of such batteries exceeds a predetermined threshold value.
[0014] A lithium battery system that includes a relatively simple and accurate system for determining the temperature of batteries in the system and reducing the occurrence of thermal runaway for such batteries.
[0015] An exemplary embodiment relates to a system for managing a lithium battery system having a plurality of cells. The battery system comprises a variable-resistance element electrically connected to a cell and located proximate a portion of the cell; and a device for determining, utilizing the variable-resistance element, whether the temperature of the cell has exceeded a predetermined threshold.
[0016] Another exemplary embodiment relates to a method of managing the temperature of a lithium battery system which comprises: determining the voltage of a variable-resistance element which is electrically connected to the battery system and positioned proximate to any one of the cells in the system; determining, utilizing the voltage of the variable-resistance element, the temperature of the cell; determining whether the temperature of the cell has exceeded a predetermined threshold; and balancing the system in the event the temperature of the cell has reached the predetermined threshold temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other features, aspects and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.
[0018] FIG. 1 is a perspective view of a lithium battery or cell according to an exemplary embodiment.
[0019] FIG. 2 is another perspective view of the battery shown in FIG. 1 .
[0020] FIG. 3 is an exploded perspective view of a battery system in the form of a module that includes a plurality of lithium batteries or cells according to an exemplary embodiment.
[0021] FIG. 4 is a schematic view of a lithium battery or cell and a system for balancing, disconnecting, or otherwise managing the battery in the event that a predetermined condition is satisfied.
DETAILED DESCRIPTION
[0022] According to an exemplary embodiment, a lithium battery system is provided that includes a system or mechanism for managing (e.g., balancing or disconnecting) one or more lithium batteries, battery modules, or cells (e.g., lithium-ion cells, lithium-polymer cells, etc. of any presently known configuration or other configuration that may be developed in the future) in the event that a predetermined condition occurs. Such a lithium battery system may be applied to individual lithium batteries or to one or more lithium batteries that are included in a module that includes a plurality of lithium batteries or cells. Further, according to an exemplary embodiment in which a module including a plurality of lithium batteries is provided, the module may be included in a system that includes a plurality of lithium battery modules of any presently known configuration or any other configuration that may be developed in the future.
[0023] Various nonexclusive exemplary embodiments of lithium batteries and lithium battery systems are shown and described in U.S. patent application Ser. No. 10/976,169, filed Oct. 28, 2004, the entire disclosure of which is hereby incorporated by reference. FIGS. 1-2 illustrate a lithium battery or cell and FIG. 3 illustrates a module that includes a plurality of lithium batteries according to exemplary embodiments shown and described in U.S. patent application Ser. No. 10/976,169 (reference numerals shown in FIGS. 1-3 correspond to the reference numerals used in U.S. patent application Ser. No. 10/976,169).
[0024] While FIGS. 1-3 illustrate particular exemplary embodiments of lithium batteries and battery systems, any of a variety of lithium batteries or battery systems may be used according to various other exemplary embodiments. For example, according to various exemplary embodiments, the physical configuration of the individual cells and/or the modules may be varied according to design objectives and considerations. According to one exemplary embodiment, a system may include a module having ten cells. According to other exemplary embodiments, a different number of cells may be included in a module.
[0025] As shown in FIG. 4 , according to an exemplary embodiment, a system 300 is provided for balancing, disconnecting or removing one or more batteries or cells 310 from a circuit when a predetermined condition has been met. According to an exemplary embodiment, system 300 is configured to disconnect one or more modules (each module including a plurality of cells) from a load (e.g., a vehicle load) when a predetermined temperature threshold has been met. In this manner, electric power provided by the cells to the vehicle is terminated to avoid continued elevated thermal conditions in any of the cells.
[0026] According to an exemplary embodiment, cell 310 is a lithium-ion cell having a fully-charged voltage of between approximately 0 and 5 volts. According to a particular exemplary embodiment, cell 310 has a fully charged voltage of between approximately 3.0 and 4.2 volts.
[0027] System 300 includes an element provided in proximity with cell 310 that is configured for sensing temperature and/or that is configured such that it exhibits characteristics that vary with temperature. According to an exemplary embodiment as shown in FIG. 4 , an element 330 in the form of a variable resistor (e.g., a thermistor such as a positive or negative temperature coefficient resistor) is electrically coupled to at least one terminal (e.g., positive terminal 312 ) of cell 310 . For convenience, element 330 is referred to below as “variable resistor 330 ,” although it should be understood that such an element may comprise other types of devices according to various other exemplary embodiments.
[0028] Variable resistor 330 is provided in relatively close proximity to a top surface 316 of cell 310 (e.g., near positive terminal 312 ). Such a variable resistor maybe provided in contact with a portion of cell 310 according to an exemplary embodiment. According to a particular exemplary embodiment, an element such as a variable resistor may be included (e.g., integrated) in a cover of cell 310 (e.g., a cover such as that shown as cover 142 in FIG. 1 ). According to another particular exemplary embodiment, a variable resistor may be included as part of a battery terminal or battery terminal assembly for cell 310 .
[0029] While variable resistor 330 is shown in FIG. 4 as being provided in relatively close proximity to top surface 316 of cell 310 , it should be noted that according to other exemplary embodiments, the variable resistor may be provided in relatively close proximity to a bottom surface 318 of cell 310 , for example, near negative terminal 314 (e.g., it may be included in a cover of the cell, etc.).
[0030] According to a particular exemplary embodiment, variable resistor 330 is a positive temperature coefficient (PTC) resistor having a resistance that varies linearly with temperature and which has a resistance of approximately 300 ohms at a temperature of approximately 80° C. According to other exemplary embodiments, one or more variable resistors may be provided in place of, or in addition to, variable resistor 330 that have different resistances (e.g., the resistance may vary non-linearly with temperature, the resistance may have a different resistance at a temperature of approximately 80° C., etc.). In other exemplary embodiments, variable resistor 330 may have a resistance that varies either linearly or logarithmically with temperature. Companies that have supplied or supply a variety of variable resistors such as variable resistor 330 are Raychem, Littelfuse, and Burroughs Corp.
[0031] Variable resistor 330 is configured such that its resistance changes (e.g., increases) with increasing temperature according to an exemplary embodiment in which the variable resistor is a positive temperature coefficient (PTC) resistor. According to an exemplary embodiment in which a negative temperature coefficient resistor is utilized, the resistance will decrease with increasing temperature.
[0032] Because of its location, variable resistor 330 may have a temperature that is similar to the temperature of cell 310 at a location adjacent the variable resistor 330 . Knowing the characteristics of variable resistor 330 (e.g., how its resistance varies with temperature, etc.), the temperature of cell 310 adjacent variable resistor 330 may be approximated or determined. According to an exemplary embodiment, a system may be provided which includes a number of elements that are configured to balance or disconnect cell 310 , or the battery module in which cell 310 is provided, when the resistance of variable resistor 330 increases to a predetermined threshold value. One exemplary embodiment of such a system is shown as system 300 in FIG. 4 , although it should be noted that various other systems may also be utilized according to other exemplary embodiments.
[0033] According to an exemplary embodiment, variable resistor 330 has a resistance of approximately 1.0 ohm when cell 310 is operating at a normal temperature, and a resistance of approximately 300 ohms or greater when the temperature of cell 310 exceeds approximately 80° C. According to other exemplary embodiments, other variable resistors may be utilized which have different resistance values and/or functions (e.g., a resistance between approximately 0.1 and 10 ohms).
[0034] As shown in FIG. 4 , a resistor 340 (e.g., a fixed resistor having constant resistance) and a switch 350 , such as a MOSFET, are provided in series with variable resistor 330 . According to an exemplary embodiment, switch 350 is configured to drain voltage from cell 310 across resistor 340 when the voltage of cell 310 exceeds a predetermined value (e.g., to balance the cell voltage with other cells in a module).
[0035] In normal operating conditions in which the temperature of cell 310 is below a predetermined threshold (e.g., 80° C.), the voltage across variable resistor 330 may be relatively small as compared to the voltage across resistor 340 . According to an exemplary embodiment, the resistance of resistor 340 is at least 10 to 100 times the resistance of variable resistor 330 under normal operating conditions. When the temperature of cell 310 increases above the predetermined threshold, the resistance in variable resistor 330 also increases, which results in a corresponding increase in voltage across variable resistor 330 . In such a situation, the voltage across resistor 340 and switch 350 will decrease. In the event that the voltage across resistor 340 and switch 350 falls below a predetermined threshold (e.g., 2.8 volts), cell 310 will be determined to be bad.
[0036] One embodiment of system 300 operates during normal operating conditions (e.g., with cell 310 within an acceptable range of operating temperatures) such that switch 350 allows current to travel through the circuit. The circuit acts as a voltage divider in which a relatively small proportion of the voltage is across variable resistor 330 (i.e., variable resistor 330 has a relatively low resistance at normal operating temperatures), and the majority of voltage in the circuit is across resistor 340 . The amount of voltage across each of the elements, of course, will depend upon the properties of the components utilized according to other exemplary embodiments (e.g., the voltages across resistors 330 and 340 may be approximately equal during normal operating conditions or may be otherwise selected in accordance with design considerations). When the temperature of variable resistor 330 increases above a predetermined threshold temperature, the resistance of variable resistor 330 changes, causing a corresponding change in voltage across both variable resistor 330 and resistor 340 (and, accordingly, across switch 350 ).
[0037] As shown in FIG. 4 , a device 360 may be provided for measuring the voltage across resistor 340 and switch 350 according to an exemplary embodiment. The measured voltage may be correlated to the temperature near terminal 312 of cell 310 to provide an approximate value of the temperature of cell 310 (i.e., knowing the voltage across and the resistance of the fixed resistor 340 allows one to determine the voltage and resistance of the variable resistor 330 , which can be used to determine the temperature of the variable resistor 330 if the relationship between temperature and resistance is known). According to another exemplary embodiment, a device similar to device 360 may be provided such that it measures the voltage across variable resistor 330 .
[0038] As further displayed in FIG. 4 , a device 370 , in the form of a computing device or the like, may be provided to manage a battery system, module, or cell. According to an exemplary embodiment, device 370 is a computer (e.g., containing or coupled to a CANbus processor). Device 370 may monitor the temperature of one or more cells. Device 370 may monitor the cell(s) by inferring the temperature of the cell(s). The temperature of the cell(s) may be inferred by device 370 via the examination of the voltage across resistor 340 and switch 350 . In one embodiment, device 370 receives the voltage information from device 360 .
[0039] Device 370 may perform a variety of actions based on the temperature and other factors (e.g., balancing a cell or removing a module). The initiation of a particular action may depend on which circumstance or circumstances are detected. For example, in one embodiment, device 370 may take an action when one or more voltage conditions exist. In one exemplary embodiment, device 370 disconnects an entire module or group of modules when it determines that any one or more of three conditions have been satisfied. These three conditions may include: (a) the temperature has reached some predetermined threshold (e.g., the temperature has reached or exceeded 80° C.); (b) the temperature has increased some predetermined temperature amount during a period of time less than some predetermined time period (e.g., the temperature has increased by 10° C. in less than one minute); and (c) a cell or group of cells has remained some predetermined temperature higher than other cells over a time period (e.g., a cell has remained at a temperature 20° C. higher than other cells in a module for a time period longer than one minute).
[0040] In one particular embodiment, device 370 uses one or more lookup tables or truth tables 380 to determine whether predetermined conditions exist in which the device should take a action. Lookup table 380 may include a column of possible voltage conditions of resistor 340 and switch 350 , matched to a column of corresponding inferred temperatures of cell 310 . One possible example of lookup table 380 is displayed below as Table I. In the exemplary embodiment in which Table I might be used, cell 310 has a 4.0 volt center tap voltage (e.g., as shown in the “Circuit Off” column in Table I, which corresponds to a situation in which switch 350 is open), resistor 330 has a normal resistance of 0.2 milliohms, and resistor 340 is a 4 ohm resistor. When the temperature of cell 310 and resistor 330 increases, the corresponding voltage read by device 360 and device 370 across resistor 340 decreases. Device 370 may use a lookup table 380 such as that displayed in Table I to relate a read voltage to a temperature condition of cell 310 . For example, when device 360 and 370 read a voltage of 0.1 volts with the circuit on, device 370 may infer a cell 310 temperature of 80° C. by matching the voltage in the “Circuit On” column of Table I to the “Temperature in Degrees Celsius” column of Table I (the “Circuit On” column corresponds to a situation in which the switch 350 is closed). According to one embodiment, when this temperature condition is reached or exceeded, device 370 may take the action of disconnecting the battery module. In other embodiments, device 370 may disconnect the entire battery or turn the vehicle off.
[0000]
TABLE I
Temperature in
Degrees Celsius
Circuit Off
Circuit On
80
4
0.1
70
4
0.4
60
4
2.6
50
4
3.7
40
4
3.82
30
4
3.9
20
4
3.95
10
4
3.98
0
4
4
−10
4
4
−20
4
4
−30
4
4
[0041] According to another exemplary embodiment, device 370 may balance a cell relative to other cells when the voltage of the cell falls below or climbs above certain predetermined thresholds. In one embodiment, device 370 will drain voltage from the cell by using resistor 340 as a discharging resistor (e.g., during a time when the vehicle is not operating, such as during the night). To begin the process of balancing the cell, device 370 will close switch 350 . Upon closing switch 350 , the resulting circuit, including discharging resistor 340 , will cause the voltage in cell 310 to drop. The switch 350 may be opened when the cell 310 reaches the desired voltage level.
[0042] In this embodiment, circuit 300 may be configured to balance cell 310 . In a normal state, switch 350 may be open and devices 360 and 370 may read a normal cell voltage. In this exemplary embodiment, low or no current may flow through device 360 and device 370 (device 360 having a resistance of 1-10 mega ohms). If the voltage of cell 310 increases, the voltage read by devices 360 and 370 will also increase. If the voltage read by devices 360 and 370 increases beyond a certain predetermined threshold, device 370 may close switch 350 . When switch 350 closes, the current through discharging resistor 340 will cause the voltage of cell 310 to begin decreasing. Discharging cell 310 through resistor 340 may balance cell 310 with the rest of the cells in the battery module.
[0043] In an exemplary embodiment, device 370 may also include a process in which the computer will track how often it balances particular cells or modules. In the event that device 370 detects or recognizes a relatively frequent balancing of one or more cells or modules, device 370 can disconnect the bad cell or the entire module from the power delivery system of the vehicle.
[0044] It should be understood by those of ordinary skill in the art reviewing this disclosure that any of a variety of variable resistors, resistor(s) (e.g., resistor 340 , which may comprise one or more resistors), and switches may be utilized according to various exemplary embodiments. For example, the resistances of the variable resistor and the fixed resistor may differ according to other exemplary embodiments. The various components of system 300 may be selected based on a variety of factors, including availability, cost, and other design considerations. Any suitable combination of components as described above may be utilized to provide a system that balances, disconnects, or otherwise manages a cell or battery module such as that described above when a predetermined condition (e.g., a temperature) is reached. The various components may be selected to balance, remove, or otherwise manage the cells, battery modules, or batteries in a circuit when temperatures above 80° C. or any other predetermined threshold temperature or other temperature events or conditions occur.
[0045] It should also be noted that a system such as system 300 described above may be utilized to balance, disconnect, or otherwise manage an entire module from a vehicle electrical system in the event that one or more of the batteries included in the module have a temperature that exceeds a predetermined threshold. A variable resistor or similar element may be provided adjacent each cell included in the module or at one or more locations within the module (e.g., to sense the “composite” temperature of the entire module). In the event that the temperature of one or more of the batteries (or the composite temperature of the entire module) exceeds a predetermined threshold temperature, the module may be disconnected (e.g., using a switch such as a MOSFET) from a circuit (e.g., thus disconnecting the module from a vehicle electrical system).
[0046] It is important to note that the construction and arrangement of the system as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied (e.g., the variable temperature resistor may be provided adjacent a negative terminal of a battery), and the nature or number of discrete elements or positions may be altered or varied (e.g., a plurality of resistors may be provided in place of a single resistor). Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present inventions.
[0047] While the exemplary embodiments illustrated in the FIGs and described above are presently preferred, it should be understood that these embodiments are offered by way of example only. For example, the teachings herein can be applied to any battery system and are not limited to lithium battery systems in vehicles. Accordingly, the battery system is not limited to a particular embodiment, but extends to various modifications that nevertheless fall within the scope of the appended claims. | Provided is a system for managing a lithium battery system having a plurality of cells. The battery system comprises a variable-resistance element electrically connected to a cell and located proximate a portion of the cell; and a device for determining, utilizing the variable-resistance element, whether the temperature of the cell has exceeded a predetermined threshold. A method of managing the temperature of a lithium battery system is also included. | 7 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of international patent application PCT/EP2005/005622, filed on May 25, 2005 designating the U.S., which international patent application has been published in German language and claims priority from German patent application De 10 2004 037 490.2, filed on Jul. 23, 2004. The entire contents of these priority applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a sensor module for a probe head of a tactile coordinate measuring machine, and to a probe head comprising such a sensor module and a stylus attached to the sensor module.
[0003] In the prior art, coordinate measuring machines are used inter alia for measuring the shape of a measurement object with high accuracy. For example, the shape of workpieces produced by machine may be checked in this way in the course of quality control. For the measurement process, the probe head of the coordinate measuring machine is moved towards the measurement object by means of a suitable movement mechanism until the stylus touches a desired measurement point on the measurement object. The spatial coordinates of the measurement point can then be determined from the position of the probe head and, if appropriate, from the relative position of the stylus with respect to the sensor module.
[0004] German patent application DE 101 08 774 A1 discloses a probe head in which the stylus is arranged on a lateral mount. In an embodiment, the lateral mount comprises a stationary frame having a square base area, at whose center a part is arranged which can move relative to the frame. The moveable part is sometimes referred to as a “boss” by the skilled persons, and it carries the stylus. In the described embodiment, the boss is connected to the frame either via four or via eight webs. When the stylus is deflected, the webs are twisted, and this can be evaluated by means of strain sensors arranged on the sensor module. In this embodiment, the frame, the webs and the boss are produced from a solid silicon body by an etching process.
[0005] The basic concept of such a sensor module is also discussed in an article by Kleine-Besten et al. entitled “Miniaturisierter 3D-Tastsensor für die Metrologie an Mikrostrukturen” [Miniaturized 3D Probe Sensor for Metrology of Microstructures], which appeared in the German Journal “tm—Technisches Messen” [tm—Technical Measurement], Issue 12/99, pages 490-495. This article describes investigation results on a semiconductor sensor module, wherein, in contrast to DE 101 08 774 A1, the boss of the sensor module is held on the frame via a single solid membrane. The use of individual webs for holding the boss, as disclosed by DE 101 08 774 A1, is mentioned in a brief outlook at the end of the article in connection with ideas for compensating different bending stiffnesses of the module in the three spatial directions. This is because the investigation of the sensor module having the solid membrane has shown that the bending stiffness is considerably less when the stylus is deflected in a plane parallel to the frame (X direction or Y direction) than when it is deflected perpendicularly to the frame (Z direction).
[0006] The use of webs for mounting the boss and the stylus rather than a solid membrane leads to some degree of matching the bending stiffnesses in the three special directions. However, there are still considerable difficulties in scanning measurement processes, i.e. measurement processes in which the probe head is guided in continuous contact with the measurement object (what is referred to as “scanning”). It is still very problematic to determine the deflection in the Z direction in such measurement scenarios, despite the matching of the bending stiffnesses already achieved so far by means of the webs.
SUMMARY OF THE INVENTION
[0007] Against this background, it is an object of the invention to provide for a sensor module for use in a probe head of a coordinate measuring machine, which allows to carry out scanning measurement processes more easily and more accurately.
[0008] It is another object to provide for a probe head for a tactile coordinate measuring machine, which facilitates scanning measurements on a measurement object, even if the measurement object is very small and a high measurement accuracy is desired.
[0009] According to one aspect of the invention, there is provided a sensor module for a probe head of a tactile coordinate measuring machine, the sensor module comprising a frame which forms a stationary module base and thereby defines a first measurement plane, and comprising a moving part configured to move relative to the frame and configured to hold the proximal end of a stylus, wherein the moving part is held on the frame via at least two webs separated from one another, wherein each web has a cross section perpendicularly to the first measurement plane, with the cross section showing a first web portion having a first material thickness and two second web portions having at least a second material thickness, wherein the first web portion is arranged between the two second web portions, and wherein the first material thickness is thicker than the second thickness.
[0010] According to another aspect, there is provided a probe head for a tactile coordinate measuring machine, the probe head comprising a sensor module having a frame which forms a stationary module base and thereby defines a first measurement plane, and having a moving part configured to move relative to the frame and configured to hold a first end of a stylus, wherein the moving part is held on the frame via at least two separate webs, wherein each web has a thick-material web portion arranged between two thin-material web portions in a cross section perpendicularly to the first measurement plane.
[0011] Previous approaches relating to sensor modules for coordinate measuring machines of this kind tried to make the cross section of the membrane area between the frame and the moving part (“boss”) as thin as possible, in order to obtain as much flexibility as possible in the Z direction. The present approach differs from these prior approaches in that the webs are formed with a thick-material area or portion, i.e. with a material thickness considerably greater than the minimum thickness that is technically possible. Practical experiments have shown that it is sufficient to provide two thin-material web portions in order to achieve a relatively low stiffness in the Z direction. On the other hand, the thick-material web portion located between the thin web portions provide greater torsional stiffness in the X direction and Y direction. The bending stiffnesses in the three spatial directions are thus better matched to one another compared to previous approaches. Due to the better matching, it is easier to determine the deflection of the stylus in the Z direction, in particular in the case of scanning measurement processes, in which the stylus might be deflected in all three spatial directions at a time. Because the deflection behavior is matched considerably better, the novel sensor module can carry out scanning measurement processes more easily and more accurately.
[0012] In a preferred refinement, the material thickness of the thin-material web portions is at most 50% of the material thickness of the thick-material web portion, preferably at most 30% and even more preferably about 3% to 10%.
[0013] In general, it can be said that the bending stiffness in the Z direction on the one hand and in the X/Y directions on the other hand are better matched to one another the thinner the thin-material web portions are compared to the thick-material web portion. The present refinement, however, takes into account adequate resistance to fracture. This further improves the reliable implementation of scanning measurement processes.
[0014] In a further refinement, the webs have a web width and a web length parallel to the first measurement plane, with the web width being at least one third, and preferably about one half of the web length or more.
[0015] These ratios of the length to the width of the webs improve the torsional stiffness and thus contribute to further matching the bending stiffness in the X/Y directions on the one hand and in the Z direction on the other. This further facilitates the implementation of scanning measurement processes.
[0016] In a further refinement, the thin-material web portions and the thick-material web portion have approximately the same web width.
[0017] In principle, as an alternative to this, it would also be possible to make the thin-material web portions broader or narrower as the thick-material web portion. However, thinner thin-material web portions would result in a reduction in the torsional stiffness, which would be disadvantageous from the point of view of matching of the bending stiffness. The preferred embodiment of the web portions with approximately the same web width avoids this disadvantage, and on the other hand can be achieved easily from the production engineering point of view. Furthermore, the novel sensor module of this refinement has good robustness for scanning measurements, despite the unequal material thicknesses of the web portions.
[0018] In a further refinement, the thin-material web portions are formed as slots extending transversely with respect to the web, wherein each slot has a slot width in the direction of the web, and wherein the slot width is at most 20% of the length of the thick-material area, preferably about 2% to 10%.
[0019] Investigations by the applicant have shown that the matching of the bending stiffnesses becomes better the smaller the thin-material web portions are with respect to the web length of the thick-material area. The above orders of magnitude have been found to be particularly advantageous, with respect to the desired bending stiffnesses on the one hand and with respect to the robustness of the sensor module on the other hand.
[0020] In a further refinement, the thin-material web portions form connection points of the web to the frame and to the moving part.
[0021] This refinement is based on the discovery that the desired matching of the bending stiffnesses in the three spatial directions becomes better the further the thin-material web portions of each web are away from one another. The formation of the thin-material web portions as connection points for the web to the frame and to the moving part represents the preferred refinement, because the distance between the thin-material web portions is a maximum in this refinement.
[0022] In a further refinement, the moving part has a cruciform shape in a view perpendicularly to the first measurement plane.
[0023] This refinement allows robust connection of the webs to the moving part (“boss”), in particular in view of the fact that the thin-material web portions are intrinsically more sensitive to fracture loads than thick-material web portions. The cruciform shape allows stable transitions in the area of the connection points. The moving part is preferably designed in the form of a “short-arm cross”, with very short free ends. In this refinement, the advantage of thin-material web portions which are as far away from one another as possible is combined with the stability of the cruciform moving part.
[0024] In an alternative refinement, however, the moving part is square in a view perpendicularly to the first measurement plane.
[0025] This refinement leads to a structure which is very simple from the production engineering point of view and has maximum web lengths.
[0026] In a further refinement, the frame has a material thickness which is approximately the same as the material thickness of the thick-material web portion in a cross section perpendicularly to the first measurement plane.
[0027] This refinement can be produced easily from the production engineering point of view on the one hand, and it contributes to particularly good matching of the bending stiffness in the spatial directions X/Y and Z on the other hand. It is particularly preferable that the frame and the thick-material web portions have approximately the same thickness as a typical silicon wafer. This results in high robustness with low production costs.
[0028] In a further refinement, the frame and the webs have side flanks, which run substantially perpendicularly to the first measurement plane.
[0029] This refinement allows the thin-material web portions to be very small in the longitudinal direction of the webs. The bending stiffness in the three spatial directions can thus be matched to one another even better. It is even easier to carry out an exact scanning measurement.
[0030] In a further refinement, the frame and the webs are etched out of a solid semiconductor material, preferably by means of a dry-etching method.
[0031] This refinement has the advantage that very small sensor modules can be produced, whose bending stiffness in the three spatial directions are well matched to one another. This applies in particular to the use of a dry-etching method in contrast to wet-etching methods, because it has been found that steeper edge profiles and contours can be achieved by dry etching. The preferred refinement of substantially perpendicular side flanks is thus feasible particularly easily and at low cost by using a dry-etching method.
[0032] In a further refinement, the webs are separated from the frame only by a continuous groove.
[0033] In other words, in this refinement, the sensor module is largely in the form of a solid body, from which the webs and the moving parts are machined by introduction of relatively narrow slots. In this case, the solid body preferably has a substantially square base area. The slots pass through the solid body parallel to the longitudinal faces of the webs, in order to achieve the separation of the web and frame. In contrast, the slots on the lateral-face ends of the webs, that is to say at their connection points to the frame and to the moving part, do not extend entirely as far as the base of the solid body, so that the thin-material web portions remain here.
[0034] From the present point of view, this refinement is particularly preferable because, on the one hand, it allows very high manufacturing precision. This is because it has been found that the depth profile, which is important for the present invention, when etching out the thin-material web portions can be produced more exactly if only relatively narrow material parts are etched out of the solid body. Furthermore, this refinement has the advantage that the frame has relatively large fixed surface areas, which can be used advantageously for an inscription or for fitting of an electronic data memory for identification and/or calibration data.
[0035] In a further refinement, the sensor module comprises a stylus which is attached to the moving part in a non-removable manner.
[0036] In this refinement, the sensor module is some sort of a “disposable item” which is a fundamental reversal of previous approaches with stylus units for coordinate measuring machines. While it was heretofore typical to design the probe head sensor system to be stationary and, if appropriate, to replace the stylus, this refinement takes the approach of the stylus and sensor system forming a stylus/sensor module which can be replaced in its entirety. The refinement has the advantage that the characteristics of the stylus can be taken into account in an optimum manner in the design of the bending stiffness. The behavior of the novel sensor module can thus be matched even better to continuous measurement processes.
[0037] In a further refinement, the stylus has a stylus length which is approximately twice to six times of the web length.
[0038] This refinement exploits the above-mentioned advantages by including the length of the stylus in the design of the sensor module. The above order of magnitude makes this refinement highly suitable for carrying out continuous measurement processes.
[0039] In a further refinement, the sensor module comprises a plurality of sensor elements which are arranged in the area of the webs, and a plurality of electrical contact surfaces for connecting the sensor elements, wherein the contact surfaces are arranged on the frame, and preferably on a side of the frame facing away from the stylus.
[0040] This refinement also contributes to making the novel sensor module a completely integrated unit, which is arranged on a probe head as an entity. In this case, it is particularly preferable to position the electrical contact surfaces on the rear face of the frame, because this allows the sensor module to be replaced very easily. Irrespective of this, the arrangement of the contact surfaces on the frame has the advantage that the bending stiffness and thus the measurement response of the sensor module are not influenced by the connection to the probe head. This allows continuous measurements to be carried out with high accuracy, even after replacement of the sensor module.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] It goes without saying that the features mentioned above and those yet to be explained below can be used not only in the respectively stated combination but also in other combinations or on their own, without departing from the scope of the present invention.
[0042] Exemplary embodiments of the invention will be explained in more detail in the following description and are illustrated in the drawing, in which:
[0043] FIG. 1 shows a simplified illustration of a coordinate measuring machine, in which the novel sensor module is used,
[0044] FIG. 2 shows a plan view of an embodiment of the novel sensor module “from underneath”, i.e. from that side on which the stylus is arranged,
[0045] FIG. 3 shows a cross section along line III-III through the sensor module shown in FIG. 2 ,
[0046] FIG. 4 shows a plan view of the rear face (upper face) of the sensor module shown in FIG. 2 ,
[0047] FIG. 5 shows a perspective illustration of the sensor module from FIG. 2 , but without a stylus,
[0048] FIG. 6 shows a perspective illustration of another preferred embodiment of the novel sensor module, and
[0049] FIG. 7 shows a view from the rear of the sensor module shown in FIG. 6 .
DESCRIPTION OF PREFERRED EMBODIMENTS
[0050] In FIG. 1 , a coordinate measuring machine is designated in its totality by reference number 10 . The coordinate measuring machine 10 is illustrated here in the form of a gantry structure, as is typical with many coordinate measuring machines. However, the present invention is not restricted to this form. In principle, the novel sensor module can also be used with other configurations, such as with horizontal-arm measuring machines. It is particularly preferable for the novel sensor module to be used with a coordinate measuring machine as is described in prior international patent application WO 2005/100906 A1, which is incorporated by reference.
[0051] This preferred coordinate measuring machine has a movement mechanism for the probe head which differs from the conventional designs and whose fundamental principle is also described in a dissertation by Marc Vermeulen entitled “High Precision 3D-Coordinate Measuring Machine”, which can be obtained using the ISBN number 90-386-2631-2. This publication is also incorporated by reference herewith.
[0052] For the sake of simplicity, however, the following description refers to the gantry configuration of the coordinate measuring machine illustrated in FIG. 1 , because its movement mechanism is easier to understand and more conventional.
[0053] The coordinate measuring machine 10 has a base plate 12 on which a gantry 14 is arranged such that it can be moved in the longitudinal direction. This longitudinal direction is normally referred to as the Y axis. A carriage 16 which can be moved in the X direction is arranged on the upper transverse mount of the gantry 14 . The carriage is in turn fitted with a ram 18 which can be moved in the Z direction. The reference numbers 20 , 22 , 24 denote scales from which the respective movement position of the gantry 14 , the carriage 16 and the ram 18 can be read in the three spatial directions X, Y, Z. Generally, the scales 20 , 22 , 24 may be simple measurement scales, which are read by an operator of the coordinate measuring machine 10 . However, they are preferably distance measurement transmitters, which are read by machine. The latter is particularly appropriate if the coordinate measuring machine 10 is fitted with the novel sensor module, since this allows extremely high measurement accuracies.
[0054] A probe head 26 is arranged in a manner known per se at the lower free end of the ram 18 and is fitted with a stylus 28 , which is not illustrated to scale here. The stylus 28 is used to touch defined measurement points on a measurement object 30 . For this purpose, the measurement object 30 is arranged on the base plate 12 of the coordinate measuring machine 10 . The spatial coordinates of the measurement point that has been touched can be determined from the position of the probe head 26 in the measurement volume of the coordinate measuring machine 10 , and from the deflection of the stylus 28 relative to the probe head.
[0055] For the sake of completeness, the coordinate measuring machine 10 is in this case illustrated with an evaluation and control unit 32 , via which the measurement procedure is controlled and which is also used for processing and outputting of the measured values. A control panel 34 may also optionally be provided, in order to additionally manually control the movements of the probe head 26 .
[0056] In FIGS. 2 to 5 , an embodiment of the novel sensor module is designated by reference number 40 in its totality. The sensor module 40 has a frame 42 which in this case has a square basic shape. A moving part 44 , the so-called “boss”, is arranged at the center of the frame 42 . The moving part 44 is connected to the frame 42 via four webs 46 . In a preferred embodiment, the moving part has a cruciform shape (in a plan view), with the free arms of the cross being very short in comparison to the width B S of the webs 46 , that is to say this is a “short-arm cross”. The four webs 46 are connected flush to the free arms of the short-arm cross, and continue it to one of the inner faces of the frame 42 . Overall, the sensor module 40 thus has a basic structure in the form of a square ring (frame 42 ), at whose center a cruciform structure (moving part 44 with webs 46 ) is fitted symmetrically. Those areas within the frame 42 which are neither the moving part 44 nor the web 46 are open, i.e. these areas are square “holes” 48 .
[0057] Each web 46 has a thick-material, central portion 50 as well as two slots 52 , 54 , which represent the thin-material areas for the purposes of the present invention. The material thickness of the thick-material portion 50 is designated by D S in. FIG. 3 , while the material thickness of the thin-material portions 52 , 54 is designated by d S . The material thickness of the frame 42 is designated by D R and, in this preferred embodiment, is equal to the thickness D S of the thick-material portions 50 .
[0058] The moving part 44 is fitted with a stylus 56 (this is indicated only schematically in FIG. 2 , and is not shown at all in FIG. 5 , for the sake of clarity), which in the preferred embodiment is attached to the moving part 44 in a non-removable manner. In an embodiment, the stylus 56 is designed with an end flange 58 at the proximal end. The free end of the end flange 58 is adhesively bonded to the moving part 44 .
[0059] Strain-gauge sensors are illustrated schematically at reference number 59 in FIG. 3 . In an embodiment, these sensors are piezo-resistive elements which detect expansion, compression and/or twisting of the webs in the region of the thin-material areas, as is already known from DE 101 08 774 A1 which is incorporated by reference herewith.
[0060] The frame 42 may be firmly clamped into a holder (not illustrated here) on the probe head 26 , as is shown by way of example in the already cited DE 101 08 774 A1. The frame thus defines a first plane of movement or measurement plane, which is indicated by reference number 60 in FIG. 3 . The measurement plane 60 in the coordinate measurement device 10 lies parallel to the movement axes X and Y, as shown in FIG. 1 .
[0061] In a preferred exemplary embodiment, the sensor module 40 is connected to a specific probe head holder (not illustrated here) to form a physical unit, which is attached to the probe head 26 of the coordinate measuring machine 10 as an entity. One preferred embodiment of such a probe head holder is described in later published WO 2004/068068 which is incorporated by reference. The combination of the sensor module 40 with a probe head holder of this kind allows automated replacement of the stylus, and reliable contact to be made with the strain gauge sensors 59 .
[0062] In the illustrated embodiments, the length L τ of the stylus 56 is between about 3 mm and about 15 mm, and is preferably about 7 mm. The length L S of the thick-material portions 50 is in this embodiment about 1.5 mm, and the length l S of each slot portion 52 , 54 is about 0.05 mm to about 0.1 mm. The width B S of each web 46 is in this embodiment about 0.8 mm. The width B B of the moving part 44 is about 1.3 mm in a preferred embodiment. The width B R of the frame 42 is about 1 mm, and the overall width B M of the sensor module 40 is about 6.5 mm to about 7 mm.
[0063] The material thickness D S of the thick-material web portions 50 is in this case about 0.45 mm, and the material thickness d S of the thin-material portions 52 , 54 is in this case about 0.025 mm.
[0064] In an exemplary embodiment, a sensor module 40 with these dimensions was produced from a monocrystalline silicon wafer material by means of a dry-etching process. The above dimensions resulted in a bending stiffness in the Z direction which came close to the bending stiffness in the X and Y directions within a factor of about 3.
[0065] The rear view of the sensor module shown in FIG. 4 illustrates preferred contact surfaces 70 . In this exemplary embodiment, four contact surfaces 70 are arranged alongside one another on each limb of the frame 42 . Overall, the frame 42 thus has 16 contact surfaces 70 , with which the strain-gauge sensors 59 make contact when the sensor module 40 is inserted into the probe head holder. The arrangement of the contact surfaces 70 on the rear face of the frame 42 allows to make the contact by spring-loaded pins, which press against the frame 42 from above (or from underneath).
[0066] The novel sensor module has been illustrated here with four webs 46 , which corresponds to the exemplary embodiment preferred by the applicant at the moment. However, the present invention can also be used for sensor modules which have a different number of webs. For example, the use of thick-material and thin-material web portions can also be applied to a “braces structure” with eight webs, as is known from DE 101 08 774 A1 already cited above. Furthermore, the novel sensor module could also be produced with a lesser number, and/or an odd number of webs, for example with three or five webs. In addition, the use of thin-material and thick-material web portions according to the invention can also be applied to only two webs 46 , although this is not preferred at the moment for robustness reasons.
[0067] In another embodiment, the thin-material web portions 52 , 54 can also be provided with an opening 72 , which is indicated by a dotted line in FIG. 4 . Each web 46 is then connected to the frame 42 and to the moving part 44 by “point-like” connection points. In this embodiment, the frame 42 and the webs 46 each have side flanks which run virtually perpendicularly to the first measurement plane 60 . However, in contrast to this, it is also possible for the side flanks to be formed with an oblique profile, which facilitates the use of a wet-etching method for production of the novel sensor module. Furthermore, the webs 46 may, in contrast to the illustrated embodiment, have a surface which is trapezoidal in a plan view, with the broader side of each trapezium then being arranged on the frame 42 , while the narrower trapezium side is seated on the moving part 44 .
[0068] FIGS. 6 and 7 show a further preferred embodiment of the novel sensor module (illustrated without a stylus), which is designated by reference number 80 in its totality. Apart from this, same reference symbols denote the same elements as before.
[0069] The sensor module 80 has a frame 42 which is separated from the webs only by a groove 82 . In contrast to the previous embodiments, the sensor module 80 thus has no large-area openings between the webs and the frame. As can be seen from the plan view in FIG. 6 , the groove 82 is a groove which is circumferential around the webs 46 with an accurate fit. In one embodiment, the width of the groove is 0.1 mm. In contrast, from the rear face as shown in FIG. 7 , the groove 82 appears in four angled pieces, two of which are annotated here with 82 a and 82 b. Each piece 82 a, 82 b has two limbs of equal length, which are arranged perpendicularly to one another. The “missing” pieces of the groove 82 in comparison to the circumferential groove on the front face are the thin-material web portions 52 , 54 .
[0070] In other words, the sensor module is in this case produced largely as a solid body. The webs and the moving parts are implemented by the introduction of narrow slots.
[0071] The sensor module 82 has a square base area, with one of the corners of the square (at the reference number 84 ) being chamfered. The corner 84 thus forms an orientation mark, which ensures that the sensor module 80 is always attached to the coordinate measuring machine 10 in the same, defined installation position. This results in constant high precision, even after replacement of the sensor module.
[0072] Two piezo-resistive resistors are designated by reference number 59 ( FIG. 7 ), as being representative of further positions. Four such resistors are in this case arranged on one web, and are connected in a bridge circuit. However, it is also possible to provide a greater or lesser number of resistors such as these on each web. The resistors act as sensors, by means of which the deflections of the stylus, which is not illustrated here, can be determined. As shown in FIG. 7 , two resistors are in each case arranged on the rear face of each thin-material web portion 52 , 54 , and this has been found to be a particularly advantageous embodiment.
[0073] Furthermore, reference number 86 denotes a chip which is arranged on one of the “free” frame areas on the rear face of the frame 42 . In the preferred exemplary embodiment, the chip is an integrated ID circuit, by means of which each individual sensor module 80 can be unambiguously identified. For example, chip 86 contains an individual tag, which allows specifically associated calibration data to be assigned to each sensor module 80 . This data may, for example, be stored in the controller 32 for the coordinate measuring machine 10 and may be called up on the basis of the chip tag as soon as the sensor module has been inserted into the coordinate measuring machine. Alternatively or in addition to this, module-specific data can also be stored directly in the chip 86 . | A sensor module for a probe head of a tactile coordinate measuring machine has a frame forming a stationary module base, thereby defining a first measurement plane. A moving part is connected to the frame via webs. Each web has a thick-material web portion arranged between two thin-material web portions, if seen in a cross section perpendicularly to the first measurement plane. The thick-material web portion has a material thickness greater than the corresponding material thickness of the thin-material web portions. | 6 |
FIELD OF THE INVENTION
[0001] The instant invention is concerned with N-substituted indoles having aryloxyalkanoic acid substituents, and pharmaceutically acceptable salts and prodrugs thereof, which are useful as therapeutic compounds, particularly in the treatment of Type 2 diabetes mellitus, often referred to as non-insulin dependent diabetes (NIDDM), of conditions that are often associated with this disease, and of lipid disorders.
BACKGROUND OF THE INVENTION
[0002] Diabetes refers to a disease process derived from multiple causative factors and characterized by elevated levels of plasma glucose or hyperglycemia in the fasting state or after administration of glucose during an oral glucose tolerance test. Persistent or uncontrolled hyperglycemia is associated with increased and premature morbidity and mortality. Often abnormal glucose homeostasis is associated both directly and indirectly with alterations of the lipid, lipoprotein and apolipoprotein metabolism and other metabolic and hemodynamic disease. Therefore patients with Type 2 diabetes mellitus are at especially increased risk of macrovascular and microvascular complications, including coronary heart disease, stroke, peripheral vascular disease, hypertension, nephropathy, neuropathy, and retinopathy. Therefore, therapeutical control of glucose homeostasis, lipid metabolism and hypertension are critically important in the clinical management and treatment of diabetes mellitus.
[0003] There are two generally recognized forms of diabetes. In type 1 diabetes, or insulin-dependent diabetes mellitus (IDDM), patients produce little or no insulin, the hormone which regulates glucose utilization. In type 2 diabetes, or noninsulin dependent diabetes mellitus (NIDDM), patients often have plasma insulin levels that are the same or even elevated compared to nondiabetic subjects; however, these patients have developed a resistance to the insulin stimulating effect on glucose and lipid metabolism in the main insulin-sensitive tissues, which are muscle, liver and adipose tissues, and the plasma insulin levels, while elevated, are insufficient to overcome the pronounced insulin resistance.
[0004] Insulin resistance is not primarily due to a diminished number of insulin receptors but to a post-insulin receptor binding defect that is not yet understood. This resistance to insulin responsiveness results in insufficient insulin activation of glucose uptake, oxidation and storage in muscle and inadequate insulin repression of lipolysis in adipose tissue and of glucose production and secretion in the liver.
[0005] The available treatments for type 2 diabetes, which have not changed substantially in many years, have recognized limitations. While physical exercise and reductions in dietary intake of calories will dramatically improve the diabetic condition, compliance with this treatment is very poor because of well-entrenched sedentary lifestyles and excess food consumption, especially of foods containing high amounts of saturated fat. Increasing the plasma level of insulin by administration of sulfonylureas (e.g. tolbutamide and glipizide), which stimulate the pancreatic β-cells to secrete more insulin, and/or by injection of insulin after the response to sulfonylureas fails, will result in high enough insulin concentrations to stimulate the very insulin-resistant tissues. However, dangerously low levels of plasma glucose can result from these last two treatments, and increasing insulin resistance due to the even higher plasma insulin levels can occur. The biguanides increase insulin sensitivity resulting in some correction of hyperglycemia. However, the two biguanides, phenformin and metformin, can induce lactic acidosis and nausea/diarrhea, respectively.
[0006] The glitazones (i.e. 5-benzylthiazolidine-2,4-diones) are a more recently described class of compounds with potential for a novel mode of action in preventing or ameliorating many symptoms of type 2 diabetes. These agents substantially increase insulin sensitivity in muscle, liver and adipose tissue in several animal models of type 2 diabetes resulting in partial or complete correction of the elevated plasma levels of glucose without occurrence of hypoglycemia.
[0007] Disorders of lipid metabolism or dyslipidemias include various conditions characterized by abnormal concentrations of one or more lipids (i.e. cholesterol and triglycerides), and/or apolipoproteins (i.e., apolipoproteins A, B, C and E), and/or lipoproteins (i.e., the macromolecular complexes formed by the lipid and the apolipoprotein that allow lipids to circulate in blood, such as LDL, VLDL and IDL) . Cholesterol is mostly carried in Low Density Lipoproteins (LDL), and this component is commonly known as the “bad” cholesterol because it has been shown that elevations in LDL-cholesterol correlate closely to the risk of coronary heart disease. A smaller component of cholesterol is carried in the High Density Lipoproteins and is commonly known as the “good” cholesterol. In fact, it is known that the primary function of HDL is to accept cholesterol deposited in the arterial wall and to transport it back to the liver for disposal through the intestine. Although it is desirable to lower elevated levels of LDL cholesterol, it is also desirable to increase levels of HDL cholesterol. Generally, it has been found that increased levels of HDL are associated with lower risk for coronary heart disease (CHD). See, for example, Gordon, et al., Am. J. Med., 62, 707-714 (1977); Stampfer, et al., N. England J. Med., 325, 373-381 (1991); and Kannel, et al., Ann. Internal Med., 90, 85-91 (1979). An example of an HDL raising agent is nicotinic acid, a drug with limited utility because doses that achieve HDL raising are associated with undesirable effects, such as flushing.
[0008] Dyslipidemias were originally classified by Fredrickson according to the combination of alterations mentioned above. The Fredrickson classification includes 6 phenotypes (i.e., I, IIa, IIb, III, IV and V) with the most common being the isolated hypercholesterolemia (or type IIa) which is usually accompained by elevated concentrations of total and LDL cholesterol. The initial treatment for hypercholesterolemia is often to modify the diet to one low in fat and cholesterol, coupled with appropriate physical exercise, followed by drug therapy when LDL-lowering goals are not met by diet and exercise alone
[0009] A second common form of dyslipidemia is the mixed or combined hyperlipidemia or type IIb and III of the Fredrickson classification. This dyslipidemia is often prevalent in patients with type 2 diabetes, obesity and the metabolic syndrome. In this dyslipidemia there are modest elevations of LDL-cholesterol, accompanied by more pronounced elevations of small dense LDL-cholesterol particles, VLDL and/or IDL (i.e., triglyceride rich lipoproteins), and total triglycerides. In addition, concentrations of HDL are often low.
[0010] Peroxisome proliferators are a structurally diverse group of compounds that when administered to rodents elicit dramatic increases in the size and number of hepatic and renal peroxisomes, as well as concomitant increases in the capacity of peroxisomes to metabolize fatty acids via increased expression of the enzymes of the beta-oxidation cycle. Compounds of this group include but are not limited to the fibrate class of lipid modulating drugs, herbicides and phthalate plasticizers. Peroxisome proliferation is also triggered by dietary or physiological factors such as a high-fat diet and cold acclimatization.
[0011] Three sub-types of peroxisome proliferator activated receptor (PPAR) have been discovered and described; they are peroxisome proliferator activated receptor alpha (PPARα), peroxisome proliferator activated receptor gamma (PPARλ) and peroxisome proliferator activated receptor delta (PPARδ). Identification of PPARα, a member of the nuclear hormone receptor superfamily activated by peroxisome proliferators, has facilitated analysis of the mechanism by which peroxisome proliferators exert their pleiotropic effects. PPARα is activated by a number of medium and long-chain fatty acids, and it is involved in stimulating β-oxidation of fatty acids. PPARα is also associated with the activity of fibrates and fatty acids in rodents and humans. Fibric acid derivatives such as clofibrate, fenofibrate, benzafibrate, ciprofibrate, beclofibrate and etofibrate, as well as gemfibrozil, each of which are PPARα ligands and/or activators, produce a substantial reduction in plasma triglycerides as well as some increase in HDL. The effects on LDL cholesterol are inconsistent and might depend upon the compound and/or the dyslipidemic phenotype. For these reasons, this class of compounds has been primarily used to treat hypertriglyceridemia (i.e, Fredrickson Type IV and V) and/or mixed hyperlipidemia.
[0012] The PPARλ receptor subtypes are involved in activating the program of adipocyte differentiation and are not involved in stimulating peroxisome proliferation in the liver. There are two known protein isoforms of PPARλ: PPARλ1 and PPARλ2 which differ only in that PPARλ2 contains an additional 28 amino acids present at the amino terminus. The DNA sequences for the human isotypes are described in Elbrecht, et al., BBRC 224;431-437 (1996). In mice, PPARλ2 is expressed specifically in fat cells. Tontonoz et al., Cell 79: 1147-1156 (1994) provide evidence to show that one physiological role of PPARλ2 is to induce adipocyte differentiation. As with other members of the nuclear hormone receptor superfamily, PPARλ2 regulates the expression of genes through interaction with other proteins and binding to hormone response elements, for example in the 5′ flanking regions of responsive genes. An example of a PPARλ2 responsive gene is the tissue-specific adipocyte P2 gene. Although peroxisome proliferators, including the fibrates and fatty acids, activate the transcriptional activity of PPAR's, only prostaglandin J 2 derivatives have been identified as potential natural ligands of the PPARλ subtype, which also binds thiazolidinedione antidiabetic agents with high affinity.
[0013] The human nuclear receptor gene PPARδ (hPPARδ) has been cloned from a human osteosarcoma cell cDNA library and is fully described in A. Schmidt et al., Molecular Endocrinology, 6:1634-1641 (1992). It should be noted that PPARδ is also referred to in the literature as PPARβ and as NUC 1, and each of these names refers to the same receptor; in Schmidt et al. the receptor is referred to as NUC 1.
[0014] In WO96/01430, a human PPAR subtype, hNUC1B, is disclosed. The amino acid sequence of hNUC1B differs from human PPARδ (referred to therein as hNUCl) by one amino acid, i.e., alanine at position 292. Based on in vivo experiments described therein, the authors suggest that hNUC1B protein represses hPPARα and thyroid hormone receptor protein activity.
[0015] It has been disclosed in WO97/28149 that agonists of PPARδ are useful in raising HDL plasma levels. WO97/27857, 97/28115, 97/28137 and 97/27847 disclose compounds that are useful as antidiabetic, antiobesity, anti-atherosclerosis and antihyperlipidemic agents, and which may exert their effect through activation of PPARs.
[0016] It is generally believed that glitazones exert their effects by binding to the peroxisome proliferator activated receptor (PPAR) family of receptors, controlling certain transcription elements having to do with the biological entities listed above. See Hulin et al., Current Pharm. Design (1996) 2, 85-102. In particular, PPARλ has been implicated as the major molecular target for the glitazone class of insulin sensitizers.
[0017] A number of glitazones that are PPAR agonists have been approved for use in the treatment of diabetes. These are troglitazone, rosiglitazone and pioglitazone, all of which are primarily or exclusively PPARλ agonists. Although glitazones are beneficial in the treatment of NIDDM, there have been some serious adverse events associated with the use of the compounds. The most serious of these has been liver toxicity, which has resulted in a number of deaths. The most serious problems have occurred using troglitazone, which was recently withdrawn from the market because of toxicity concerns.
[0018] In addition to potential hepatotoxicity, there are several shortcomings associated with the glitazones: (1) Monotherapy for NIDDM produces modest efficacy—reductions in average plasma glucose of ≈20% or a decline from ≈9.0% to ≈8.0% in HemoglobinA1C. (2) There is room for improvement in lipid effects; troglitazone causes a slight increase in LDL cholesterol, and triglyceride lowering is modest relative to the effect of fibrates; results reported to date with rosiglitazone suggest no effect on triglycerides and a possible net increase in the LDL:HDL ratio. Currently available data on pioglitazone appear to indicate that it lowers triglycerides modestly and may also have a neutral or positive effect on LDL vs. HDL (i.e. slight HDL raising with no effect on LDL). (3) All three glitazones have been associated with significant weight gain as well as other AE's (mild edema and mild anemia). These shortcomings provide an opportunity to develop better insulin sensitizers for Type 2 diabetes which function via similar mechanism(s) of action.
[0019] Because of the problems that have occurred with the glitazones, researchers in a number of laboratories have been investigating classes of PPAR agonists that are not glitazones and do not contain 1,3-thiazolidinedione moieties, but that modulate the three known PPAR subtypes, in concert or in isolation, to varying degrees (as measured by intrinsic potency, maximal extent of functional reponse or spectrum of changes in gene expression). Such classes of compounds are expected to be useful in the treatment of diabetes and associated conditions, dyslipidemias and associated conditions and several other indications and may be free of some of the side effects that have been found in many of the glitazones.
SUMMARY OF THE INVENTION
[0020] The class of compounds described herein is a new class of PPAR agonists that do not contain a 1,3-thiazolidinedione moiety and therefore are not glitazones. The class of compounds includes compounds that are primarily PPARλ agonists and PPARλ partial agonists. Some compounds may also have PPARα activity in addition to the PPARλ activity, so that the compounds are mixed PPARα/λ agonists. These compounds are useful in the treatment, control and/or prevention of diabetes, hyperglycemia, and insulin resistance. The compounds of the invention exhibit reduced side effects relating to body and heart weight gain in preclinical animal studies compared with other PPARλ compounds including rosiglitazone.
[0021] The compounds may also be useful in the treatment of mixed or diabetic dyslipidemia and other lipid disorders (including isolated hypercholesterolemia as manifested by elevations in LDL-C and/or non-HDL-C and/or hyperapoBliproteinemia, hypertriglyceridemia and/or increase in triglyceride-rich-lipoproteins, or low HDL cholesterol concentrations), atherosclerosis, obesity, vascular restenosis, inflammatory conditions, neoplastic conditions, psoriasis, polycystic ovary syndrome and other PPAR mediated diseases, disorders and conditions.
[0022] The present invention is directed to compounds of formula I:
[0023] wherein:
[0024] R 1 is methyl, optionally substituted with 1-3 F;
[0025] R 2 , R 3 and R 4 are each independently selected from the group consisting of H, halogen, C 1 —C 6 alkyl, C 2 —C 6 alkenyl, C 2 —C 6 alkynyl, C 3 —C 8 cycloalkyl, aryl, OC 1 —C 6 alkyl, OC 2 —C 6 alkenyl, OC 2 —C 6 alkynyl, O-aryl, OH, SC 1 —C 6 alkyl, SC 2 —C 6 alkenyl, SC 2 —C 6 alkynyl, SO 2 C 1 —C 6 alkyl, SO 2 C 2 —C 6 alkenyl, SO2C 2 —C 6 alkynyl,OCON(R 5 ) 2 , OCO(C 1 —C 6 -alkyl) and CN, wherein all instances of alkyl, alkenyl and alkynyl are optionally linear or branched and all instances of alkyl, alkenyl, alkynyl, cycloalkyl and aryl are optionally substituted with 1-5 substituents independently selected from the group consisting of halogen, aryl, 0-aryl and OMe;
[0026] R 5 and R 6 are, at each occurrence, independently selected from the group consisting of H, F, OH and C 1 —C 5 alkyl, and R 5 and R 6 groups that are on the same carbon atom optionally may be joined to form a C 3 —C 6 cycloalkyl group;
[0027] R 7 and R 8 are each independently selected from the group consisting of H, F, and C 1-5 alkyl, or R 7 and R 8 optionally may be joined to form a C 3 —C 6 cycloalkyl group;
[0028] R 9 is selected from the group consisting of H and C 1 —C 5 alkyl, said alkyl being optionally linear or branched;
[0029] Ar 1 is phenyl, 1-naphthyl, 2-naphthyl, pyridyl or quinolyl wherein Ar 1 is substituted with 1-3 groups independently selected from R 4 ;
[0030] X is selected from the group consisting of C=O, S(O) 2 , CH 2, CH(CH 3 ), C(CH 3 ) 2 , CF 2 , and cyclopropylidene;
[0031] Y is O or S; and
[0032] n is 0-5;
[0033] and pharmaceutically acceptable salts and prodrugs thereof.
[0034] The present compounds are effective in lowering glucose, lipids, and insulin in diabetic animals and lipids in non-diabetic animals. The compounds are expected to be efficacious in the treatment, control and/or prevention of non-insulin dependent diabetes mellitus (NIDDM) in humans and in the treatment, control, and/or prevention of conditions associated with NIDDM, including hyperlipidemia, dyslipidemia, obesity, hypercholesterolemia, hypertrigyceridemia, atherosclerosis, vascular restenosis, inflammatory conditions, neoplastic conditions, and other PPAR mediated diseases, disorders and conditions.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The invention has numerous embodiments. It provides compounds of formula I, including pharmaceutically acceptable salts of these compounds, prodrugs of these compounds, and pharmaceutical compositions comprising any of the compounds described and a pharmaceutically acceptable carrier.
[0036] In one embodiment, in compounds having the formula I, R 1 is CH 3 .
[0037] In another embodiment of compounds having the formula I, R 1 is CH 3 ;
[0038] R 2 , R 3 , and R 4 are each independently selected from the group consisting of H, halogen, C 1 —C 6 alkyl, C 2 —C 6 alkenyl, C 2 —C 6 alkynyl, C 3 —C 8 cycloalkyl, aryl, OC 1 —C 6 alkyl, OC 2 —C 6 alkenyl, OC 2 —C 6 alkynyl, O-aryl, OH, SC 1 —C 6 alkyl, SC 2 —C 6 alkenyl, SC 2 —C 6 alkynyl, OCON(R 5 ) 2 , OCO(C 1 —C 6 -alkyl) and CN, wherein all instances of alkyl, alkenyl and alkynyl are optionally linear or branched and all instances of alkyl, alkenyl, alkynyl, cycloalkyl and aryl are optionally substituted with 1-5 substituents independently selected from the group consisting of halogen, aryl, O-aryl and OMe; and
[0039] X is selected from the group consisting of C=O, CH 2 , CH(CH 3 ), C(CH 3 ) 2 , CF 2, and cyclopropylidene.
[0040] In another embodiment, in compounds having the formula I, R 2 , R 3 , and R 4 are each independently selected from the group consisting of H, OCH 3 , OCF 3 , F, Cl and CH 3 , where CH 3 is optionally substituted with 1-3 groups independently selected from F, Cl, and OCH 3. In more specific embodiments, R2, R3, and R4 are each independently selected from the group consisting of H, OCH 3 , OCF 3 , and C1.
[0041] In another group of compounds having the formula I, R 5 and R 6 are H.
[0042] In another group of compounds having the formula I, R 7 and R 8 are each independently CH 3 or H.
[0043] In preferred groups of compounds having the formula I, R 9 is H.
[0044] In other compounds having formula I, X is C=O.
[0045] In other compounds having formula I, Y is O.
[0046] In another group of compounds having formula I, n is 0, 1, or 2. In a more specific subset of this group of compounds, n is 1.
[0047] Another group of compounds having formula I includes compounds in which Ar 1 is phenyl, 1-naphthyl or 2-naphthyl. A subset of this group of compounds includes compounds in which Ar 1 is phenyl or 2-naphthyl. In either case, Ar 1 is substituted with 1-3 groups independently selected from R 4 .
[0048] In preferred groups of compounds, aryl substituents are phenyl groups.
[0049] A preferred set of compounds having formula I has the following substituents:
[0050] R 1 is CH 3 ;
[0051] R 2 is selected from the group consisting of H, OCH 3 , and OCF 3 ;
[0052] R 3 , R 5 , R 6 , and R 9 are H;
[0053] R 4 is selected from the group consisting of H, C1, and OCH 3 ;
[0054] R 7 and RS are each independently selected from the group consisting of H and CH 3 ;
[0055] X is C=O;
[0056] Y is O;
[0057] and n is 1.
[0058] Specific examples of compounds of this invention are provided as Examples 1-31, named below:
[0059] Example 1: (2S)-2-(3 - { [1 -(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)- 1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0060] Example 2: 2-(2-{[1-(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3-yl]methyl }phenoxy)acetic acid
[0061] Example 3: 2-(3- { [1 -(4-Chlorobenzoyl)-2-Methyl-5 -(methoxy)- 1H-indol-3-yl]methyl}phenoxy)acetic acid
[0062] Example 4: 2-(4- { [1 -(4-Chlorobenzoyl)-2-methyl-5-(methoxy)- 1H-indol-3-yl]methyl }phenoxy)acetic acid
[0063] Example 5: 2-(2- { [1-(4-Chlorobenzoyl)-2-methyl-5-(methoxy)- H-indol-3-yl]methyl }phenoxy)propanoic acid
[0064] Example 6: 2-(3-{ [ 1 -(4-Chlorobenzoyl)-2-methyl-5-(methoxy)- 1H-indol-3-yl]methyl }phenoxy)propanoic acid
[0065] Example 7: 2-(4-{ [1-(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3-yllmethyl }phenoxy)propanoic acid
[0066] Example 8: 2-(2-{ [1-(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3-yl]methyl }phenoxy)-2-methylpropanoic acid
[0067] Example 9: 2-(3-{ [1 -(4-Chlorobenzoyl)-2-methyl-5-(methoxy)- 1H-indol-3-yl]methyl }phenoxy)-2-methylpropanoic acid
[0068] Example 10: 2-(4-{ [1-(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3-yl]methyl }phenoxy)-2-methylpropanoic acid
[0069] Example 11: 2-(2-{ [1 -(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl }phenoxy)acetic acid
[0070] Example 12: 2-(3-{ [1-(4-Methoxybenzoyl)-2-Methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl }phenoxy)acetic acid
[0071] Example 13: 2-(2- { [1-(4-methoxybenzoyl)-2-Methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl }phenoxy)propanoic acid
[0072] Example 14: 2-(2- { [1-(2-naphthoyl)-2-Methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl }phenoxy)propanoic acid
[0073] Example 15: (2R)-2-(2-{ [1 -(4-methoxybenzoyl)-2-Methyl-5-(trifluoromethoxy)- 1H-indol-3-yl]methyl }phenoxy)propanoic acid
[0074] Example 16: (2S)-2-(2-{ [ 1 -(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)- 1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0075] Example 17: 2-(3- {[1 -(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0076] Example 18: 2-(3-{[1 -(2-Naphthoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0077] Example 19: 2-(3-{[1 -(4-Chlorobenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0078] Example 20: 2-(3-{[1-(2,4-Dichlorobenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0079] Example 21: (2R)-2-(3 -{[1 -(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0080] Example 22: (2R)-2-(3-{[1 -(2-Naphthoyl)-2-methyl-5 -(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0081] Example 23: (2S)-2-(3-{ 8 1-(2-Naphthoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0082] Example 24: 2-(2-{[1 -(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)-2-methylpropanoic acid
[0083] Example 25: 2-(3-{[1-(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)-2-methylpropanoic acid
[0084] Example 26: 2-(2-{[1 -(2-Naphthoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)-2-methylpropanoic acid
[0085] Example 27: 2-(3-{[1 -(2-Naphthoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)-2-methylpropanoic acid
[0086] Example 28:: (2R)-2-(3-{2-[1-(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]ethyl}phenoxy)propionic acid
[0087] Example 29: (2S)-2-{3-[1 -(4-methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H -indol-3-yl]phenoxy}propionic acid
[0088] Example 30: (2S)-2-(3-{1-{1-(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]cyclopropyl}phenoxy)propanoic acid
[0089] Example 31: 2-{3-[1-(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]phenoxy}-2-methylpropanoic acid.
[0090] The structures of these specific compounds are shown in the following Table of Examples:
TABLE OF EXAMPLES Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 Example 9 Example 10 Example 11 Example 12 Example 13 Example 14 Example 15 Example 16 Example 17 Example 18 Example 19 Example 20 Example 21 Example 22 Example 23 Example 24 Example 25 Example 26 Example 27 Example 28 Example 29 Example 30 Example 31
[0091] The compounds as defined above are useful in the following methods of treating, controlling, and preventing diseases, as well as other diseases not listed below:
[0092] (1) a method for treating, controlling or preventing diabetes mellitus, and particularly non-insulin dependent diabetes mellitus, in a mammalian patient in need of such treatment which comprises administering to the patient a therapeutically effective amount of a compound of Formula I;
[0093] (2) a method for treating, controlling, or preventing hyperglycemia in a mammalian patient in need of such treatment which comprises administering to the patient a therapeutically effective amount of a compound of Formula I;
[0094] (3) a method for treating, controlling, or preventing lipid disorders, hyperlipidemia, or low HDL in a mammalian patient in need of such treatment which comprises administering to the patient a therapeutically effective amount of a compound of Formula I;
[0095] (4) a method for treating, controlling, or preventing obesity in a mammalian patient in need of such treatment which comprises administering to the patient a therapeutically effective amount of a compound of Formula I;
[0096] (5) a method for treating, controlling, or preventing hypercholesterolemia in a mammalian patient in need of such treatment which comprises administering to the patient a therapeutically effective amount of a compound of Formula I;
[0097] (6) a method for treating, controlling, or preventing hypertriglyceridemia in a mammalian patient in need of such treatment which comprises administering to the patient a therapeutically effective amount of a compound of Formula I;
[0098] (7) a method for treating, controlling, or preventing dyslipidemia, including low HDL cholesterol, in a mammalian patient in need of such treatment which comprises administering to the patient a therapeutically effective amount of a compound of Formula I;
[0099] (8) a method for treating, controlling, or preventing atherosclerosis in a mammalian patient in need of such treatment which comprises administering to the patient a therapeutically effective amount of a compound of Formula I. It is understood that the sequellae of atherosclerosis (angina, claudication, heart attack, stroke, etc.) are thereby treated.
[0100] Definitions
[0101] “Ac” is acetyl, which is CH 3 C(O)—.
[0102] “Alkyl”, as well as other groups having the prefix “alk”, such as alkoxy or alkanoyl, means carbon chains which may be linear or branched or combinations thereof, unless the carbon chain is defined otherwise. Examples of alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, sec - and tert -butyl, pentyl, hexyl, heptyl, octyl, nonyl, and the like.
[0103] “Alkenyl” means carbon chains which contain at least one carbon- carbon double bond, and which may be linear or branched or combinations thereof. Examples of alkenyl include vinyl, allyl, isopropenyl, pentenyl, hexenyl, heptenyl, 1-propenyl, 2-butenyl, 2-methyl-2-butenyl, and the like.
[0104] “Alkynyl” means carbon chains which contain at least one carbon-carbon triple bond, and which may be linear or branched or combinations thereof. Examples of alkynyl include ethynyl, propargyl, 3-methyl-1-pentynyl, 2-heptynyl and the like.
[0105] “Cycloalkyl” means mono- or bicyclic saturated carbocyclic rings, each having from 3 to 10 carbon atoms, unless otherwise stated. The term also includes a monocyclic ring fused to an aryl group in which the point of attachment is on the non- aromatic portion. Examples of cycloalkyl include cyclopropyl, cyclopentyl, cyclohexyl, cycloheptyl, and the like.
[0106] “Aryl” (and “arylene” ) when used to describe a substituent or group in a structure means a monocyclic, bicyclic or tricyclic compound in which all the rings are aromatic and which contains only carbon ring atoms. The term “aryl” can also refer to an aryl group fused to a monocyclic cycloalkyl or monocyclic heterocycle in which the point(s) of attachment is on the aromatic portion. “Heterocyclyl,” “heterocycle,” and “heterocyclic” means a fully or partially saturated monocyclic, bicyclic or tricyclic ring system containing at least one heteroatom selected from N, S and O, each of said rings having from 3 to 10 atoms. Examples of aryl substitiuents include phenyl and naphthyl. Aryl rings fused to cycloalkyls are found in indanyl, indenyl, and tetrahydronaphthyl. Examples of aryl fused to heterocyclic groups are found in 2,3-dihydrobenzofuranyl, benzopyranyl, 1,4-benzodioxanyl, and the like. Examples of heterocycles include tetrahydrofuran, piperazine, and morpholine. Preferred aryl groups are phenyl rings.
[0107] “Heteroaryl” (and heteroarylene) means a mono-, bi- or tricyclic aromatic ring containing at least one ring heteroatom selected from N, 0 and S (including SO and SO 2 ), with each ring containing 5 to 6 atoms. Examples of heteroaryl include pyrrolyl, isoxazolyl, isothiazolyl, pyrazolyl, pyridyl, oxazolyl, oxadiazolyl, thiadiazolyl, thiazolyl, imidazolyl, triazolyl, tetrazolyl, furanyl, triazinyl, thienyl, pyrimidyl, pyridazinyl, pyrazinyl, benzisoxazolyl, benzoxazolyl, benzothiazolyl, benzimidazolyl, benzofuranyl, benzothiophenyl (including S-oxide and dioxide), furo(2,3-b)pyridyl, quinolyl, indolyl, isoquinolyl, dibenzofuran and the like.
[0108] “Halogen” includes fluorine, chlorine, bromine and iodine.
[0109] “Me” represents methyl.
[0110] The term “composition,” as in pharmaceutical composition, is intended to encompass a product comprising the active ingredient(s), and the inert ingredient(s) 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 the present invention and a pharmaceutically acceptable carrier.
[0111] Optical Isomers - Diastereomers - Geometric Isomers - Tautomers
[0112] 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.
[0113] Some of the compounds described herein may contain olefinic double bonds, and unless specified otherwise, are meant to include both E and Z geometric isomers.
[0114] 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 mixtures thereof are encompassed with compounds of Formula I.
[0115] Compounds of the Formula I having two asymmetric centers may be separated into diastereoisomeric pairs of enantiomers by, for example, fractional crystallization from a suitable solvent, for example methanol or ethyl acetate or a mixture thereof. The pair of enantiomers thus obtained, and enantiomeric pairs in general, may be separated into individual stereoisomers by conventional means, for example by the use of an optically active acid or base as a resolving agent or chiral separation columns.
[0116] Alternatively, any enantiomer of a compound of the general Formula I or Ia may be obtained by stereospecific synthesis using optically pure starting materials or reagents of known configuration.
[0117] Salts
[0118] The term “pharmaceutically acceptable salts” refers to salts prepared from pharmaceutically acceptable non-toxic bases or acids including inorganic or organic bases and inorganic or organic acids. Salts derived from inorganic bases include aluminum, ammonium, calcium, copper, ferric, ferrous, lithium, magnesium, manganic salts, manganous, potassium, sodium, zinc, and the like. Particularly preferred are the ammonium, calcium, magnesium, potassium, and sodium salts. Salts in the solid form may exist in more than one crystal structure, and may also be in the form of hydrates. Salts derived from pharmaceutically acceptable organic non-toxic bases include salts of primary, secondary, and tertiary amines, substituted amines including naturally occurring substituted amines, cyclic amines, and basic ion exchange resins, such as arginine, betaine, caffeine, choline, N,N′-dibenzylethylenediamine, diethylamine, 2-diethylaminoethanol, 2-dimethylaminoethanol, ethanolamine, ethylenediamine, N-ethyl-morpholine, N-ethylpiperidine, glucamine, glucosamine, histidine, hydrabamine, isopropylamine, lysine, methylglucamine, morpholine, piperazine, piperidine, polyamine resins, procaine, purines, theobromine, triethylamine, trimethylamine, tripropylamine, tromethamine, and the like.
[0119] When the compound of the present invention is basic, salts may be prepared from pharmaceutically acceptable non-toxic acids, including inorganic and organic acids. Such acids include acetic, benzenesulfonic, benzoic, camphorsulfonic, citric, ethanesulfonic, fumaric, gluconic, glutanic, hydrobromic, hydrochloric, isethionic, lactic, maleic, malic, mandelic, methanesulfonic, mucic, nitric, pamoic, pantothenic, phosphoric, succinic, sulfuric, tartaric, p-toluenesulfonic acid, and the like. Particularly preferred are citric, hydrobromic, hydrochloric, maleic, phosphoric, sulfuric, and tartaric acids.
[0120] It will be understood that, as used herein, references to the compounds of Formula I are meant to also include the pharmaceutically acceptable salts.
[0121] Metabolites - Prodrugs
[0122] Therapeutically active metabolites of other compounds, where the metabolites themselves fall within the scope of the claims herein, are also claimed. Prodrugs, which are compounds that are converted to the claimed compounds as they are being administered to a patient or after they have been administered to a patient, are also claimed as part of this invention. A non-limiting example of a prodrug of the carboxylic acids of this invention would be an ester of the carboxylic acid group, for example a C 1 to C 6 ester, which may be linear or branched, which metabolizes to a compound claimed herein. An ester which has functionality that makes it more easily hydrolyzed after administration to a patient may also be a prodrug.
[0123] Prodrugs of the class of compounds of this invention may be described as compounds having the Formula I, wherein R 9 is now defined as a group that is easily removed under physiological conditions during or after administration to a mammalian patient to yield a compound having Formula I, where R 9 is H, or the carboxylate anion thereof (in solution), or a pharmaceutically acceptable salt thereof, where the substituents and groups and values of n are as defined above for compounds having Formula I.
[0124] Examples of prodrugs of Formula I include compounds in which OR 9 of the CO 2 R 9 group is selected from the group consisting of —OR 10 , —OCH 2 OR 10 , —OCH(CH 3 )OR 10, —OCH 2 OC(O)R 10 , —OCH(CH 3 )OC(O)R 10 , —OCH 2 OC(O)OR 10 , —OCH(CH 3 )OC(O)OR 10 , —NR 11 R 11 , and —ONR 11 R 11 , where each R 10 is independently selected from C 1-6 alkyl optionally substituted with one or two groups selected from —CO 2 H, —CONH 2 , —NH 2 , —OH, —OAc, NHAc, and phenyl; and wherein each R 11 is independently selected from H and R 10 . Compounds having Formula Ia, where R 9 has the chemical structure described above, are described as prodrugs. However, regardless of whether they are active as prodrugs, yielding compounds or salts of Formula I, or whether they have a different means of exhibiting pharmaceutical activity, such compounds are included in this invention. Such compounds are claimed herein, regardless of the mechanism leading to their activity.
[0125] Utilities
[0126] Compounds of the present invention are potent ligands with agonist or partial agonist activity on the various peroxisome proliferator activator receptor subtypes, particularly PPARλ. The compounds may also be ligands or agonists of the PPARα subtype as well, resulting in mixed PPARα/λ agonism or in agonism of mainly the PPARλ subtype. These compounds are useful in treating, controlling or preventing diseases, disorders or conditions, wherein the treatment is mediated by the activation of an individual PPAR subtype (λ or α) or a combination of PPAR subtypes (e.g. α/λ), and particularly the PPARλ subtype. One aspect of the present invention provides a method for the treatment, control or prevention of such diseases, disorders, or conditions in a mammal which comprises administering to such mammal a therapeutically effective amount of a compound of Formula I. Compounds of the present invention may be useful in treating, controlling or preventing many PPAR mediated diseases and conditions, including, but are not limited to, (1) diabetes mellitus, and especially non-insulin dependent diabetes mellitus (NIDDM), (2) hyperglycemia, (3) low glucose tolerance, (4) insulin resistance, (5) obesity, (6) lipid disorders, (7) dyslipidemia, (8) hyperlipidemia, (9) hypertriglyceridemia, (10) hypercholesterolemia, (11) low HDL levels, (12) high LDL levels, (13) atherosclerosis and its sequelae, (14) vascular restenosis, (15) irritable bowel syndrome, (16) inflammatory bowel disease, including Crohn's disease and ulcerative colitis, (17) other inflammatory conditions, (18) pancreatitis, (19) abdominal obesity, (20) neurodegenerative disease, (21) retinopathy, (22) neoplastic conditions, (23) adipose cell tumors, (24) adipose cell carcinomas, such as liposarcoma, (25) prostate cancer and other cancers, including gastric, breast, bladder and colon cancers, (26) angiogenesis, (27) Alzheimer's disease, (28) psoriasis, (29) high blood pressure, (30) Syndrome X, (31) ovarian hyperandrogenism (polycystic ovarian syndrome), and other disorders where insulin resistance is a component.
[0127] Another aspect of the invention provides a method for the treatment, control, or prevention of hypercholesterolemia, atherosclerosis, low HDL levels, high LDL levels, hyperlipidemia, hypertriglyceridemia, and/or dyslipidemia, which comprises administering to a mammal in need of such treatment a therapeutically effective amount of a PPAR agonist or partial agonist having formula I. The PPAR agonist may be used alone or advantageously may be administered with a cholesterol biosynthesis inhibitor, particularly an HMG-CoA reductase inhibitor such as lovastatin, simvastatin, pravastatin, fluvastatin, atorvastatin, rivastatin, itavastatin, or ZD-4522. The PPAR agonist may also be used advantageously in combination with other lipid lowering drugs such as cholesterol absorption inhibitors (for example stanol esters, sterol glycosides such as tiqueside, and azetidinones such as ezetimibe), ACAT inhibitors (such as avasimibe), and with niacin, bile acid sequestrants, microsomal triglyceride transport inhibitors, and bile acid reuptake inhibitors. These combination treatments may also be effective for the treatment, control or prevention of one or more related conditions selected from the group consisting of hypercholesterolemia, atherosclerosis, hyperlipidemia, hypertriglyceridemia, dyslipidemia, high LDL, and low HDL.
[0128] Another aspect of the invention provides a method of treating inflammatory conditions, including inflammatory bowel disease, Crohn's disease, and ulcerative colitis by administering an effective amount of a PPAR agonist, which may be a PPARα agonist, a PPARλ agonist, or a PPARα/λ dual agonist. Additional inflammatory diseases that may be treated with the instant invention include gout, rheumatoid arthritis, osteoarthritis, multiple sclerosis, asthma, ARDS, psoriasis, vasculitis, ischemia/reperfusion injury, frostbite, and related diseases.
[0129] Administration and Dose Ranges
[0130] Any suitable route of administration may be employed for providing a mammal, especially a human, with an effective dose 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, and the like. Preferably compounds of Formula I are administered orally.
[0131] The effective dosage of active ingredient employed may vary depending on the particular compound employed, the mode of administration, the condition being treated and the severity of the condition being treated. Such dosage may be ascertained readily by a person skilled in the art.
[0132] When treating or preventing diabetes mellitus and/or hyperglycemia or hypertriglyceridemia or other diseases for which compounds of Formula I are indicated, generally satisfactory results are obtained when the compounds of the present invention are administered at a daily dosage of from about 0.1 milligram to about 100 milligram per kilogram of animal body weight, preferably given as a single daily dose or in divided doses two to six times a day, or in sustained release form. For most large mammals, the total daily dosage is from about 1.0 milligrams to about 1000 milligrams, preferably from about 1 milligrams to about 50 milligrams. In the case of a 70 kg adult human, the total daily dose will generally be from about 7 milligrams to about 350 milligrams. This dosage regimen may be adjusted to provide the optimal therapeutic response.
[0133] Pharmaceutical Compositions
[0134] Another aspect of the present invention provides pharmaceutical compositions which comprise a compound of Formula I and a pharmaceutically acceptable carrier. The pharmaceutical compositions of the present invention comprise a compound of Formula I or a pharmaceutically acceptable salt or prodrug thereof as an active ingredient, as well as a pharmaceutically acceptable carrier and optionally other therapeutic ingredients. 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.
[0135] The compositions include compositions suitable for oral, rectal, topical, parenteral (including subcutaneous, intramuscular, and intravenous), ocular (ophthalmic), pulmonary (nasal or buccal 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.
[0136] In practical use, the compounds of Formula I can be combined as the active ingredient in intimate admixture with a pharmaceutical carrier according to conventional pharmaceutical compounding techniques. The carrier may take a wide variety of forms depending on the form of preparation desired for administration, e.g., oral or 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, oils, alcohols, flavoring agents, preservatives, coloring agents and the like in the case of oral liquid preparations, such as, for example, suspensions, elixirs and solutions; or carriers such as starches, sugars, microcrystalline cellulose, diluents, granulating agents, lubricants, binders, disintegrating agents and the like in the case of oral solid preparations such as, for example, powders, hard and soft capsules and tablets, with the solid oral preparations being preferred over the liquid preparations.
[0137] 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. Such compositions and preparations should contain at least 0.1 percent of active compound. The percentage of active compound in these compositions may, of course, be varied and may conveniently be between about 2 percent to about 60 percent of the weight of the unit. The amount of active compound in such therapeutically useful compositions is such that an effective dosage will be obtained. The active compounds can also be administered intranasally as, for example, liquid drops or spray.
[0138] The tablets, pills, capsules, and the like may also contain a binder such as gum tragacanth, acacia, corn starch or gelatin; excipients such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid; a lubricant such as magnesium stearate; and a sweetening agent such as sucrose, lactose or saccharin. When a dosage unit form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier such as a fatty oil.
[0139] Various other materials may be present as coatings or to modify the physical form of the dosage unit. For instance, tablets may be coated with shellac, sugar or both. A syrup or elixir may contain, in addition to the active ingredient, sucrose as a sweetening agent, methyl and propylparabens as preservatives, a dye and a flavoring such as cherry or orange flavor.
[0140] Compounds of formula I may also be administered parenterally. Solutions or suspensions of these active compounds can be prepared in water suitably mixed with a surfactant such as hydroxy-propylcellulose. Dispersions can also be prepared in glycerol, liquid polyethylene glycols and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
[0141] The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syringability exists. It must be stable under the conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (e.g. glycerol, propylene glycol and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oils.
[0142] Combination Therapy
[0143] Compounds of Formula I may be used in combination with other drugs that may also be useful in the treatment, prevention, suppression or amelioration of the diseases or conditions for which compounds of Formula I are useful. Such other drugs may be administered, by a route and in an amount commonly used therefor, contemporaneously or sequentially with a compound of Formula I. When a compound of Formula I is used contemporaneously with one or more other drugs, a pharmaceutical composition in unit dosage form containing such other drugs and the compound of Formula I is preferred. However, the combination therapy also includes therapies in which the compound of Formula I and one or more other drugs are administered on different overlapping schedules. It is also contemplated that when used in combination with one or more other active ingredients, the compound of the present invention and the other active ingredients may be used in lower doses than when each is used singly. Accordingly, the pharmaceutical compositions of the present invention include those that contain one or more other active ingredients, in addition to a compound of Formula I.
[0144] Examples of other active ingredients that may be administered in combination with a compound of Formula I, and either administered separately or in the same pharmaceutical composition, include, but are not limited to:
[0145] (a) (i) other PPAR agonists such as the glitazones (e.g. troglitazone, pioglitazone, englitazone, MCC-555, rosiglitazone, and the like), and compounds disclosed in WO97/27857, 97/28115, 97/28137 and 97/27847; (ii) biguanides such as metformin and phenformin; (iii) protein tyrosine phosphatase-1B (PTP-1B) inhibitors, and (iv) dipeptidyl peptidase IV (DP-IV) inhibitors;
[0146] (b) insulin or insulin mimetics;
[0147] (c) sulfonylureas such as tolbutamide and glipizide, or related materials;
[0148] (d) α-glucosidase inhibitors (such as acarbose);
[0149] (e) cholesterol lowering agents such as (i) HMG-CoA reductase inhibitors (lovastatin, simvastatin, pravastatin, fluvastatin, atorvastatin, rivastatin, itavastatin, ZD-4522 and other statins), (ii) sequestrants (cholestyramine, colestipol, and dialkylaminoalkyl derivatives of a cross-linked dextran), (iii) nicotinyl alcohol, nicotinic acid or a salt thereof, (iv) PPARα agonists such as fenofibric acid derivatives (gemfibrozil, clofibrate, fenofibrate and benzafibrate), (v) PPARα/λ dual agonists, such as KRP-297, (vi) inhibitors of cholesterol absorption, such as for example beta-sitosterol, (vii) acyl CoA:cholesterol acyltransferase inhibitors, such as for example avasimibe, and (viii) anti-oxidants, such as probucol;
[0150] (f) PPARδ agonists such as those disclosed in WO97/28149;
[0151] (g) antiobesity compounds such as fenfluramine, dexfenfluramine, phentiramine, sulbitramine, orlistat, neuropeptide Y5 inhibitors, and β3 adrenergic receptor agonists;
[0152] (h) an ileal bile acid transporter inhibitor; and
[0153] (i) agents intended for use in inflammatory conditions such as aspirin, non-steroidal anti-inflammatory drugs, glucocorticoids, azulfidine, and cyclo-oxygenase 2 selective inhibitors.
[0154] The above combinations include combinations of a compound of the present invention not only with one other active compound, but also with two or more other active compounds. Non-limiting examples include combinations of compounds having Formula I with two or more active compounds selected from biguanides, sulfonylureas, HMG-CoA reductase inhibitors, other PPAR agonists, PTP-1B inhibitors, DP-IV inhibitors, and anti-obesity compounds.
BIOLOGICAL ASSAYS
[0155] A) PPAR Binding Assays
[0156] For preparation of recombinant human PPARλ, PPARδ, and PPARα: Human PPARλ 2 , human PPARδ and human PPARα were expressed as gst-fusion proteins in E. coli . The full length human cDNA for PPARλ 2 was subcloned into the pGEX-2T expression vector (Pharmacia). The full length human cDNAs for PPARδ and PPARα were subcloned into the pGEX-KT expression vector (Pharmacia). E. coli containing the respective plasmids were propagated, induced, and harvested by centrifugation. The resuspended pellet was broken in a French press and debris was removed by centrifugation at 12,000 X g. Recombinant human PPAR receptors were purified by affinity chromatography on glutathione sepharose. After application to the column, and one wash, receptor was eluted with glutathione. Glycerol (10%) was added to stabilize the receptor and aliquots were stored at −80° C. For binding to PPARλ, an aliquot of receptor was incubated in TEGM (10 mM Tris, pH 7.2, 1 mM EDTA, 10% glycerol, 7 μL/100 mL β-mercaptoethanol, 10 mM Na molybdate, 1 mM dithiothreitol, 5 μg/mL aprotinin, 2 μg/mL leupeptin, 2 μg/mL benzamidine and 0.5 mM PMSF) containing 0.1% non-fat dry milk and 10 nM [ 3 H 2 ] AD5075, (21 Ci/mmole), ± test compound as described in Berger et al (Novel peroxisome proliferator-activated receptor (PPARλ) and PPARδ ligands produce distinct biological effects. J. Biol. Chem. (1999), 274: 6718-6725. Assays were incubated for ˜16 hr at 4° C. in a final volume of 150 μL. Unbound ligand was removed by incubation with 100 μL dextran/gelatin-coated charcoal, on ice, for ˜10 min. After centrifugation at 3000 rpm for 10 min at 4° C., 50 μL of the supernatant fraction was counted in a Topcount.
[0157] For binding to PPARδ, an aliquot of receptor was incubated in TEGM (10 mM Tris, pH 7.2, 1 mM EDTA, 10% glycerol, 7 μL/100 mL β-mercaptoethanol, 10 mM Na molybdate, 1 mM dithiothreitol, 5 μg/mL aprotinin, 2 μg/mL leupeptin, 2 μg/mL benzamide and 0.5 mM PMSF) containing 0.1% non-fat dry milk and 2.5 nM [ 3 H 2 ]L-783483, (17 Ci/mmole), ± test compound as described in Berger et al (Novel peroxisome proliferator-activated receptory (PPARλ) and PPARδ ligands produce distinct biological effects.1999 J Biol Chem 274: 6718-6725). (L-783483 is 3-chloro-4-(3-(7-propyl-3-trifluoromethyl-6-benz-[4,5]-isoxazoloxy)propylthio)phenylacetic acid, Ex. 20 in WO 97/28137). Assays were incubated for ˜16 hr at 4° C. in a final volume of 150 μL. Unbound ligand was removed by incubation with 100 μL dextran/gelatin-coated charcoal, on ice, for ˜10 min. After centrifugation at 3000 rpm for 10 min at 4° C., 50 μL of the supernatant fraction was counted in a Topcount.
[0158] For binding to PPARα, an aliquot of receptor was incubated in TEGM (10 mM Tris, pH 7.2, 1 mM EDTA, 10% glycerol, 7 μL/100 mL β-mercaptoethanol, 10 mM Na molybdate, 1 mM dithiothreitol, 5 μg/mL aprotinin, 2 μg/mL leupeptin, 2 μg/mL benzamide and 0.5 mM PMSF) containing 0.1% non-fat dry milk and 5.0 nM [ 3 H 2 ]L-797773, (34 Ci/mmole), ± test compound. (L-797733 is (3-(4-(3-phenyl-7-propyl-6-benz-[4,5]-isoxazoloxy)butyloxy))phenylacetic acid, Ex.62 in WO 97/28137). Assays were incubated for ˜16 hr at 4° C. in a final volume of 150 μL. Unbound ligand was removed by incubation with 100 μL dextran/gelatin-coated charcoal, on ice, for ˜10 min. After centrifugation at 3000 rpm for 10 min at 4° C., 50 μL of the supernatant fraction was counted in a Topcount.
[0159] B) Gal-4 hPPAR Transactivation Assays
[0160] The chimeric receptor expression constructs, pcDNA3-hPPARλ/GAL4, pcDNA3-hPPARδ/GAL4, pcDNA3-hPPARα/GAL4 were prepared by inserting the yeast GAL4 transcription factor DBD adjacent to the ligand binding domains (LBDs) of hPPARλ, hPPARδ, hPPARα, respectively. The reporter construct, pUAS(5X)-tk-luc was generated by inserting 5 copies of the GAL4 response element upstream of the herpes virus minimal thymidine kinase promoter and the luciferase reporter gene. pCMV-lacZ contains the galactosidase Z gene under the regulation of the cytomegalovirus promoter. COS-1 cells were seeded at 12×10 3 cells/well in 96 well cell culture plates in high glucose Dulbecco's modified Eagle medium (DMEM) containing 10% charcoal stripped fetal calf serum (Gemini Bio-Products, Calabasas, CA), nonessential amino acids, 100 units/ml Penicillin G and 100 mg/ml Streptomycin sulfate at 37 ° C. in a humidified atmosphere of 10% CO 2 . After 24 h, transfections were performed with Lipofectamine (GIBCO BRL, Gaithersburg, Md.) according to the instructions of the manufacturer. Briefly, transfection mixes for each well contained 0.48 μl of Lipofectamine, 0.00075 ,μg of pcDNA3-PPAR/GAL4 expression vector, 0.045 μg of pUAS(5X)-tk-luc reporter vector and 0.0002 μg of pCMV-lacZ as an internal control for transactivation efficiency. Cells were incubated in the transfection mixture for 5 h at 37° C. in an atmosphere of 10% CO 2 The cells were then incubated for ˜48 h in fresh high glucose DMEM containing 5% charcoal stripped fetal calf serum, nonessential amino acids, 100 units/ml Penicillin G and 100 mg/ml Streptomycin sulfate ± increasing concentrations of test compound. Since the compounds were solubilized in DMSO, control cells were incubated with equivalent concentrations of DMSO; final DMSO concentrations were≦0. 1%, a concentration which was shown not to effect transactivation activity. Cell lysates were produced using Reporter Lysis Buffer (Promega, Madison, Wis.) according to the manufacturer's instructions. Luciferase activity in cell extracts was determined using Luciferase Assay Buffer (Promega, Madison, Wis.) in an ML3000 luminometer (Dynatech Laboratories, Chantilly, Va.). β-galactosidase activity was determined using β-D-galactopyranoside (Calbiochem, San Diego, Calif.). Partial agonism was determined by comparison of maximal transactivation activity with standard PPAR agonists such as rosiglitazone and pioglitazone. If the maximal stimulation of transactivation was less than 50% of the effect observed with standard compounds, then the compound was designated as a partial agonist.
[0161] C) In Vivo Studies
[0162] Male db/db mice (10-11 week old C57Bl/KFJ, Jackson Labs, Bar Harbor, Me.) were housed 5/cage and allowed ad lib. access to ground Purina rodent chow and water. The animals, and their food, were weighed every 2 days and were dosed daily by gavage with vehicle (0.5% carboxymethylcellulose) ± test compound at the indicated dose. Drug suspensions were prepared daily. Plasma glucose, and triglyceride concentrations were determined from blood obtained by tail bleeds at 3-5 day intervals during the study period. Glucose, and triglyceride, determinations were performed on a Boehringer Mannheim Hitachi 911 automatic analyzer (Boehringer Mannheim, Indianapolis, Ind.) using heparinized plasma diluted 1:6 (v/v) with normal saline. Lean animals were age-matched heterozygous mice maintained in the same manner.
EXAMPLES
[0163] The following Examples are provided to illustrate the invention, including methods of making the compounds of the invention, and are not to be construed as limiting the invention in any manner. The scope of the invention is defined by the appended claims.
Example 1
[0164] [0164]
[0165] (2S)-2-(3-{[1-(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl]}phenoxy)propanoic acid
[0166] Step 1. (3E)-4-(3-Hydroxyphenyl)-3-buten-2-one (2):
[0167] 3-Hydroxybenzaldehyde (4.0 g, 32.8 mmole) was dissolved in THF (165 mL) and 1- triphenylphosphoranylidene-2-propanone (20.9 g, 65.6 mmole) was added. The solution was heated to reflux until TLC monitoring determined reaction was complete. Silica gel chromatography with 20% ethyl acetate in hexanes as eluent was used to isolate the title compound in 65% yield.
[0168] [0168] 1 H NMR (400 MHz, CDCl 3 ): δ 7.50 (d, 1H), 7.30 (t, 1H), 7.14 (d, 1H), 7.09 (s, 1H), 6.93 (dd, 1H), 6.72 (d, 1H), 5.70 (s, 1H), 2.42 (s, 3H).
[0169] Step 2. 4-(3- Hydroxyphenyl)-2-butanone (3):
[0170] Compound 2 from Ste p 1 (2.0 g, 12.3 mmole) was dissolved in ethyl acetate (120 mL). The reaction vessel was evacuated and charged with nitrogen gas. Then 10% p alladium on activated charcoal was added (200 mg). The reaction vessel was then evacuated and charged with hydrogen gas and the reaction monitored by TLC. After 1 hour the reaction was filtered over celite and the filtrate evaporated to give the title compound in nearly quantitative yield.
[0171] [0171] 1 HNMR (400MHz, CDC13): δ 7.17 (t, 1H), 6.78 (d, 1H), 6.70 (s, 1H), 6.69 (d, 1H), 5.00 (br s, 1H), 2.88 (t, 2H), 2.78 (t, 2H), 2.18 (s, 3H).
[0172] Step 3. 3-{[2-Methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenol (4):
[0173] p-Trifluoromethoxyphenyl hydrazine hydrochloride (2.58 gr, 11.3 mmole) and Compound 3 (1.86 gl, 11.3 mmole) were stirred in acetic acid at 110° C. for 45 minutes, at which time reaction was complete by HPLC. Acetic acid was removed by rotary evaporation and the resulting residue was purified by normal phase chromatography to give an orange oil (2.83 gr, 78%).
[0174] [0174] 1 H NMR (400MHz, CDC13): δ 7.91 (br s, 1H), 7.1-7.25 (m, 3H), 6.99 (m, 1H), 6.83 (d, 1H), 6.62 (m, 2H), 5.05 (br s, 1H), 3.99 (s, 2H), 2.38 (s, 3H).
[0175] Step 4. Allyl (2S)-2-(3-{[2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoate (5)
[0176] The phenolic indole (4) (50 mg, 0.16 mmole) was dissolved in dichloromethane (2 mL). To the phenol solution was added (S)-allyl lactate (24 mg, 0.19 mmole), triphenylphosphine (50 mg, 0.19 mmole), and diethylazodicarboxylate (DEAD) (0.030 mL, 0.19 mmole) and the reaction was monitored by TLC. Once complete the reaction was purified by silica gel chromatography to give the title compound (44.1 mg, 64%).
[0177] [0177] 1 H NMR (400MHz, CDCl 3 ): δ 7.93 (s, 1H), 7.24 (d, 1H), 7.21 (s, 1H), 7.17 (t, 1H), 6.98 (d, 1H), 6.86 (d, 1H), 6.73 (s, 1H), 6.68 (d, 1H), 5.84 (m, 1H), 5.22 (m, 2H), 4.72 (q, 1H), 4.58 (m, 2H), 4.01 (s, 2H), 2.39 (s, 3H), 1.59 (d, 3H)
[0178] Step 5. Allyl (2S)-2-(3-{[1-(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol -3-yl]methyl}phenoxy)propanoate (6)
[0179] Compound 5 (467 mg, 1.1 mmole) was dissolved in tetrahydrofuran ( 11 mL) and cooled to -78° C. Sodium bis(trimethylsilyl)amide 1.3 mL of a 1.0N solution in THF) was added and the reaction mixture was stirred for 10 minutes. p-Anisoyl chloride (221 mg, 1.3 mmole) was then added. The reaction was warmed to 0° C. then quenched with saturated ammonium chloride and diluted with ether (100 ml). The ether layer was washed with water (2×), brine (1×) and dried over sodium sulfate followed by filtration and evaporation of the filtrate giving the title compound after silica gel chromatography (490 mg, 79%).
[0180] [0180] 1 H NMR (400MHz, CDCl 3 ): δ 7.77 (d, 2H), 7.21 (t, 1H), 7.18 (s, 1H), 7.24 (d, 1H), 7.01 (d, 2H), 6.91 (d, 1H), 6.87 (d, 1H), 6.76 (s, 1H), 6.71 (d, 1H), 5.84 (m, 1H), 5.22 (m, 2H), 4.72 (q, 1H), 4.58 (m, 2H), 4.02 (s, 2H), 3.93 (s, 3H), 2.40 (s, 3H), 1.61 (d, 3H).
[0181] Step 6. (2S)-2-(3-{[1 -(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)- 1H-indol-3-yl]methyl}phenoxy)propanoic acid (7)
[0182] Compound 6 (490 mg, 0.86 mmole) was dissolved in DMF (9 mL). 5,5-Dimethyl-1,3-cyclohexanedione (181 mg, 1.29 mmole), N,N-diisopropylethylamine (0.225 mL, 1.29mmole) and (tetrakistriphenylphoshine)palladium (50 mg, 0.043 mmole) were then added and the solution stirred for 2 hours. Then aqueous ammonium chloride was added and the solution was extracted repeatedly with dichloromethane. The combined organics were dried over sodium sulfate, filtered and the filtrate was evaporated. The crude isolate was then purified by silica gel chromatography to give the title compound (395 mg, 87%).
[0183] [0183] 1 H NMR (400MHz, CDCl 3 ): 7.76 (d, 2H), 7.23 (t, 1H), 7.18 (s,1H), 7.02 (d, 1H), 7.01 (d, 2H), 6.92 (d, 1H), 6.91 (d, 1H), 6.76 (s, 1H), 6.75 (d, 1H), 4.76 (q, 1H), 4.05 (s, 2H), 3.94 (s, 3H), 2.41 (s, 3H), 1.63 (d, 3H).
Examples 2-31
[0184] The following compounds were prepared in a similar fashion to that shown in the above scheme and in Example 1 from commercially available starting materials.
[0185] Example 2
[0186] 2-(2-{[1 -(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3-yl]methyl}phenoxy)acetic acid
[0187] [0187] 1 H NMR (400 MHz, CDCl 3 ): δ 7.69(d,2H), 7.49(d,2H), 7.21 (dt,1H), 7.05 (dd,1H), 6.93 (m,2H), 6.83 (m,2H), 6.66 (dd,1H), 4.78 (s, 2H), 4.10 (s, 2H), 3.74 (s, 3H), 2.38 (s, 3H).
[0188] Example 3
[0189] 2-(3-{[1-(4-Chlorobenzoyl)-2-Methyl-5-(methoxy)-1H-indol-3-yl]methyl}phenoxy)acetic acid
[0190] [0190] 1 H NMR (400 MHz, CDCl 3 ): δ 7.69(d, 2H), 7.49(d, 2H), 7.24 (t, 1H), 6.94 (d, 1H), 6.88 (d, 1H), 6.80 (d, 2H), 6.76 (dd, 1H), 6.66 (dd, 1H), 4.64 (s, 2H), 4.03 (s, 2H), 3.77 (s, 3H), 2.39 (s, 3H).
[0191] Example 4
[0192] 2-(4-{[1 -(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3-yl]methyl}phenoxy)acetic acid
[0193] [0193] 1 H NMR (400 MHz, CDCl 3 ): δ 7.68(d, 2H), 7.49(d, 2H), 7.16 (m, 2H), 6.85 (m, 3H), 6.79 (d, 1H), 6.66 (dd, 1H), 4.64 (s, 2H), 3.99 (s, 2H), 3.76 (s, 3H), 2.39 (s, 3H).
[0194] Example 5
[0195] 2-(2- { [1 -(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3 -yl]methyl}phenoxy)propanoic acid
[0196] [0196] 1 H NMR (400 MHz, CDCl 3 ): δ 7.69(d, 2H), 7.48(d, 2H), 7.18(m, 1H), 7.05 (d, 1H), 6.91 (m, 2H), 6.82 (m, 2H), 6.65 (dd, 1H), 4.92 (q, 1H), 4.09 (q, 2H), 3.74 (s, 3H), 2.37 (s, 3H) 1.71 (d, 3H).
[0197] Example 6
[0198] 2-(3-{[1 -(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0199] [0199] 1 H NMR (400 MHz, CDCl 3 ): δ 7.69(d, 2H), 7.49(d, 2H), 7.21(t, 1H), 6.90 (d, 1H), 6.88 (d, 1H), 6.81 (d, 1H), 6.78 (br t, 1H), 6.73 (dd, 1H), 6.65 (dd, 1H), 4.75 (q, 1H), 4.01 (s, 2H), 3.77 (s, 3H), 2.38 (s, 3H) 1.64 (d, 3H).
[0200] Example 7
[0201] 2-(4-{[1 -(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0202] [0202] 1 H NMR (300 MHz, CDCl 3 ): δ 7.66 (d, 2H), 7.48 (d, 2H), 7.17 (m, 2H), 6.80 (m, 4H), 6.62 (d, 1H), 4.74 (q, 1H), 3.96 (s, 2H), 3.75 (s, 3H), 2.38 (s, 3H), 1.61 (d, 3H); ES_MS (M+1) 478, 480.
[0203] Example 8
[0204] 2-(2-{[1 -(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3-yl]methyl}phenoxy)-2-methylpropanoic acid
[0205] [0205] 1 H NMR (400 MHz, CDCl 3 ): δ 7.69(d, 2H), 7.49(d, 2H), 7.13(m,1H), 7.01 (d,1H), 6.89 (m,3H), 6.77 (d, 1H), 6.66 (dd, 1H), 4.04 (s, 2H), 3.73(s, 3H), 2.36 (s, 3H) 1.69(s, 6H).
[0206] Example 9
[0207] 2-(3-{[1 -(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3-yl]methyl}phenoxy)-2-methylpropanoic acid
[0208] [0208] 1 H NMR (400 MHz, CDCl 3 ): δ 7.69(d, 2H), 7.49(d, 2H), 7.19(m, 2H), 6.96 (d, 1H), 6.88 (d, 1H), 6.79 (m, 2H), 6.66 (dd, 1H), 4.00 (s, 2H), 3.76 (s, 3H), 2.38 (s, 3H) 1.55 (s, 6H).
[0209] Example 10
[0210] 2-(4-{[1 -(4-Chlorobenzoyl)-2-methyl-5-(methoxy)-1H-indol-3-yl]methyl}phenoxy)-2-methylpropanoic acid
[0211] [0211] 1 H NMR (400 MHz, CDCl 3 ): δ 7.69(d, 2H), 7.49(d, 2H), 7.24(d, 2H), 6.88 (m, 3H), 6.79 (d, 1H), 6.66 (d, 1H), 4.00 (s, 2H), 3.76 (s, 3H), 2.39 (s, 3H) 1.57 (s, 6H).
[0212] Example 11
[0213] 2-(2-{[1 -(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)acetic acid
[0214] [0214] 1 H NMR (400 MHz, CDCl 3 ): δ 7.74 (d, 2H), 7.28 (s, 1H), 7.21 (dt, 1H), 7.05 (m, 2H), 7.01 (d, 2H), 6.92 (t, 1H), 6.89 (dd, 1H), 6.82 (d, 1H), 4.78 (s, 2H), 4.13 (s, 2H), 3.93 (s, 3H), 2.41(s, 3H).
[0215] Example 12
[0216] 2-(3-{[1 -(4-Methoxybenzoyl)-2-Methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)acetic acid
[0217] [0217] 1 H NMR (400 MHz, CDCl 3 ): δ 7.78 (d, 2H), 7.22 (t, 1H), 7.18 (s, 1H), 7.01 (m, 3H), 6.92 (m, 2H), 6.80 (s, 1H), 6.78 (d, 1H), 4.63 (s, 2H), 4.15 (s, 2H), 3.93 (s, 3H), 2.41 (s, 3H). Example 13
[0218] 2-(2-{[1 -(4-methoxybenzoyl)-2-Methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0219] [0219] 1 H NMR (400 MHz, CDCl 3 ): δ 7.74 (d, 2H), 7.25 (s, 1H), 7.19 (dt, 1H), 7.05 (d, 1H), 7.03 (d, 1H), 7.00 (d, 2H), 6.90 (m, 2H), 6.82 (d, 1H), 4.93 (q, 1H), 4.12 (q, 2H), 3.93 (s, 3H), 2.41(s, 3H), 1.72 (d, 3H).
[0220] Example 14
[0221] [0221] 2 -(2-{[1 -(2-naphthoyl)-2-Methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0222] [0222] 1 H NMR (500 MHz, DMSO-d 6 ): δ 12.96 (s, 1H), 8.35 (s, 1H), 8.07 (m, 3H), 7.76 (dd, 1H), 7.70 (t, 1H), 7.63 (t, 1H), 7.46 (s, 1H), 7.13 (m, 2H), 7.09 (d, 1H), 6.99 (s, IH), 6.85 (t, 2H), 4.91 (q, 1H), 4.06 (s, 2H), 2.31 (s, 3H), 1.51 (d, 3H).
[0223] Example 15
[0224] (2R)-2-(2-{[1 -(4-methoxybenzoyl)-2-Methyl-5-(trifluoromethoxy)- 1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0225] [0225] 1 H NMR (500 MHz, CDCl 3 ): δ 7.74 (d, 2H), 7.25 (s, 1H), 7.19 (dt, 1H), 7.05 (d, 1H), 7.03 (d, 1H), 7.00 (d, 2H), 6.90 (m, 2H), 6.82 (d, IH), 4.93 (q, 1H), 4.12 (q, 2H), 3.93 (s, 3H), 2.41(s, 3H), 1.72 (d, 3H).
[0226] Example 16
[0227] (2S)-2-(2-{[1-(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0228] [0228] 1 H NMR (500 MHz, CDCl 3 ): δ 7.74 (d, 2H), 7.25 (s, 1H), 7.19 (dt, 1H), 7.05 (d, 1H), 7.03 (d, 1H), 7.00 (d, 2H), 6.90 (ms,2H), 6.82 (d, 1H), 4.93 (q, 1H), 4.12 (q, 2H), 3.93 (s, 3H), 2.41(s, 3H), 1.72 (d, 3H).
[0229] Example 17
[0230] [0230] 2 -(3-{[1 -(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0231] [0231] 1 HNMR (400MHz, CDCl 3 ): 7.76 (d, 2H), 7.23 (t, 1H), 7.18 (s,1H), 7.02 (d, 1H), 7.01 (d, 2H), 6.92 (d, 1H), 6.91 (d, 1H), 6.76 (s, 1H), 6.75 (d, 1H), 4.76 (q, 1H), 4.05 (s, 2H), 3.94 (s, 3H), 2.41 (s, 3H), 1.63 (d, 3H).
[0232] Example 18
[0233] 2-(3 -{[1 -(2-Naphthoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0234] [0234] HNMR ( 400MHz, CDC1 3 ): d 8.30 (s, 1H), 7.97 (m, 3H), 7.80 (d, 1H), 7.68 (t, 1H), 7.61 (t, 1H), 7.24 (t, 1H), 7.20 (s, 1H), 7.03 (d, 1H), 6.92 (d, 1H), 6.86 (d, 1H), 6.80 (s, 1H), 6.75 (d, 1H), 4.78 (q, 1H), 4.06 (s, 2H), 2.41 (s, 3H), 1.65 (d, 3H).
[0235] Example 19
[0236] 2-(3-{[1-(4-Chlorobenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0237] [0237] 1 H NMR (400 MHz, CDCl 3 ): δ 6.69 (d, 2H), 7.50 (d, 2H), 7.24 (s, 1H), 7.15 (t, 1H), 7.03 (m, 2H), 6.90 (m, 2H), 6.79 (d, 1H), 4.91 (q, 1H), 4.07 (dd, 2H), 2.38 (s, 3H), 1.72 (d, 3H); ES-MS (M+1) 532, 534.
[0238] Example 20
[0239] 2-(3-{[1 -(2,4-Dichlorobenzoyl)-2-methyl-5 -(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0240] [0240] H NMR ( 400 MHz, CDCl 3 ): δ 7.49 (m, 4H), 7.24 (s, 1H), 7.18 (t, 1H), 6.99 (m, 2H), 6.87 (t, 1H), 6.78 (d, 1H), 4.93 (q, 1H), 4.08 (dd, 2H), 2.21 (s, 3H), 1.71 (d, 3H); ES-MS (M+1) 566, 568, 570.
[0241] Example 21
[0242] (2R)-2-(3-{[1 -(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0243] [0243] 1 H NMR (400MHz, CDCl 3 ): 7.76 (d, 2H), 7.23 (t, 1H), 7.18 (s,1H), 7.02 (d, 1H), 7.01 (d, 2H), 6.92 (d, 1H), 6.91 (d, 1H), 6.76 (s, 1H), 6.75 (d, 1H), 4.76 (q, IH), 4.05 (s, 2H), 3.94 (s, 3H), 2.41 (s, 3H), 1.63 (d, 3H).
[0244] Example 22
[0245] (2R)-2-(3 -{[1 -(2-Naphthoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0246] [0246] 1 H NMR (400MHz, CDCl 3 ): d 8.30 (s, 1H), 7.97 (m, 3H), 7.80 (d, 1H), 7.68 (t, 1H), 7.61 (t, 1H), 7.24 (t, 1H), 7.20 (s, 1H), 7.03 (d, 1H), 6.92 (d, IH), 6.86 (d, 1H), 6.80 (s, 1H), 6.75 (d, 1H), 4.78 (q, 1H), 4.06 (s, 2H), 2.41 (s, 3H), 1.65 (d, 3H).
[0247] Example 23
[0248] (2S)-2-(3-{[1 -(2-Naphthoyl)-2-methyl-5-(trifluoromethoxy)- 1H-indol-3-yl]methyl}phenoxy)propanoic acid
[0249] [0249] 1 H NMR (400MHz, CDCl 3 ): d 8.30 (s, 1H), 7.97 (m, 3H), 7.80 (d, 1H), 7.68 (t, 1H), 7.61 (t, 1H), 7.24 (t, 1H), 7.20 (s, 1H), 7.03 (d, 1H), 6.92 (d, 1H), 6.86 (d, 1H), 6.80 (s, 1H), 6.75 (d, 1H), 4.78 (q, 1H), 4.06 (s, 2H), 2.41 (s, 3H), 1.65 (d, 3H).
[0250] Example 24
[0251] 2-(2-{[1 -(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)-2-methylpropanoic acid
[0252] [0252] H NMR ( 400 MHz, CDCl 3 ): δ 7.74 (d, 2H), 7.15 (m, 2H), 7.01 (m, 4H), 6.85 (m, 3H), 4.08 (s, 2H), 3.93 (s, 3H), 2.39 (s, 3H), 1.68 (s, 6H); ES-MS (M+1) 542.
[0253] Example 25
[0254] 2-(3-{[1 -(4-Methoxybenzoyl)-2-methyl-5 -(trifluoromethoxy)- 1H-indol-3-yl]methyl}phenoxy)-2-methylpropanoic acid
[0255] [0255] H NMR ( 400 MHz, CDCl 3 ): δ 7.76 (d, 2H), 7.19 (m, 2H), 7.00 (m, 4H), 6.82 (d, 2H), 6.78 (m, 2H), 4.22 (s, 2H), 3.91 (s, 3H), 2.21 (s, 3H), 1.57 (s, 6H); ES-MS (M+1) 542.
[0256] Example 26
[0257] 2-(2-{[1-(2-Naphthoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)-2-methylpropanoic acid
[0258] [0258] 1 H NMR (400 MHz, CDCl 3 ): δ 8.29 (s, 1H), 9.98 (m, 3H), 7.79 (d, 1H), 6.15 (m, 2H), 7.20 (s, 1H), 7.17 (t, 1H), 7.05 (m, 2H), 6.91 (t, 1H), 6.84 (m, 2H), 4.09 (s, 2H), 2.39 (s, 3H), 1.70 (s, 6H); ES-MS (M+1) 562.
[0259] Example 27
[0260] 2-(3-{[1 -(2-Naphthoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]methyl}phenoxy)-2-methylpropanoic acid
[0261] [0261] H NMR ( 400 MHz, CDCl 3 ): δ 8.31 (s, 1H), 7.95 (m, 3H), 7.80 (d, 1H), 7.65 (m, 2H), 7.20 (m, 2H), 7.03 (d, 1H), 6.97 (d, 1H), 6.83 (d, 1H), 6.79 (M, 2H), 4.07 (s, 2H), 2.21 (s, 3H), 1.58 (s, 6H); ES-MS (M+1) 363.
[0262] Example 28
[0263] (2R)-2-(3-{2-[1-(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)- 1H-indol-3-yl]ethyl}phenoxy)propionic acid
[0264] [0264] 1 H NMR (400 MHz, CDCl 3 ): δ 7.75-7.60 (br m, 2H), 7.33-7.29 (m, 2H), 7.21 (t, 1H), 7.02 (d, 1H), 6.97-6.95 (m, 2H), 6.88 (d, 1H), 6.80 (d, 1H), 6.01 (s, 1H), 4.51 (br m, 1H), 3.92 (s, 3H), 3.11-3.02 (m, 2H), 2.81-2.75 (m, 2H), 1.65 (s, 3H), 1.56 (d, 3H); ES-MS (M+1) 542.
[0265] Example 29
[0266] (2S)-2-{3-[1 -(4-methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)- 1H -indol-3-yl]phenoxy}propionic acid
[0267] [0267] 1 H NMR (500 MHz, CDC1 3 ): δ 7.81 (d, 2H), 7.46 (t, 1H), 7.39 (br s, 1H), 7.16 (d, 1H), 7.11 (d, 1H), 7.04 (m, 3H), 6.97 (m, 2H), 4.91 (q, 1H), 3.95 (s, 3H), 2.44 (s, 3H), 1.74 (d, 3H).
[0268] Example 30
[0269] (2S)-2-(3 -{1 -{1-(4-Methoxybenzoyl)-2-methyl-5 -(trifluoromethoxy)-1H-indol-3 -yl]cyclopropyl}phenoxy)propanoic acid
[0270] [0270] 1 H NMR (500 MHz, CDCl 3 ): δ 7.77 (d, 2H), 7.46, (s, 1H), 7.18 (t, 1H), 7.02 (m, 3H), 6.92 (d, 1H), 6.75 (d, 2H), 6.69-6.66 (m. 2H), 4.70 (q, 1H), 3.94 (s, 3H), 2.47 (s, 3H), 1.63 (d, 3H), 1.50 (m, 2H), 1.33 (m, 2H); ES-MS (M+1) 554.
[0271] Example 31
[0272] 2- {3-[1-(4-Methoxybenzoyl)-2-methyl-5-(trifluoromethoxy)-1H-indol-3-yl]phenoxy}-2-methylpropanoic acid
[0273] [0273] 1 H NMR (500 MHz, CDCl 3 ): δ 7.80 (d, 2H), 7.43 (t, 1H), 7.38 (br s, 1H), 7.20 (d, 1H), 7.10 (d, 1H), 7.02(m, 5H), 3.94 (s, 3H), 2.43 (s, 3H), 1.69 (s, 6H). | Certain N-substituted indoles having aryloxyacetic acid substituents are agonists or partial agonists of PPAR gamma, and are useful in the treatment, control or prevention of non-insulin dependent diabetes mellitus (NIDDM), hyperglycemia, dyslipidemi a, hyperlipidemi a, hypercholesterolemia, hypertriglyceridemia, atherosclerosis, obesity, vascular restenosis, inflammation, and other PPAR mediated diseases, disorders and conditions. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to data transmission systems between a plurality of central processing units (CPU's).
The data transmission system of the type referred to is effective to be used for the data transmission between the respective CPU's incorporated in a key telephone system.
In general, the key telephone system must process various sorts of signals in a short time. To satisfy such demand, the system is so arranged that constituent hardwares are installed on a plurality of boards as divided according to their function respectively with a main CPU or a sub-CPU.
The conventional data transmission system, however, has been defective specifically in that latch and buffer stages must be provided to the respective boards which carry, in particular, the sub-CPU, so that the number of required components will have to be thereby increased. This renders the system to be expensive, and fails to minimize installation space. Furthermore, the system requires a plurality of command control lines, which disadvantageously involves a large wiring space and troublesome wiring work.
SUMMARY OF THE INVENTION
A primary object of the present invention is, therefore, to provide a data transmission system which can realize high speed transmission with a simple and inexpensive arrangement so that installation space and wiring labor can be minimized.
According to the present invention, this object can be attained by providing a transmission system which comprises a main CPU, a plurality of sub-CPU's, a data bus connected between the respective CPU's, a CPU select line for sending therethrough a CPU select signal from the main CPU to the respective sub-CPU's, a latch circuit for providing a wait signal to the main CPU itself upon write or read of the main CPU with respect to the sub-CPU's, and a wait clear line for providing therethrough to the latch circuit a wait clear signal indicative of completion of input and output of the sub-CPU to release the waited state of the main CPU, wherein data and command transmission is performed through the write or read of the main CPU.
Other objects and advantages of the present invention shall become clear from the following description of the invention detailed with reference to preferred embodiments illustrated in accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a data transmission system according to the present invention;
FIG. 2 shows waveforms of signals appearing at various points in data transmission system of FIG. 1;
FIG. 3 is a circuit arrangement of a practical embodiment of a latch circuit used in the data transmission system of FIG. 1;
FIG. 4 shows waveforms of signals appearing at various points in the latch circuit of FIG. 3;
FIG. 5 is a circuit arrangement of another practical embodiment of the latch circuit used in the data transmission system of FIG. 1; and
FIGS. 6A to 6C show waveforms of signals appearing at various points in the latch circuit of FIG. 5.
While the present invention shall now be described with reference to the preferred embodiments shown in the drawings, it should be understood that the intention is not to limit the invention only to the particular embodiments shown but rather to cover all alterations, modifications and equivalent arrangements possible within the scope of appended claims.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the data transmission system of the present invention as shown in FIG. 1, a main CPU M is mounted on a main board MBD and a plurality of sub-CPU's, CPU S1 to CPU Sn operatively associated with the main CPU are mounted respectively on each of sub-boards SBD 1 to SBD n which are connected to the main board MBD through a data bus DABU, a CPU select line SCTL and a wait clear line CLRL. In this case, the main CPU, CPU M mounted on the main board MBD is connected at its data terminal DAT to the data bus DABU through a bilateral buffer BUF1 and at its address terminal ADT to an address decoder DEC which generates a CPU select signal SCTS. When the main CPU, CPU M provides one of the addresses allocated every one of the sub-CPU' S , CPU S1 to CPU Sn , the address decoder DEC activates the CPU select signal SCTS being provided to the addressed one of the sub-CPU' S , CPU S1 to CPU Sn . On the main board MBD, the address decoder DEC further provides a wait set signal SETS to a data input terminal DAT of a latch circuit LAT which in turn provides a wait signal WITS to a wait terminal WIT of the main CPU, CPU M .
Furthermore, the main CPU, CPU M provides to the bilateral buffer BUF1 a switching signal SWS1 for switching the signal transmission direction of the buffer BUF1 according to the data transmission or reception, while the address decoder DEC also provides to the buffer BUF1 a comman signal COS for causing signals to pass therethrough.
On the other hand, the sub-CPU' S , CPU S1 to CPU Sn on the sub-boards SBD 1 to SBD n are connected respectively at their data terminal DAT through each of bilateral buffers BUF2 1 to BUF2 n to the data bus DABU to receive data therefrom, and at their output terminal OUT to one of the input terminals of OR gates GAT 1 to GAT n (or AND gates in negative logic), while the OR gates GAT 1 to GAT n are respectively connected at their other input terminal to the CPU select line SCTL to receive the CPU select signal SCTS and at their output terminal to the latch circuit LAT of the main board MBD to provide thereto a wait clear signal CLRS. The sub-CPU' S , CPU S- to CPU Sn are further made to provide to associated ones of the bilateral buffers BUF2 1 to BUF2 n a switching signal SWS2 for switching the signal transmission direction of the buffers BUF2 1 to BUF2 n according to the data transmission or reception.
The operation of the data transmission system according to the present invention shall be explained as follows:
DATA TRANSMISSION FROM MAIN CPU TO SUB-CPU
I. The main CPU, CPU M specifies the address of one of the sub-CPU' S , CPU S1 to CPU Sn to write it and provides data of such a waveform as shown in FIG. 2(a) to the data bus DABU, and the CPU select signal SCTS is provided to the addressed sub-CPU. At the same time, the address decoder DEC provides the wait set signal SETS such as shown in FIG. 2(b) to the latch circuit LAT, through which the wait signal WITS such as shown in FIG. 2(c) is provided to the main CPU, CPU M so as to hold the main CPU, CPU M to a state in which the write has been performed, and the main CPU stops its operation.
II. Upon receipt of the CPU select signal SCTS, the addressed sub-CPU reads the data from the data bus DABU through the associated bilateral buffer BUF2.
III. Upon completion of the data read, the sub-CPU provides a completion signal from its output terminal OUT to the associated OR gate GAT 1 to GAT n which in turn transmits the wait clear signal CLRS such as shown in FIG. 2(d) to the latch circuit LAT on the main board MBD.
IV. The wait signal WITS is thereby cleared, the main CPU, CPU M resumes its operation at a predetermined clock cycle, and the write is completed.
DATA TRANSMISSION FROM SUB-CPU TO MAIN CPU
I. A command is previously provided from the main CPU, CPU M to the addressed sub-CPU upon the data transmission, and the sub-CPU is prepared to transmit its data.
II. The main CPU, CPU M performs a read and, at the same time, the main CPU, CPU M is waited.
III. In response to the previously received command, the addressed sub-CPU receives the CPU select signal SCTS and provides the data through the associated bilateral buffer BUF2 to the data bus DABU and also provides a signal from its output terminal OUT to the associated OR gate GAT 1 to GAT n to have the wait clear signal CLRS provided to the main CPU.
IV. The main CPU, CPU M is thereby released from the waited state and resumes its operation to read the data. Here, the signals are shown in FIG. 2 in the negative logic.
According to another feature of the present invention, the latch circuit is arranged to ensure a more reliable operation. That is, the arrangement of FIG. 1 is satisfactory so long as the wait clear signal CLRS is always properly transmitted from the sub-CPU side to the main CPU side, but, in practice, it is necessary to take into consideration such a possibility that the wait clear signal CLRS is not always properly generated. For example, the address decoder DEC for the generation of the CPU select signal SCTS is usually provided with the capability to decode a larger number than the actually installed number of the boards and sub-CPU's in view of a possible future expansion or modification of the system, so that any presence of error in the control program may happen to cause such a wrong operation of the system that the data is transmitted to a board that is actually not installed. Furthermore, it is also considered possible that some other circuit than the main CPU is partly involved in a problem resulting in no generation of the wait clear signal CLRS, in which event the main CPU is caused to be maintained as waited so as not to do any operation.
Referring now to FIG. 3, a latch circuit LAT20 shown is designed to have the foregoing feature of the present invention, in which, upon transmission of such data as shown in FIG. 4(a), a wait set signal SETS such as shown in FIG. 4(b) is provided from the address decoder DEC simultaneously to a data input terminal D of a latch element LAT21 and to a trigger terminal T of a one-shot multivibrator ONM. Furthermore, a wait clear signal CLRS such as shownin FIG. 4(d) is provided from the addressed sub-CPU simultaneously to a clear terminal CL of the latch element LAT21 and to a clear terminal CL of the multivibrator ONM. The latch element LAT 21 and one-shot multivibrator ONM are connected at their output terminals Q, respectively to each of a pair of input terminals of a NAND gate GAT21, and such a wait signal WITS as shown in FIG. 4(c) is provided at the output terminal of the NAND gate GAT21.
In an event when, for example, data is caused to be transmitted to a sub-CPU not actually installed in the above arrangements, the wait clear signal CRLS or FIG. 4(d) is kept, for example, at its high level, the one-shot multivibrator ONM is started simultaneously with the receipt of the wait set signal SETS of FIG. 4(b) and, after a predetermined time interval, the wait clear signal CLR 22 provided out of the multivibrator ONM to the NAND gate GAT21 is made to be a low level as shown in FIG. 4(f), whereby the wait signal WITS provided out of the NAND gate GAT21 is made positively to be at high level as will be clear from FIG. 4(c), that is, the wait signal is caused to disappear. When, on the other hand, the wait clear signal CLRS is normally transmitted from the addressed sub-CPU, that is, when the latch element LAT21 and one-shot multivibrator ONM receive a low level input, they are both cleared, and the NAND gate GAT21 provides a low level output so that the wait signal WITS will be at a high level to disappear. When the latch element LAT21 receives normally the wait clear signal CLRS, the output wait clear signal CLRS21 of the latch element LAT21 shifts to its low level but, in a state where the wait clear is forcibly performed by the one-shot multivibrator ONM, the wait clear signal CLRS21 shifts to a high level. Therefore, a proper detection of the output wait clear signal CLRS21 of the latch element LAT21 makes it possible to judge whether or not the data transmission is being effectively performed between the addressed sub-CPU and the main CPU.
According to a further feature of the present invention, means are provided for ensuring that the wait clear signal is prevented from being unnecessarily transmitted continuously from the sub-CPU side. While no problem should arise so long as the wait clear signal CLRS is transmitted in normal manner from the sub-CPU side, there may be such a possibility that any arbitrary running takes place on, for example, the sub-CPU side so as to cause the wait clear signal CLRS to be continuously transmitted. On such an occasion, the main CPU, which is likely to be shifted through the latch circuit LAT to the waited state after the write operation, will be immediately cleared due to the wait clear signal CLRS being continuously provided to the latch circuit LAT, so that the main CPU will falsely judge that the data transmission has been completed in a short time so as to have a useless data transmission repeated intermittently.
Shown in FIG. 5 is a latch circuit LAT30 embodying the said further feature of the present invention, in which the wait set signal SETS is provided, upon the data transmission, from the address decoder DEC simultaneously to a clock terminal CLK of a first latch element LAT31 and to a trigger terminal T of a first one-shot multivibrator ONM31, while the first latch element LAT31 and one-shot multivibrator ONM31 are connected at their output terminal Q to each of a pair of input terminals of a first NAND gate GAT31 which provides the wait signal WITS at the output terminal. The first latch element LAT31 is also connected at its data input terminal D to the positive side of a power source, and an output at the output terminal Q of the first latch element LAT31 is made a high level upon rising of the wait set signal to the clock terminal CLK and is kept at the high level until the first one-shot multivibrator ONM31 receives a low level input at its clear terminal CLR. The wait set signal SETS is also provided simultaneously to a trigger terminal T of a second one-shot multivibrator ONM32, so that the first and second one-shot multivibrators ONM31 and ONM32 will concurrently operate with a positive trigger to provide high level signals for a time determined by a time constant of an RC circuit of a resistor R and capacitor C. The first one-shot multivibrator ONM31 resets to the original state in response to the low level signal received at clear terminal CLR.
The wait clear signal CLRS transmitted from the addressed sub-CPU is provided through an inverter INV to one of a pair of input terminals of a second NAND gate GAT33 which also receives the wait set signal SETS at the other input terminal. The second NAND gate GAT33 is connected at its output terminal to a data input terminal D of the second latch element LAT32 which receives at a clock terminal CLK the clock signal CLKS from the main CPU, so that a latching operation of the second latch element LAT32 will be achieved upon positive rising of the clock signal CLKS. Furthermore, the second latch element LAT32 is connected at its output terminal Q to one of two input terminals of an OR gate (or AND gate in the negative logic) GAT32, the other input terminal of which is connected to an output terminal Q of the second one-shot multivibrator ONM32, and an output of the OR gate GAT32 is provided to a clear terminal CLR of the first latch element LAT31. The output terminal Q of the second latch element LAT32 is connected to the clear terminal CLR of the first one-shot multivibrator ONM31 to provide the low level signal for the reset of this multivibrator.
In the foregoing latch circuit LAT30, it is preferable that set time t 1 and t 2 for the first and second one-shot multivibrators ONM31 and ONM32 are set to be several hundred usec and several usec, respectively. In other words, the set time t 1 for the first one-shot multivibrator ONM31 is set to be sufficiently longer than a time from the reception of the wait set signal SETS to the reception of the wait clear signal CLRS during normal generation of the latter signal CLRS, whereas the set time t 2 for the second one-shot multivibrator ONM32 is sufficiently shorter than the time, so that any low level state of the wait clear signal CLRS during in particular the set time t 2 for the second one-shot multivibrator ONM32 can be judged as being the condition where arbitrary running took place on the sub-CPU side, while any high level state of the wait clear signal CLRS kept even after termination of the set time t 1 for the first one-shot multivibrator ONM31 can be determined to be an addressing made to an unstalled sub-CPU or a problem which occurred at a part of the circuit. If the wait clear signal CLRS is held at a high level, then the output of the one-shot multivibrator ONM31 is inverted to a low level after a predetermined time interval so that the wait signal WITS can be released. Even under such abnormal condition, the output of the first latch element LAT31 is not cleared and is kept at a high level so that, on the basis of the state of this output, it can be judged whether or not the data transmission performed immediately before has been valid.
The data transmission performed with the system employing the latch circuit LAT30 of FIG. 5 shall be explained by referring also to FIGS. 6A to 6C. FIG. 6A shows waveforms of signals appearing at various points in the system during normal transmission of the wait clear signal CLRS. Now, when such a clock signal CLKS as shown in FIG. 6A (a) is transmitted from the main CPU, a write data is determined as shown in FIG. 6A (b) in the latter half of a cycle T 1 , the address for a predetermined sub-CPU is provided in the former half of the next cycle T 2 , and the CPU select signal SCTS is activated as shown in FIG. 6A (c). Upon generation of one CPU select signal, the wait set signal SETS is activated as shown in FIG. 6A (d) and is provided through the address decoder DEC to the clock terminal CLK of the first latch element LAT31 in the latch circuit LAT30 and also to the respective trigger terminals T of the first and second one-shot multivibrators ONM31 and ONM32, and to the first latch element LAT31. First and second one-shot multivibrators ONM31 and ONM32 then generate high level output signals at their output terminals Q respectively as shown in FIG. 6A (j), (k) and (h) to activate the wait signal WITS sent from the NAND gate GAT 31 as shown in FIG. 6A (1), consequent on which the main CPU is put in a wait cycle T 2 .
In the second NAND gate GAT33 of the latch circuit LAT30, on the other hand, "NAND" between the wait set signal SETS and the wait clear signal CLRS inverted through the inverter INV is taken, and such an output signal as shown in FIG. 6A (f) is provided. The second latch element LAT32 receives the output signal (f) of the gate GAT33 upon rising of the clock signal CLKS of FIG. 6A (a) provided to the clock terminal CLK of the element, but this output signal (f) is kept at high level as seen in FIG. 6A (g) until the element receives the wait clear signal CLRS as in FIG. 6A (e), so that no clear signal will be provided to the clear terminal CLR of the first one-shot multivibrator ONM 31. As the output of the OR gate GAT32 is also at a high level as in FIG. 6A (i), the first latch element LAT31 receives no clear signal at its clear terminal CLR.
Since the set time t 2 of the second one-shot multivibrator ONM31 is set to be sufficiently shorter than the return transmission time of the wait clear signal CLRS from the sub-CPU, the output signal of this multivibrator ONM32 is reset to a low level prior to the activation of the wait clear signal CLRS as in FIG. 6A (h), so that an output signal (i) of the OR gate GAT32 will be at a low level. After this, the second NAND gate GAT33 receives the wait clear signal CLRS as shown in FIG. 6A (e) from the sub-CPU, upon which the output signal of this gate shifts to a low level as in FIG. 6A (f), and the output signal (g) of the second latch element LAT32 also shifts to a low level upon rising of the subsequent clock signal CLKS. Accordingly, the first one-shot multivibrator ONM31 is cleared, and the first latch element LAT31 is also cleared through the OR gate GAT32, whereby the output of the first NAND gate GAT31 is reset to a high level as in FIG. 6A (1) and the wait signal WITS is released. With this release of the wait, the CPU select signal is caused to disappear as in FIG. 6A (c) in subsequent cycle T 3 of the clock signal of FIG. 6A (a) and the data transmission disappears with the termination of the cycle T 3 .
FIG. 6B shows waveforms of signals appearing at various points during continuous transmission of the wait clear signal from the sub-CPU due to its arbitrary running or the like, in which the signal waveforms (a) to (1) appear at the same points as the signal waveforms (a) to (1) of FIG. 6B, as will be readily appreciated. In the present latch circuit LAT30, in the case in particular of the arbitrary running of the sub-CPU, the output as in FIG. 6B (f) of the second NAND gate GAT33 is caused to vary in response to such wait set signal WETS as in FIG. 6B (d). The output as in 6B (g) of the second latch element LAT32 shifts to low level upon rising of the subsequent clock signal CLKS of FIG. 6B (a) to clear the first one-shot mutivibrator ONM31, and the output signal (k) which has shifted to a high level with the rising of the wait set signal SETS is caused to immediately shift to a low level, whereupon the wait signal WITS of FIG. 6B (1) shifts to high level to be released. On the other hand, the OR gate GAT32 receives at one of the input terminals a high level input during receipt at the other input terminal of the signal from the second one-shot multivibrator ONM32, so as to be guarded for allowing no low level signal to pass therethrough, and thus the first latch element LAT31 will not be cleared. Accordingly, a proper detection of such output signal as in FIG. 6B (j) of the first latch element LAT31 makes it possible to judge whether or not the data transmission is effectively executed between the main CPU and the addreseed sub-CPU.
FIG. 6C shows waveforms of signals appearing at various points when the wait clear signal CLRS does not reach the latch circuit LAT30 for such reason as a false addressing of the main CPU to an uninstalled sub-CPU, or, a problem occurring in a part of any other circuit than the main CPU or the like. Signal waveforms (a) to (1) are the ones appearing at the same points as the signal waveforms (a) to (1) of FIG. 6A when, in particular, the wait clear signal is not provided to the latch circuit LAT30 within a predetermined time. In the present latch circuit LAT30, the output level of the first one-shot multivibrator ONM31 is inverted to a low level as shown in FIG. 6C (k) upon termination of the set time t 1 sufficiently larger than the normal generation time of the wait clear signal CLRS, whereby the output signal of the first NAND gate GAT31 as shown in FIG. 6C (1), i.e., the wait signal WITS is forcibly shifted to a high level to release the wait. In this case, too, the first latch element LAT31 is not cleared, and a proper detection of the output signal as in FIG. 6C (j) of the first latch element LAT31 makes it possible to judge whether or not the data transmission is effectively executed between the main CPU and the addressed sub-CPU. | A data transmission system between a main CPU and a plurality of sub-CPU's includes a data bus connected between them, a CPU select line for transmitting a CPU select signal from the main CPU to the sub-CPU's, a latch circuit for providing a wait signal to the main CPU upon write or read in the main CPU with respect to the sub-CPU's and a wait clear line connected between the respective CPU's to provide to the latch circuit a wait clear signal upon completion of input and output of the sub-CPU to release the waited state of the main CPU, the transmission system being thereby simplified to reduce installation space and wiring labor. | 6 |
RELATED APPLICATIONS
[0001] This application claims the benefit of provisional application 60/575,214 filed on May 27, 2004, and nonprovisional application Ser. No. 10/900,854, filed on Jul. 27, 2004.
BACKGROUND OF THE INVENTION
[0002] The traditional method for forming electrostatic dissipative articles is by combining a polymeric resin with carbon fibers, and carbon powder. However, these compositions are characterized by an undesirable shrinkage rate and variable surface properties.
SUMMARY OF THE INVENTION
[0003] The present invention relates to compositions comprising polymeric resins, glass fiber, carbon powder and antioxidant. The compositions are injection molded to form molded articles having conductive, dissipative and antistatic properties suitable for storage trays, including trays for storing electronic components such as circuit boards, semiconductor devices, and bare dies. Molding articles formed in accordance with the present invention exhibit an improvement in the shrinkage rate and surface resistivity compared to molding articles in the prior art. The molding articles of this invention also exhibit excellent mechanical properties and superior baking performance. As a result, the molding articles made from these compositions can be used for electrostatic dissipation or antistatic purposes in packages, electronic components, and storage trays.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a plot of surface resistivity versus carbon powder content for the composition of Example 1.
[0005] FIG. 2 is a plot of the shrinkage rate versus glass fiber content for the composition of Example 1.
[0006] FIG. 3 is a process flow for manufacturing an IC tray with the composition of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0007] The conductive/dissipative composition of the present invention is composed of four main ingredients: (A) a polymeric resin or blend of polymeric resins; (B) glass fiber; (C) carbon power; and (D) antioxidant. The resin (A) is present from 40 to 70 wt %; each individual resin is present in a range from 0.5 to 95 wt %. Glass fiber (B) is present in amounts ranging from 0.1 to 50 wt %. Carbon Powder (C) is present from 10 to 35 wt %. Antioxidant (D) is added in small amounts in the composition—in amounts of up to 0.5 wt %. All amounts indicated herein are weight percents based on the total weight of the composition unless otherwise indicated. A suitable antioxidant would include Irganox 245 which is available from Ciba Specialty Chemicals. Other additives may be included in the composition including stabilizers, impact modifiers, and polymerization catalysts. The compositions of the present invention exclude the use of vaporized carbon fibers. In preferred embodiments of the invention, carbon fibers are omitted altogether.
[0008] The polymeric resin may be selected from a wide variety of thermoplastic resins and blends of thermoplastic resins. Polymeric resins suitable for the present invention include acrylonitrile-butadiene-styrene, polystyrene or a high impact styrene (HIPS), polyethylene, polycarbonate, polypropylene, polyphenylene ether, polybutylene terephthalate, polysulphone, polyether ether ketone, polyether imide, styrene-butadiene-styrene copolymer, hydrogenated styrene-butadiene-styrene copolymer (SEBS), polyethersulphone, polyphenylene sulfide, and mixtures comprised of any of the aforementioned suitable resins. The polystyrene resins and the styrene copolymers incorporated in this invention are atactic and thus have an amorphous morphology. Specific non-limiting examples of suitable mixtures of polymers include acrylonitrile-butadiene-styrene mixed with polycarbonate; polysulphone mixed with polycarbonate; and polyphenylene ether combined with polystyrene, polyethylene, and styrene-butadiene-styrene.
[0009] The glass fiber suitable for this invention is cut to between 3 mm to 12 mm in length. Preferably the glass fiber strands will be cut to a length that ranges between 3.2 and 6.4 mm inclusive. Most preferably the glass fibers will be cut to 4.5 mm in length. A suitable type of glass fiber for this invention is sold as Chop Vantage® 3786 glass fibers available from PPG Industries Inc., Pittsburgh Pa. Other types of glass fibers may also be used, including TGFS-183E sold by Taiwan Glass Industrial Company.
[0010] Carbon powder in this invention is conductive carbon powder having an average diameter ranging from 25 to 50 nm.
[0011] In the present invention a polymeric resin or resinous mixture is blended together for approximately 15 minutes and then compounded with glass fibers and carbon powder in a compounding machine, such as a twin screw extruder. The glass fibers and carbon powder are introduced at separate times in a side feeder into the main screw of the twin screw extruder, where they are compounded with the selected polymeric resin or polymeric resin blend. However, where a compounding machine is used having multiple feeders, ingredients (A)-(D) may be compounded together in the aforementioned weight percent amounts. Antioxidant(s) are premixed with the polymeric resin or resinous mixture prior to the compounding steps. Upon completion of the compounding an extrudate is produced which is cooled and pelletized. The preferred extrusion temperature range is 240-280° C. over a period ranging from 30-60 seconds in the barrel of the twin screw extruder. Other additives may be included in the composition including stabilizers, impact modifiers, and polymerization catalysts.
[0012] In a first preferred embodiment, a first composition comprising polymeric resin along with antioxidant is compounded with glass fiber at a compounding temperature ranging from 250° C. to 275° C. The polymeric resin (A) may be selected from any one of the thermoplastic resins or blends of thermoplastic resins previously identified as being suitable for the present invention. The polymeric resin (A) is present from 40 to 70 wt %, each individual resin is present in a range from 0.5 to 95 wt %.
[0013] A second composition comprised of polyphenylene ether or polycarbonate is then compounded with carbon powder at a temperature ranging from 240° C. to 260° C. in a twin screw extruder. The first and second compositions are then blended together in a standard industrial blender to yield the pelletized composition of the present invention.
[0014] An example of the first preferred embodiment is to form a first composition comprising a polymeric resin, such as ABS resin, mixed with antioxidant and then to compound the ABS mixture in a twin screw extruder with glass fiber at a temperature ranging from 250° C. to 275° C. Thereafter, a second composition comprising polycarbonate is compounded with carbon powder at a temperature ranging from 240° C. to 260° C. in a twin screw extruder. The first and second compositions are then blended together to yield compounded pellets. The first preferred embodiment is preferred in the situation where a compounding machine with one side feeder is used
[0015] In a second preferred embodiment, ingredients (A)-(D) [(A) a polymeric resin or blend of polymeric resins; (B) glass fiber; (C) carbon power; and (D) antioxidant] are mixed together, forming a mixture referred to herein as G4. Sixty percent of the G4 mixture is compounded with glass fiber in the twin screw extruder (hereinafter referred to as the first compounded composition). Compounding with glass fiber preferably occurs at a barrel temperature of 240° C. to approximately 260° C. Subsequently, 40% of the G4 mixture is compounded with carbon powder in the twin screw extruder (hereinafter referred to as the second compounded composition). Compounding with carbon powder preferably occurs at a barrel temperature of 250° C. to approximately 275° C. The first and second compounded compositions are then mixed together to form pellets suitable for an injection molding process.
[0016] Baking performance is determined by subjecting the molding articles to a baking test. A plurality of trays are stacked on top of each other and placed in an oven. The trays are baked at a temperature ranging from 125° C. to 150° C., and more preferably at 135° C. for approximately 24 hours. After the trays cool to room temperature, they are measured for tray warpage. If all trays within the stack pass warpage inspection, the trays are deemed to have also passed the baking test. Conversely, if any one of the trays in the stack fails warpage inspection, the trays are deemed to have failed the baking test. Individual trays are measured for warpage by placing a tray on a surface plate and inspecting 8 points on the underside of the try with a shim gauge that has a thickness of 30 mils. If the shim gauge can slide underneath one or more of the inspection points, the tray is rejected for being warped.
[0017] The pelletized composition formed at the end of the compounding process, after all compounded compositions are mixed together, is predried at 150° C. for a minimum of 4 hours inside the hopper of the injection molding machine. A mold attached to the barrel of the injection molding machine is pressure filled with the molding composition. The molded article or tray is cooled down and cleaned with a detergent to remove mold release agent from the molded article and then prerinsed and rinsed. The tray is annealed in an oven at temperatures ranging from 140° C. to 150° C., and preferably at 145° C. for a period of approximately 2 hours to relieve the build-up stress caused by the injection molding. Thereafter the trays are inspected for general appearance, warpage dimension characteristics, surface resistivity, shrinkage and other mechanical properties. If the trays pass quality assurance they are packed and shipped to the warehouse for storage.
[0018] The resulting IC trays exhibited excellent mechanical properties, including a stable shrinkage rate and superior baking performance. The IC trays were determined to have a surface resistivity between 10 5 to 10 11 ohms/square.
EXAMPLE 1
[0019] About 50 wt % of GPP13 (a blend of polyphenylene ether, polypropylene and polyethylene) was mixed with 0.14 wt % antioxidant and compounded with 18 wt % carbon powder first at a temperature ranging from 240° C.-260° C. and then compounded with 29 wt % glass fiber in a twin screw extruder at a temperature ranging from 250° C.-275° C. in accordance with the process flow shown in FIG. 5 . The pelletized composition was injection molded into IC trays in accordance with the process flow shown in FIG. 3 .
EXAMPLE 2
[0020] A mixture of between 40-70 wt % of GPP13-R (a blend of polyphenylene ether, SEBS, and polyethylene) and 0.14 wt % antioxidant was compounded with 29 wt % glass fiber, and 18 wt % carbon powder in a twin screw extruder. The composition was compounded at a temperature of 275° C. The pelletized composition was injection molded into IC trays in accordance with the process flow shown in FIG. 3 . The resulting IC trays had excellent mechanical properties, including a stable shrinkage rate and superior baking performance. The IC trays were determined to have a surface resistivity between 10 5 to 10 11 ohms/square.
EXAMPLE 3
[0021] Approximately 49 wt % of GPP5 (a blend of polycarbonate, acrylonitrile-butadiene-styrene, and HIPS) was compounded with 29 wt % glass fiber, 20 wt % carbon powder and 0.14 wt % antioxidant in a twin screw extruder. More specifically, 60% of the 49 wt % GPP5 was compounded with 29 wt % of glass fiber at a temperature of 275° C., and then 40% of the 49 wt % GPP5 was compounded with 20 wt % carbon powder at a temperature ranging from 240-260° C. The pelletized composition was injection molded into IC trays in accordance with the process flow shown in FIG. 3 . The resulting IC trays had excellent mechanical properties, including a stable shrinkage rate and superior baking performance. The IC trays were determined to have a surface resistivity between 10 5 to 10 11 ohms/square.
EXAMPLE 4
[0022] A composition comprising 94.7 wt % polyphenylene ether resin, 0.3 wt % Irganox 245 as antioxidant with 5 wt % PPO resin (available as Noryl N300X from GE Plastics in Pittsfield, Mass. 01201) is blended together and then compounded at a temperature ranging from 240-275° C. in a twin screw extruder with 39 wt % glass fiber to obtain a first compounded composition. Then 70 wt % PPO resin is compounded at a temperature ranging from 240-260° C. in a twin screw extruder with 30 wt % carbon powder to obtain a second compounded composition. In this example, 74.5 wt % of the first compounded composition is mixed with 23.5 wt % of the second compounded composition, along with 1.5 wt % polypropylene and 0.5 wt % of polyethylene in a standard industrial blender for 15 minutes at room temperature. The resulting pelletized composition was injection molded into IC trays in accordance with the process flow shown in FIG. 3 . The resulting IC trays had excellent mechanical properties, including a stable shrinkage rate and superior baking performance. The IC trays were determined to have a surface resistivity between 10 5 to 10 11 ohms/square.
[0023] Table 1 compares the various properties of GPP13 (the composition described in Example 1 and covered by the present invention) with a prior art composition called PP3.
TABLE 1 PROPERTY GPP 13 PP 3 Tensile strength (psi) 11500 8100 Elongation (%) 4.6 3 Impact strength (notched) (Lb 0.75 0.56 ft/in) Molding Shrinkage (%) 0.22 0.78 Heat Deflection Temperature 170 155 (° C.)
PP3 is comprised of 20 wt % carbon powder and 80 wt % polyphenylene ether. PP3 does not contain any glass fibers in its composition. As can be seen from Table 1, GPP13 has excellent mechanical properties such as superior tensile and impact strength, superior elongation (%), as well has an improved shrinkage rate compared to the shrinkage rate of PP3. The shrinkage ratio of the molded articles will depend on the length of the molded article prior to annealing (A) and the length of the molded article after annealing (B). The shrinkage ratio is accordingly computed by subtracting the quantity (B divided by A) from A.
[0024] The examples described herein are solely representative of the present invention. It is understood that various modifications and substitutions may be made to the foregoing examples without departing from either the spirit or scope of the invention. In some instances certain features of the invention will be employed without other features depending on the particular situation encountered by the ordinary person skilled in the art. It is therefore the intent that the invention not be limited to the particular examples disclosed herein. | A conductive plastic composition comprises a polymeric resin or mixture of polymeric resins; glass fiber; carbon power; and antioxidant. Molding articles formed in accordance with the present invention have an improved shrinkage ratio and surface resistivity. The molding articles of this invention can be used for electrostatic dissipation or antistatic purposes in packages, electronic components, and storage trays. Also disclosed is a method of fabricating a tray comprising molding the composition of the present invention. | 2 |
FIELD OF THE INVENTION
This invention relates to a parlor game played by two or more participants.
The invention consists of a method of manipulating and interpreting playing pieces in an alignment style board game.
DISCUSSION OF PRIOR ART
Heretofore, board games have several carefully defined basic structures. Typically, each player has a turn, in which they make their move(s) as outlined by the rules. The players take their turns in "round-robin" style. Additionally, the manner in which playing pieces are placed is strongly regulated by markings on the board or playing field.
In a fictional story called "Icehouse", by Andrew J. Looney (appearing in the book Open 24 Hours, copyright © 1986), the author suggested a board game which departed from these typical structures. In his fictional game, players were not required to wait for their turn, but could make plays whenever they chose. Also, the layout of the playing field in which the game was played was entirely free form.
However, since this was merely a work of fiction, the author did not disclose an actual process by which a game with these atypical characteristics could be played. The author simply suggested the idea. At that time, the outlined game concepts were not workable.
SUMMARY OF THE INVENTION
This invention is an improvement over the prior art in that it provides a workable process for a previously unworkable idea. The invention presents a method for manipulating playing pieces in a manner in which players may make plays at any time they choose. Also, the markings on the playing field regulate the game only by specifying where unplayed pieces are stored and where legitimate plays may be made. This method of manipulating playing pieces can be used as the basis for a board game that provides entertainment and challenges the logic and skill of the participants.
In the inventive game, each player is assigned a multiplicity of small playing pieces which are distinguishable in color, composition, or external markings, or in some other visual manner, from the playing pieces of his opponent(s). The playing pieces can be of varying but similar appearances, such as pyramids of several distinct sizes. It will be possible for the player to position playing pieces in either of two ways, one way having a uniformly-shaped footprint, such as a pyramid standing upright, and the other way indicating a specific direction, such as a pyramid lying on its side. The first of these is a defending position, and the second is an attacking position.
The playing field will be a board or other flat surface with markings or patterns that distinguish the playing area from areas in which each player will store his or her pieces prior to play. Before the game starts, all players will position all of their pieces within the boundaries that define their own storage areas.
The game is then played with all players moving their pieces from their storage areas into the playing field. Pieces can be played in either the defending position or the attacking position. Pieces played in the attacking position will be pointing at those in the defending position. Defending pieces can be protected through a variety of strategies. Attacking pieces can break through such protections through the use of other strategies.
Players may play their pieces at any time they choose. The game will continue until all of the playing pieces have been played. Each player will then receive a final score. The invention includes a method for interpreting the final arrangement of the playing pieces and determining a winner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial representation of the basic playing piece used in the preferred embodiment of the game.
FIG. 2 is a detailed perspective view depicting the game elements in a possible configuration during the game.
FIGS. 3-13 are simple top views depicting various arrangements of playing pieces at different stages during the game. FIG. 14 depicts an alternate embodiment of the playing pieces of this invention.
DESCRIPTION OF THE INVENTION
FIG. 1 depicts the basic playing piece of the preferred embodiment of this invention, a pyramid 20. Pyramid 20 will exist in a multiplicity of different forms. In the preferred embodiment, it will be extant in several clearly distinguishable sizes and several clearly distinguishable colors. Each player will be assigned a given quantity of pyramids of a single color. This will include pyramids of differing sizes. In the preferred embodiment, each player will receive 15 playing pieces, 5 each of small, medium, and large sizes.
Refering to FIG. 2, the game is depicted in a typical configuration while the game is in progress. Pyramid 20 is shown in 3 different colors, one for each of three players, and in three different sizes.
The playing field for the game will be comprised of a flat surface with areas delineating different zones used for the game. A storage zone 22 is an area in which pieces are stored before play. A playing zone 24 is a open area in which legal plays can be made. Storage zone 22 should be just large enough to comfortably receive all of the pieces allocated to a single player. Since the game can be played in a variety of settings, the boundaries of playing zone 24 do not necessarily need to be defined. If the game is played, for example, on a table, the edges of the table might comprise the boundaries of playing zone 24. However, if the game were played on a floor, playing zone 24 might have no specific boundaries.
OPERATION OF THE INVENTION
Before starting to play, each player will position his assigned pieces in his assigned storage zone. On a mutually agreed upon starting signal, all players will be allowed to begin playing. Players will move their assigned pieces out of storage zone 22 and into playing zone 24. They may place their pieces anywhere in the playing zone, within certain limits of the rules as described below. Pyramid 20 may be positioned in either of two ways, either standing upright or lying on its side. A piece placed standing up is called a defending piece and is open to attack. A piece lying on its side is called an attacking piece and can attack defending pieces. Players may place pieces at any time they choose, as frequently or infrequently as they think best. The game ends only when all pieces have been played.
Each playing piece will be assigned a value, which will represent the strength of the playing piece in relation to other playing pieces. In the preferred embodiment, a small pyramid would have a value, or strength, of 1. A medium size pyramid would have a value of 2, and a large pyramid would have a value of 3. These values will have meaning during the game, in analyzing the success or failure of attacks, and can also be used at the end of the game, for the calculation of scores.
The object of the game is to neutralize as many of your opponent's defending pieces as possible, via attack, while keeping as many of your own defending pyramids free from attack as you can. In the preferred embodiment, points will be awarded at the end of the game only for those pieces that were successful in either attacking or defending. The player with the highest score will be the winner.
A successful attack is one in which attacking pieces of a combined strength greater than their target are pointing, in an unobstructed fashion, at an opponent's defending piece. For example, to successfully attack an opponent's defending piece having a value of 2, you must attack it with attacking pieces comprising a total combined value of at least 3. This could be done with a single 3 point pyramid, or with a 2 point pyramid and a 1 point pyramid, or even with three 1 point pyramids. For an attacking piece to be validly attacking a defending piece, its tip must be pointing in an unobstructed fashion at a defending piece, and it must be within a distance of less than its own height away from the defending piece.
FIG. 3 shows a simple attack. A large attacking piece, with a value of 3, is pointing at a small defending piece, with a value of 1. The attack is successful, and the defending piece is defeated.
FIG. 4 shows a more complex attack. A large defending piece, with a value of 3, is being attacked by two mid-sized attacking pieces, each having a value of 2. The combined values of the attacking pieces is 4, so the attack is successful, and the defending piece is defeated.
FIG. 5 shows an unsuccessful attack. The mid-sized attacking pyramid is not really pointing at the small defending piece. The direction of attack, indicated by the tip of the attack piece, does not strike the intended target. In this case, the attack has failed, and the defending piece is defending successfully.
FIG. 6 shows another unsuccessful attack. The two pieces involved are of equal size. Therefore the attack has failed, and the defending piece is defending successfully. However, if another attacking piece were brought to bear on the defending piece, the attacks would then succeed.
Since the object of the game is, in part, to keep defending pieces free from attack (in addition to attacking the opponents' pieces), there are strategies that allow for protection of defending pieces. These strategies involve building walls around defending pieces such that attacking pieces cannot be successfully brought to bear upon them.
FIG. 7 depicts such a defense. The defending pyramid at the center of the picture is completely surrounded by other pieces. No attacking piece can attack the protected defending piece, because there is no way to point an attack piece, in an unobstructed manner, at the protected defending piece. A protective structure such as this is called a fortress.
FIG. 8 depicts another fortress. Note that in this figure, some of the fortress walls are formed by attacking pieces. Attacking pieces and defending pieces, belonging to anyone, can be used as fortress walls. Natural boundaries, such as the edge of a table, can also serve as fortress walls.
This brings up the issue of how close pieces must be placed together to form functional fortress walls. If there is a gap of any meaningful size between the pieces that form the walls of a fortress, then attacking pieces can be placed in those gaps, breaking the defense.
For an attacking piece to successfully attack a defending piece which is protected by a fortress, it must breach the fortress walls. To do this, the tip of the attack piece must protrude past the closest approach between the two pieces that form the barrier.
Referring, then, to FIG. 9, the attacking piece is successfully attacking the defending piece, because it is protruding past the point at which the two wall pieces come nearest to each other.
However, in FIG. 10, the attacking piece is not successfully attacking the defending piece. In this picture, the point at which the two wall pieces come nearest to each other is ambiguous. In such a case, the attacking piece must protrude past the innermost closest approach of the two wall pieces.
Thus, suppose a player wishes to attack a defending piece that is inside of a fortress. There is a gap between two of the pieces forming the fortress walls, and the player thinks this gap is just big enough to squeeze in the tip of an attacking piece. The player should draw an imaginary line between the point at which the two wall pieces come closest to each other. If the player can get the tip of an attacking piece past that line, the attack is good; if not, it fails.
If the shortest line between two wall pieces falls outside of the path between the attacking piece and the targeted defending piece, then those pieces do not form a functional wall. This case is shown in FIG. 11. In this picture, the attack succeeds. The closest approach between the two wall pieces is a line that goes through the targeted defending piece. Since the barrier to be breached in this case isn't actually in the path of the attack, it isn't really a barrier.
In the preferred embodiment, pieces will not be moved after they have been played, except under certain conditions. One such case is redundant attacks. In order to successfully attack a defending piece, the attacking piece(s) must have a total value of least 1 point more than that of the defending piece. It is legal to use more force than is required, but this is not necessarily wise. If a defending piece is attacked with more force than is needed, such that any single attacking piece can be taken away without rendering the overall attack unsuccessful, then the player who owns the defending piece may do just that.
For example, suppose a player attacks a 2 point defending piece using two 3 point attacking pieces. In this case, one of the attacking pieces is redundant. Only one 3 point attacking piece is needed to do the job. The other attacking piece could be removed, and the defending piece would still be successfully attacked.
The person whose defending piece has suffered a redundant attack has the option of capturing the redundant piece(s). He may remove any of the attacking pieces he wishes, as long as the attack remains successful. Captured pieces are returned to storage area 22 of the player who captured the piece. This player then has control of the piece, even though it will be of a color (or other visually distinguishable feature) other than his own. He may play the captured piece anyway he wishes; however, any points generated by the piece are awarded to the player who originally owned the piece. The player who captures a piece merely has control, not ownership, of that piece.
Redundant attack pieces can be captured only by the player whose defending piece is being attacked. The player can capture the piece at anytime he wishes, not necessarily when he first notices it.
Redundant attacks can occur by mistake or on purpose. A player can easily attack an opponent's piece without realizing it was already attacked. A player can also redundantly attack a piece in order to break a fortress. FIG. 12 shows an example of this.
FIG. 12A shows a typical fortress. One of the walls of this fortress is formed by an attack piece. It will be possible to remove this attack piece, and thus destroy the integrity of the fortress, by making a redundant attack.
FIG. 12B shows this same fortress at a later point in the game. An additional, redundant attack piece has been put into place. Since the defending piece has a value of 1, and each attacking piece has a value of 2, either of the attacking pieces could be captured by the owner of the defending piece.
FIG. 12C shows the same fortress at a still later point in the game. The attacking piece that formed part of the fortress wall has been captured, leaving the defending piece inside the fortress unprotected.
FIG. 12D shows the final stage of the maneuver. The piece in the fortress, left unprotected, has now been successfully attacked.
The invention, as described thus far, leaves players with more incentive to play attacking pieces than to play defending pieces. Methods are therefore required to motivate players to play defending pieces.
In the preferred embodiment, therefore, players would be required to play a given number of defending pieces (typically 2) before playing any attacking pieces.
Additionally, in the preferred embodiment, players would be required to keep at least 1 defending piece free from successful attack at all times. Any player who is observed to have no successfully defending pieces in the playing zone would automatically lose the game. In the preferred embodiment, there would be a grace period during which players would be excluded from this rule. During this grace period, they would have an opportunity to build up their defenses. In the preferred embodiment, this grace period would be measured by the number of unplayed pieces that a player has remaining in his storage area. Once the number of pieces in their storage area went below a certain limit (typically 8), they would be subject to the rule requiring them to have at least 1 successfully defending piece. However, the grace period could be measured by other means. For example, it could be a simple time limit.
Other methods of motivating players to play defending pieces could be employed. For example, extra points could be awarded for each successfully defending piece, or for each discrete fortress.
The invention requires that, once played, pieces not be moved, even slightly, except under special circumstances. Frequently it is the case that a player wishes to squeeze a piece into a spot where it won't easily fit. Sometimes he will manage to do this without jarring any of the pieces already in place, and sometimes he won't. A player should pay a penalty if he moves any of the pieces already on the board while attempting to place his own piece. In the preferred embodiment, he will give away the piece he was attempting to play, to the opponent of his choice. The recipient of the penalty piece will treat it as a captured piece, as discussed above. An attempt should also be made to restore the played pieces to the state they were in before they were shifted.
In the preferred embodiment, players would be limited in the speed with which they play pieces. Players should be allowed to remove only one piece from their storage area at a time. Each play they make should be a single, discrete action. There should be no two fisted playing. Players should not be placing one piece in the playing area with one hand while using the other hand to retrieve the next piece from their storage area. Players should not be allowed to alternate hands in order to play quickly. However, this should not compel players to use only one hand during the course of the game. Players should be allowed to use two hands to place or remove a piece in a difficult spot. They should also be allowed to change hands, as long as they do so only by passing a piece from one hand to the other.
In the preferred embodiment, attacking pieces are not permitted to attack other attacking pieces. They are also not permitted to attack pieces of their own color, or to be positioned such that they are not attacking anything. Such attacks would be unsuccessful, and no points would be awarded to attacking pieces played in this way. Normally, players would not be allowed to make such plays. However, it is possible for an attacking piece to be affected by other plays such that a situation like this could exist. If a valid attack is made, and then other pieces are played such that they obstruct the line of attack of the first attacking piece, then that attack is neutralized. Such a situation is depicted in FIG. 13.
FIG. 13A depicts a typical attack configuration. FIG. 13B depicts this same configuration at a later point in the game. In FIG. 13B, an attacking piece has been placed in such a way as to make an earlier successful attack unsuccessful.
The game ends when all pieces have been moved from the storage areas into the playing area. Any redundant attacks that are noticed after the last piece has been played, or even created by the final play, must remain as they are.
In the preferred embodiment, scores will be awarded to each player at the end of the game. Each player would receive points, equal to the values of the pieces, for each of their successful attacking pieces and successful defending pieces. The player with the highest score would be the winner.
In cases where pieces owned by different players participated jointly in successful attacks, players would still get points for their pieces. For example, a red 3 point piece might be attacked by a blue 2 point piece and a green 2 point piece. In this case, blue and green would each get 2 points, and red would get 0.
SUMMARY, REFLECTIONS, AND SCOPE
The reader will see that the described method of manipulating and interpreting playing pieces can be used as the basis for a board game in which players are not limited by traditional round-robin style play and rigid game board layouts. Such a game would be fast-paced, challenging, unpredictable and atypical.
While the above description contains many specifities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations are possible. For example, instead of using pyramid 20, which has a 4-sided base, pyramids having a 3-sided or 5-sided base could be employed. Instead of using 3 distinct sizes of pyramid 20, 5 sizes could be employed. Similarly, the playing pieces could all be of one size, but instead feature numerical markings that define the value of the piece. Pieces belonging to different players could be composed of different materials or have different patterns described upon them rather than being of differing colors. Instead of employing a single type of playing piece which can be positioned in either of 2 ways, the game could be played with 2 different types of playing pieces, one being used for defending plays and the other for attacking plays. An example of this is shown in FIG. 14, which depicts the use of pyramid 20 for attack and a cube 26 for defense. Different scoring methods could be used. For example, instead of awarding points, the game could played such that the winner is the player with the largest number of successfully defending pieces. Different numbers of players could participate. The game could be played with teams instead of individuals. However, the basic method of manipulating the playing pieces will be the same. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. | A strategy game utilizing two forms of a playing piece, one indicating direction and representing attack, the other indicating position and representing defense. Each player has a plurality of playing pieces. The game begins with all pieces held in storage During the game, playing pieces are put into play and either take up defensive positions or attack defensive pieces already in place. The game ends when all pieces have been played. Participants may make plays at any time they choose. The object of the game is to protect one's defensive pieces while attacking the defensive pieces of one's opponents. The winner is determined through a method of interpreting the success of attacks by examining placement of pieces relative to each other. | 0 |
BACKGROUND
The present invention relates to grinding machines and will be disclosed in connection with a control apparatus which varies the infeed rate of a tangential grinding machine to optimize grinding operations whenever the grinding wheel or workpiece sizes are variable.
Tangential grinders are known in the art and are characterized in that the workpiece feed vector is noncoincident with the rotary axis of the abrasive wheel. Generally, the relative infeed motion between the grinding wheel and workpiece in a tangential grinder is tangent to the periphery of the grinding wheel axis. The relative motion may be accomplished by the workpiece feeding tangent to the periphery of the grinding wheel or vice versa. Alternatively, the motion between these two elements may be skewed. The most prominent contemporary example of a tangential grinder is a surface grinder.
Like all grinders, tangential grinders are plagued with the problem of wheel breakdown, a problem which is virtually inherent in the grinding process. This breakdown is a function of the force generated between the grinding wheel and workpiece in machining operation. It is commonly expressed in terms of stock removal rate per inch and G-ratio. As a consequence of wheel breakdown, the abrasive wheel dimensions vary from the their original size to some smaller "stub out" dimension. Depending upon the original size of the abrasive wheel, the dimensional change may be quite substantial. For example, a wheel with an original 36 inch diameter might be used upon a machine until a "stub out" diameter of 26 inches is reached, utilizing five inches of wheel radius.
Prior art tangential grinding machines move the workpiece relative to the abrasive wheel at a fixed velocity during the period these two elements are in grinding engagement. This fixed velocity feed has resulted in several problems in tangential grinding. As the grinding wheel is reduced in size, workpiece contact with the wheel is delayed as the workpiece (or grinding wheel, as the case may be) must be moved through a greater distance before contact with the grinder wheel (or workpiece) commences. Thus, a greater portion of the feed stroke is non-productive (grinding air). If the rapid advance portion of the stroke is fixed, significant increases in non-productive cycle time result without offsetting advantages. Additionally, and perhaps more significantly, prior art machine control concepts have required exceedingly high stock removal rates in the diminished cutting path length whenever a large amount of stock is removed with a worn wheel. This has resulted because the prior art machines have fixed feed velocities through variable cutting path lengths, the cutting path being reduced in length in proportion to the grinding wheel wear. Further, stock material often fluctuates in its dimensions. Hot forged cylindrical workpieces, for example, often exhibit wide variations in their diameters. Thus, the cutting path often fluctuates even with a constant wheel size and is not predictable.
Prior art machines have been relegated to compromising between one of two trade off situations. If the grinding feed velocity is set for a new wheel size, exceedingly high stock removal rates will be experienced after the wheel undergoes wear. While the initially suitable, relatively rapid, feed rate reduces cycle time, continued use of this rate may result in multiple problems after the wheel experiences wear. Such problems may include, inter alia, accelerated wheel breakdown, depreciated workpiece finish and even workpiece sizing problems. On the other hand, if the machine rate is set for the worn wheel size, reduced cycle time will be experienced with a new wheel, and a slower cycle time will result. Quality control considerations frequently dictate that the worse case situation be accomodated; and this latter, slower cycle time is frequently adopted.
Applicant has alleviated the above mentioned problems with a novel and unique control scheme that contains the advantages of each of the formerly available trade off situations while eliminating the disadvantages associated with each. Consequently, many of the compromises inherent in prior art machines are removed and a new and improved grinder control results.
SUMMARY OF THE INVENTION
The invention relates to grinding machines and more particularly to an infeed control which is especially suitable for a tangential grinding machine. The tangential grinding machine has a grinding wheel and means for effectuating relative tangential movement between the wheel and a workpiece along a tangential cutting path for selective grinding contact therebetween. The length of the tangential grinding path, which varies as the grinding wheel experiences breakdown, is detected and this parameter is utilized to control the rate of the relative tangential movement.
The infeed control senses the relative positions of the grinding wheel and the workpiece when grinding action is initiated to measure the grinding path with each grinding cycle. As the grinding wheel wears and is reduced in dimension, the infeed control reduces the rate of relative grinding wheel-workpiece movement in order to optimize the grinding period. The overall grinding cycle is also reduced by varying the grinding cycle commencement position with each grinding cycle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a tangential grinding machine utilizing one form of the present invention.
FIG. 2a is a diagrammatic view of a grinding wheel and a workpiece illustrating a tangential grinding path for a new grinding wheel.
FIG. 2b is a diagrammatic view of the grinding wheel in the workpiece of FIG. 2a illustrating the change in tangential grinding path length as the grinding wheel experiences wear.
FIG. 3 is schematic depiction of one control scheme used to control the grinding machine of FIG. 1.
FIG. 4 is a schematic depiction of an alternate control scheme used to control the grinding machine of FIG. 1.
FIG. 5 is circuit diagram illustrating one method of implementing the control scheme of FIG. 3.
FIG. 6 is a circuit diagram illustrating one method of implementing the control scheme of FIG. 4.
FIG. 7 is a schematic representation of an alternate method of implementing the control scheme of FIG. 3.
FIG. 8 is a schematic representation of an alternate method of implementing the control scheme of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and to FIG. 1 in particular, a tangential grinding machine 10 is shown operating upon a cylindrical workpiece 12. The grinding machine 10 has a grinding wheel 14 rotatable about a spindle 16 contained in a housing 18. The spindle 16, and consequently the grinding wheel 14 is rotatably powered by an electrical motor 20 in a conventional manner. The housing 18 is slidable in the Y direction along a way system 22 which is attached to a column 24. The column 24 is itself slidable in the Z direction, parallel to the spindle 16 axis, along way system 26 supported upon the machine base 28. A dresser assembly 37 is mounted upon a slide 34 for common movement with the head and tail stocks 30 and 32. At selected intervals (e.g. after a predetermined number of grinding cycles) the dresser assembly 37 is interfaced with the grinding wheel 14 by further advancement of the slide 34 in the X-direction along ways 35.
The workpiece 12 is carried between respective head and tail stocks 30 and 32 also supported upon the slide 34. The slide 34 is movable in the X direction along a way system 35 under the impetus of an electrical stepping motor 38, the motor 38 rotatably powering a screw or feed mechanism 40. The directions X, Y and Z are mutually perpendicular and form a mutually perpendicular triordinant system.
FIG. 2a depicts a new grinding wheel 14 and a cylindrical workpiece 12. The workpiece 12 is illustrated in three positions as it is moved from right to left in the illustration. The workpiece position 12a at the extreme right represents the cycle commencement position for the slide 34; middle workpiece position 12b represents the point of initial contact with the grinding wheel 14; and position 12c at the extreme left represents the finish size position in which the workpiece is directly beneath the grinding wheel center line. As represented by the reduction in the diametrical workpiece dimension between positions 12b and 12c, stock is removed as the workpiece passes through a grinding path C, the path C being defined in this particular application as the distance between workpiece centerpoints, e and f, in the grind commencement and the finish size positions 12b and 12c, respectively. As should be readily apparent from a comparison of FIGS. 2a and 2b, the grinding path C diminishes as the grinding wheel 14 wears from the new size radius R and approaches its stub-out radius R'. The grinding path between positions 12b and 12c is reduced from the distance C in FIG. 2a to the distance C' in FIG. 2b.
The invention optimizes the grinding cycle time with stock removal to insure quality. The velocity of the feed slide (or grinding wheel if it is moved to effectuate the relative movement) is varied as the grinding path is altered to maintain a substantially constant grinding time. One control scheme is illustrated in schematic depiction of FIG. 3. After the slide 34 commences from its cycle start position 12a, a load detection means, shown as a power or watt transducer 42, monitors the electrical power drawn by the spindle motor 20. The transducer 42 generates a signal which is proportional to load upon the grinding wheel 14. When contact is made between the workpiece 12 and grinding wheel 14, the resulting power surge in the motor 20 will be detected by the transducer 42 and reflected in its output which is applied to a controller 46 through a meter relay 44. The controller 46 also receives inputs from a potentiometer 48 and a position sensor 50. The position sensor 50 may take any of several conventional forms, as for example, an LVDT, a voltage divider or a FARRAND scale. The distance detected by the position sensor 50 at the instance in which the transducer 42 indicates workpiece--grinding wheel contact represents the grinding path C or the distance between the workpiece center positions in the grind commencement and finish size positions 12b and 12 c. The potentiometer 48 is set at a value representing the desired time to be utilized in a predetermined stock removal. Since the desired velocity is proportional to the quotient of the distance, C, and the time, t, these inputs are mathematically combined to produce an output signal which is input to the feed mechanism 40.
FIG. 5 shows a circuit which might be employed to implement the control scheme in FIG. 3. The grinding path length C, is measured by the position sensor 50 (FARRAND scale, voltage divider, LVDT, etc.) and input to a storage element 54. Whenever the transducer 42 detects workpiece--grinding wheel contact, its output is used to open contact 52 associated with meter relay 44. The cutting path length now represented by the stored value of C is applied to a divider 56 through a buffer amplifier 55. The divider 56 has a second input from a thumbwheel switch or potentiometer 58 which applies a signal representative of the desired time period for the predetermined stock removal. The divider 56 supplies, as its output, a signal representative of the quotient of the cutting path length and the time signals. This signal which is proportional in magnitude to the desired relative tangential velocity, V, between the grinding wheel and workpiece and is used to control the grinding feed mechanism.
The output of buffer amplifier 55 is also applied to an operational amplifier 60. A second input to this amplifier 60 provides a signal proportional to the desired distance A, between the workpiece feed commencement and wheel contact positions. As will be readily appreciated from the illustrations of FIGS. 2a and 2b, if the cycle commencement position 12a remains fixed, the non-productive time required for advancing the workpiece to the grinding wheel contact position will increase with wheel wear. This non-productive time is reduced in present day machines with "gap eliminator" circuitry. The present invention reduces this period even further by combining the gap eliminator circuit with a variable cycle commencement position 12c. The distance, C, between the finish size position, 12c, and the initial wheel-workpiece contact point or grind commencement position, 12b, is added to the desired distance between cycle commencement and grind commencement positions, A, to establish a variable cycle commencement position 12a.
Referring once again to FIGS. 2a and 2b, it can be seen that whenever, as in the preferred embodiment, the grinding wheel and workpiece are cylindrical, a definite geometric relationship exists between the grinding wheel radius and the grinding path length C. Imaginary lines connecting the workpiece centerpoints e and f, in respective positions 12c and 12b, and the grinding wheel centerpoint, g, form a right triangle having the length of the cutting path C as one side. According to pythagorean theorem the square of the hypotenuse (R+r'), defined by the sum of the grinding wheel and unmachined workpiece diameters is equal to the sum of the squares of the lengths of the other two sides. This relationship may be rearranged and expressed mathematically as follows:
C.sup.2 =(R+r').sup.2 -(R+r).sup.2
where
C is the distance travelled by the part during grinding
R is the grinding wheel radius
r' is the initial part radius
and
r is the final part radius
With known grinding wheel and workpiece dimensions, the above equation can be solved for C, the grinding path length.
In many tangential grinding applications, the total stock removal is such that relatively small dimensional changes occur in the workpiece radius between rough and finish sizes. In these applications, it may be assumed without significant error that the initial and finish workpiece dimensions are approximately equal; in other words:
d'≃d
or
d'+d=2d
where
d is the initial workpiece diameter
and
d' is the final diameter With this assumption, the value of C may be expressed as:
C≃√S/2(D+d)
Where S is the stock to be removed on the workpiece, or
S=(d-d')
Since the velocity is the quotient of the length C divided by the time t, the desired velocity may be expressed as:
V≃√S/2(D+d)/t
If the grinding wheel diameter is 25 inches and the workpiece diameter is 4 inches and 0.005 inches of stock are removed, the above assumption would result in a 0.004% error. A 0.09% error would result with a 15 inch wheel diameter, 0.5 inch workpiece diameter and a 0.055 inch stock removal. It is thus seen that the above proximations are acceptable in a wide range of grinding applications.
FIG. 4 is a schematic illustration of a control scheme to estimate the grinding path length by measurement of the change in the grinding wheels dimensions. A signal representative of the grinding wheel diameter is generated from a wheel size sensor 62 and applied to a controller 64. The controller 64 also has inputs from a plurality of potentiometers represented by block 65 representative of the final part size, d, the stock to be removed, s; and the desired grinding time, t. The controller 64 mathematically combines the parameters in accordance with the above equation and delivers a control signal representative of the desired velocity, V, to the feed mechanism 40.
FIG. 6 is a circuit diagram illustrating one method to achieve the control scheme of FIG. 4. A signal representative of the wheel size radius change, ΔR, is input to a summation amplifier 68 from the position sensor 62. The sensor 62 may for example, detect the position of a compensation slide used for the grinding wheel 14. This signal from sensor 62 is subtracted from a second fixed signal input representative of the new grinding wheel diameter from a voltage source 70. The output of amplifier 68, representative of the presently measured grinding wheel diameter, is combined with still another input from a potentiometer 72. Potentiometer 72, which may be a thumbwheel switch, is set at a value representative of the desired workpiece diameter, d. A combined signal, resulting from the addition of the signals from the outputs of amplifier 68 and potentiometer 72 is applied as a first input to a multiplier unit 74. A second input to the multiplier 74 representative of the desired stock removal, S, to the multiplier unit 74 is generated by potentiometer 76 via a voltage divider 78. The multiplier unit 74, which is a commerically available unit, is in turn connected to a square root generator 80 which then modifies its input signal to produce an output which approximates the distance C. The square root generator 80 output is then applied to a voltage divider unit 82 where this signal is combined with a second divider signal 82 input representative of the desired grinding time, t, from a thumbwheel switch or potentiometer 84. The divider 82 output, proportional to the quotient of the input of the square root generator 80 and potentiometer 84 is then applied to a servo input for control of the slide 34.
The output of the square root generator 80 is also applied to a summation amplifier 86 where its value is added to that of a voltage source 88. The voltage source 88 is proportional to the value A, that is, the distance between cycle commencment and grinding wheel contact positions, 12a and 12b.
FIGS. 7 and 8 schematically illustrate alternate digital schemes to implement the control schemes of FIGS. 3 and 4 respectively. In FIG. 7, an analogue signal representing the grinding path length C is generated and converted to a digital signal in block 90. The output of block 90, which should also be an absolute encoder, is applied to an arithmetic unit 92. A second input to the arithmetic unit 92 is applied from a digital thumbwheel switch 94. The arithmetic unit 92 provides a digital output signal proportional to the quotient of the inputs from unit 90 and thumbwheel switch 94 which is then applied to a feed mechanism either directly as a digital signal or indirectly as an analogue signal through a digital to analogue converter 96. A second thumbwheel switch 98 applies an input to arithmetic unit 92 representative of the desired wheelhead advance portion of the grinding cycle, C. This signal is mathmetically added to the measured value C from unit 90 and applied to the slide table position apparatus, either directly in digital form or indirectly through a digital to analogue converter 100.
An arithmetic unit 102 in FIG. 8 receives inputs from an encoder 104 which provides a signal representative of the changes ΔR, in the radial dimension of the grinding wheel, and from a plurality of thumbwheel switches 106, 108, 110, and 112. The thumbwheel switches 106, 108, 110, and 112 provides signals representative of the workpiece diameter, desired grinding time, stock removal rate and wheelhead advance distance respectively. The arithmetic unit 102 mathematically combines these inputs according to the equation:
V=√S/2(D'-d)/t
to provide outputs representative of the desired velocity and wheelhead advance. The velocity output may be applied to the infeed apparatus directly in digital form or indirectly through a digital-to-analogue converter 114. Similarly, the wheelhead retraction signal may be applied to the table position directly in digital form or indirectly through a digital-to-analogue converter 116.
It is also desirable to control the rate of relative advancement between the grinding wheel 14 and dresser assembly 37 to accomodate wheel wear. Since, in the preferred embodiment, the dresser assembly 37 is mounted upon the slide 34, the circuitry of FIGS. 5 and 6 may also be used to regulate the rate of relative grinding wheel-dresser assembly movement during the dressing operation when two elements are interfaced.
Although the present invention has been described in conjunction with the preferred embodiments, it is to be understood that modification and variations may be resorted to without departing from the spirit of the invention as those skilled in the art will readily understand. Such modifications and variations are considered to be within the view and scope of the present invention as defined by the appended claims. | A tangential grinding machine has a variable grinding feed rate which is dependent upon the length of the cutting or grinding path which occurs between the grinding wheel and a workpiece. The variable feed rate accomodates fluctuations in grinding wheel and workpiece dimensions to control the grinding time and optimize stock removal rates. | 1 |
TECHNICAL FIELD OF THE INVENTION
The technical field of this invention is that of automatic clutch controls, and more particularly closed loop automatic clutch controls for reducing oscillatory response to launch and creep of a motor vehicle.
BACKGROUND OF THE INVENTION
In recent years there has been a growing interest in increased automation in the control of the drive train of motor vehicles, and most especially in control of the drive train of large trucks. The use of automatic transmissions in passenger automobiles and light trucks is well known. The typical automatic transmission in such a vehicle employs a fluid torque converter and hydraulically actuated gears for selecting the final drive ratio between the engine shaft and the drive wheels. This gear selection is based upon engine speed, vehicle speed and the like. It is well known that such automatic transmissions reduce the effectiveness of the transmission of power from the engine to the drive shaft, with the consummate reduction in fuel economy and power as compared with the skilled operation of a manual transmission. Such hydraulic automatic transmissions have not achieved wide spread use in large motor trucks because of the reduction in efficiency of the operation of the vehicle.
One of the reasons for the loss of efficiency when employing a hydraulic automatic transmission is loss occurring in the fluid torque converter. A typical fluid torque converter exhibits slippage and consequent loss of torque and power in all modes. It is known in the art to provide lockup torque converters that provide a direct link between the input shaft and the output shaft of the transmission above certain engine speeds. This technique provides adequate torque transfer efficiency when engaged, however, this technique provides no gain in efficiency at lower speeds.
It has been proposed to eliminate the inefficiencies inherent in a hydraulic torque converter by substitution of an automatically actuated friction clutch. This substitution introduces another problem not exhibited in the use of the hydraulic torque converters. The mechanical drive train of a motor vehicle typically exhibits considerable torsional compliance in the driveline between the transmission and the traction wheels of the vehicle. This torsional compliance may be found in the drive shaft between the transmission and the differential or the axle shaft between the differential and the driven wheels. It is often the case that independent design criteria encourages or requires this driveline to exhibit considerable torsional compliance. The existence of substantial torsional compliance in the driveline of the motor vehicle causes oscillatory response to clutch engagement. These oscillatory responses can cause considerable additional wear to the drive train components and other parts of the vehicle. In addition, these oscillatory responses can cause objectionable passenger compartment vibrations.
The oscillatory response of the driveline to clutch engagement is dependent in large degree to the manner in which the input speed of the transmission, i.e. the speed of the clutch, approaches the engine speed. A smooth approach of these speeds, such as via a decaying exponential function, imparts no torque transients on clutch lockup. If these speeds approach abruptly, then a torque transient is transmitted to the driveline resulting in an oscillatory response in the vehicle driveline.
Thus it would be an advantage to provide automatic clutch actuation of a friction clutch that reduces the oscillatory response to clutch engagement. The problem of providing such automatic clutch actuation is considerably increased in large trucks. In particular, large trucks exhibit a wide range of variability in response between trucks and within the same truck. The total weight of a particular large truck may vary over an 8 to 1 range from unloaded to fully loaded. The driveline compliance may vary over a range of about 2 to 1 among different trucks. Further, the clutch friction characteristic may vary within a single clutch as a function of degree of clutch engagement and between clutches. It would be particularly advantageous to provide such an automatic clutch actuation system that does not require extensive adjustment to a particular motor vehicle or the operating condition of the motor vehicle.
SUMMARY OF THE INVENTION
This invention is an automatic clutch controller used in a combination including a source of motive power, a friction clutch, and at least one inertially-loaded traction wheel connected to the friction clutch that has a torsional compliance exhibiting an oscillatory response to torque inputs. The automatic clutch controller is preferably used with a transmission shift controller. This automatic clutch controller provides smooth clutch engagement during vehicle launch, following transmission shifts and during creep to minimize the oscillatory response to clutch engagement. This automatic clutch controller is useful in large trucks.
The automatic clutch controller receives inputs from an engine speed sensor and a transmission input speed sensor. The transmission input speed sensor senses the rotational speed at the input to the transmission, which is the output of the friction clutch. The automatic clutch controller develops a clutch engagement signal controlling a clutch actuator between fully disengaged and fully engaged. The clutch engagement signal engages the friction clutch in a manner causing asymptotic approach of the transmission input speed to a reference speed. This minimizes the oscillatory response to torque inputs of the inertially-loaded traction wheel.
In the preferred embodiment the automatic clutch controller operates in two modes. In a launch mode, corresponding to normal start of the vehicle, the clutch engagement signal causes the transmission input speed to asymptotically approach the engine speed. This same mode may optionally also be used for clutch re-engagement upon transmission gear shifts. In a creep mode, corresponding to slow speed creeping of the vehicle, the clutch engagement signal causes the transmission input speed to asymptotically approach a creep reference signal. This creep reference signal is generated based on the amount of throttle and the engine speed. The two modes are selected based upon the throttle setting. The launch mode is selected for a throttle of more than 25% full throttle, otherwise the creep mode is selected.
The automatic clutch controller is preferably implemented in discrete difference equations executed by a digital microcontroller. The microcontroller implements a compensator having a transfer function approximately the inverse of the transfer function of the inertially-loaded traction wheel. This compensator transfer function includes a notch filter covering the region of expected oscillatory response of the driveline. The frequency band of this notch filter must be sufficiently broad to cover a range of frequencies because the oscillatory response frequency may change with changes in vehicle loading and driveline characteristics.
The clutch actuation controller preferably stores sets of coefficients for the discrete difference equations corresponding to each gear ratio of the transmission. The clutch actuation controller recalls the set of coefficients corresponding to the selected gear ratio. These recalled set of coefficients are employed in otherwise identical discrete difference equations for clutch control.
The automatic clutch controller preferably includes an integral function within the compensator for insuring full clutch engagement within a predetermined interval of time after initial partial engagement when in the launch mode. Any long term difference between the transmission input speed reference signal and the transmission input speed generates an increasing signal that eventually drives the clutch to full engagement.
The automatic clutch controller may further include a differentiator connected to the engine speed sensor. The engine speed differential signal corresponding to the rate of change of the engine speed signal is added to the signal supplied to the compensator. This differential signal causes rapid advance of clutch actuation when the engine speed is accelerating. Rapid advance of the clutch under these conditions prevents the engine speed from running away. An integrator connected to the differentiator saves the clutch actuation level needed to restrain the engine speed once the engine speed is no longer accelerating.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and aspects of the present invention will be described below in conjunction with the drawings in which:
FIG. 1 illustrates a schematic view of the vehicle drive train including the clutch actuation controller of the present invention;
FIG. 2 illustrates the typical relationship between clutch engagement and clutch torque;
FIG. 3 illustrates the ideal response of engine speed and transmission input speed over time for launch of the motor vehicle;
FIG. 4 illustrates the ideal response of engine speed and transmission input speed over time for creeping of the motor vehicle; and
FIG. 5 illustrates a preferred embodiment of the clutch actuation controller of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates in schematic form the drive train of a motor vehicle including the automatic clutch controller of the present invention. The motor vehicle includes engine 10 as a source of motive power. For a large truck of the type to which the present invention is most applicable, engine 10 would be a diesel internal combustion engine. Throttle 11, which is usually a foot operated pedal, controls operation of engine 10 via throttle filter 12. Throttle filter 12 filters the throttle signal supplied to engine 10 by supplying a ramped throttle signal upon receipt of a step throttle increase via throttle 11. Engine 10 produces torque on engine shaft 15. Engine speed sensor 13 detects the rotational velocity of engine shaft 15. The actual site of rotational velocity detection by engine speed sensor may be at the engine flywheel. Engine speed sensor 13 is preferably a multitooth wheel whose tooth rotation is detected by a magnetic sensor.
Friction clutch 20 includes fixed plate 21 and movable plate 23 that are capable of full or partial engagement. Fixed plate 21 may be embodied by the engine flywheel. Friction clutch 20 couples torque from engine shaft 15 to input shaft 25 corresponding to the degree of engagement between fixed plate 21 and movable plate 23. Note that while FIG. 1 illustrates only a single pair of fixed and movable plates, those skilled in the art would realize that clutch 20 could include multiple pairs of such plates.
A typical torque verses clutch position function is illustrated in FIG. 2. Clutch torque/position curve 80 is initially zero for a range of engagements before initial touch point 81. Clutch torque rises monotonically with increasing clutch engagement. In the example illustrated in FIG. 2, clutch torque rises slowly at first and then more steeply until the maximum clutch torque is reached upon full engagement at point 82. The typical clutch design calls for the maximum clutch torque upon full engagement to be about 1.5 times the maximum engine torque. This ensures that clutch 20 can transfer the maximum torque produced by engine 10 without slipping.
Clutch actuator 27 is coupled to movable plate 23 for control of clutch 20 from disengagement through partial engagement to full engagement. Clutch actuator 27 may be an electrical, hydraulic or pneumatic actuator and may be position or pressure controlled. Clutch actuator 27 controls the degree of clutch engagement according to a clutch engagement signal from clutch actuation controller 60.
Transmission input speed sensor 31 senses the rotational velocity of input shaft 25, which is the input to transmission 30. Transmission 30 provides selectable drive ratios to drive shaft 35 under the control of transmission shift controller 33. Drive shaft 35 is coupled to differential 40. Transmission output speed sensor 37 senses the rotational velocity of drive shaft 35. Transmission input speed sensor 31 and transmission output speed sensor 37 are preferably constructed in the same manner as engine speed sensor 13. In the preferred embodiment of the present invention, in which the motor vehicle is a large truck, differential 40 drives four axle shafts 41 to 44 that are in turn coupled to respective wheels 51 to 54.
Transmission shift controller 33 receives input signals from throttle 11, engine speed sensor 13, transmission input speed sensor 31 and transmission output speed sensor 37. Transmission shift controller 33 generates gear select signals for control of transmission 30 and clutch engage/disengage signals coupled to clutch actuation controller 60. Transmission shift controller 33 preferably changes the final gear ratio provided by transmission 30 corresponding to the throttle setting, engine speed, transmission input speed and transmission output speed. Transmission shift controller 33 provides respective engage and disengage signals to clutch actuation controller 60 depending on whether friction clutch 20 should be engaged or disengaged. Transmission shift controller also transmits a gear signal to clutch actuation controller 60. This gear signal permits recall of the set of coefficients corresponding to the selected gear. Note transmission shift controller 33 forms no part of the present invention and will not be further described.
Clutch actuation controller 60 provides a clutch engagement signal to clutch actuator 27 for controlling the position of movable plate 23. This controls the amount of torque transferred by clutch 20 according to clutch torque/position curve 80 of FIG. 2. Clutch actuation controller 60 operates under the control of transmission shift controller 33. Clutch actuation controller 60 controls the movement of moving plate 23 from disengagement to at least partial engagement or full engagement upon receipt of the engage signal from transmission shift controller 33. In the preferred embodiment it is contemplated that the clutch engagement signal will indicate a desired clutch position. Clutch actuator 27 preferably includes a closed loop control system controlling movable plate 23 to this desired position. It is also feasible for the clutch engagement signal to represent a desired clutch pressure with clutch actuator 27 providing closed loop control to this desired pressure. Depending on the particular vehicle, it may be feasible for clutch actuator 27 to operate in an open loop fashion. The exact details of clutch actuator 27 are not crucial to this invention and will not be further discussed.
Clutch actuation controller 60 preferably generates a predetermined open loop clutch disengagement signal for a ramped out disengagement of clutch 20 upon receipt of the disengage signal from transmission shift controller 33. No adverse oscillatory responses are anticipated for this predetermined open loop disengagement of clutch 20.
FIGS. 3 and 4 illustrate the two cases of starting the vehicle from a full stop. FIGS. 3 and 4 illustrate the engine speed and the transmission input speed during ideal clutch engagement. FIG. 3 illustrates the case of launch. FIG. 4 illustrates the case of creep.
FIG. 3 illustrates the case of launch, that is starting out from a stop in order to proceed at a reasonable speed. Initially, the engine speed 90 is at idle. Thereafter engine speed 90 monotonically increases within the time frame of FIG. 3. Engine speed 90 either increases or remains the same. Ideally engine speed 90 increases until the torque produced by engine 10 matches the torque required to accelerate the vehicle. At high load this engine speed may be in the mid range between the idle speed and the maximum engine speed. This constant engine speed corresponds to the engine torque required to match clutch torque and driveline torque and achieve a balance between engine output torque and the vehicle load torque. This torque level is the ideal clutch torque because a higher clutch torque would stall engine 10 and a lower clutch torque would allow the engine speed to increase too much. Ultimately the vehicle would accelerate to a speed where clutch 20 can be fully engaged. Thereafter the balance between engine torque and load torque is under the control of the driver via the throttle setting and clutch actuation controller 60 would continue to command full clutch engagement.
When the vehicle is stopped and clutch 20 fully disengaged, transmission input speed 100 is initially zero. This is the case for starting the vehicle. However, as further explained below, this same technique can be used for smooth clutch engagement upon shifting gears while moving. Thus the transmission input speed may initially be a value corresponding to the vehicle speed. Upon partial engagement of clutch 20, transmission input speed 100 increases and approaches engine speed 90 asymptotically. At a point 101, transmission input speed 100 is sufficiently close to engine speed 90 to achieve full engagement of clutch 20 without exciting the torsional compliance of the driveline of the vehicle. At this point clutch 20 is fully engaged. Thereafter transmission input speed 100 tracks engine speed 90 until clutch 20 is disengaged when the next higher final gear ratio is selected by transmission controller 33. The system preferably also operates for the case in which the vehicle is not stopped and the initial transmission input speed is nonzero.
FIG. 4 illustrates the engine speed and transmission input speed for the case of creep. In the creep mode, clutch 20 must be deliberately slipped in order to match the available engine torque at an engine speed above idle and the required torque. FIG. 4 illustrates engine speed 95 rising from idle to a plateau level. In a similar fashion input speed 105 rises from zero to a predetermined level. This predetermined level is less than the engine idle speed in this example. The creep mode is required when the desired vehicle speed implies a transmission input speed less than idle for the lowest gear ratio. The creep mode may also be required when the desired vehicle speed implies a transmission input speed above engine idle and engine 10 cannot produce the required torque at this engine speed. Note that there is a speed difference 107 between the engine speed 95 and the input speed 105 under quiescent conditions. This difference 107 represents the slip speed required for this creep operation.
FIG. 5 illustrates schematically the control function of clutch actuation controller 60. As also illustrated in FIG. 1, clutch actuation controller 60 receives the throttle signal from throttle 11, the engine speed signal from engine speed sensor 13 and the transmission input speed signal from transmission input speed sensor 31. Clutch actuation controller 60 illustrated in FIG. 5 generates a clutch engagement signal that is supplied to clutch actuator 27 for operation of the friction clutch 20. Although not shown in FIG. 5, the degree of clutch actuation, together with the throttle setting, the engine speed and the vehicle characteristics determine the transmission input speed that is sensed by transmission input speed sensor 31 and supplied to clutch actuation controller 60. Therefore, the control schematic illustrated in FIG. 5 is a closed loop system.
The control function illustrated in FIG. 5 is needed only for clutch positions between touch point 81 and full engagement. Clutch engagement less than that corresponding to touch point 81 provide no possibility of torque transfer because clutch 20 is fully disengaged. Clutch actuation controller 60 preferably includes some manner of detection of the clutch position corresponding to touch point 81. Techniques for this determination are known in the art. As an example only, the clutch position at touch point 81 can be determined by placing transmission 30 in neutral and advancing clutch 20 toward engagement until transmission input speed sensor 31 first detects rotation. Upon receipt of the engage signal from transmission shift controller 33, clutch actuation controller 60 preferably rapidly advances clutch 20 to a point corresponding to touch point 81. This sets the zero of the clutch engagement control at touch point 81. Thereafter the clutch engagement is controlled by the control function illustrated in FIG. 5.
Clutch actuation controller 60 is preferably realized via a microcontroller circuit. Inputs corresponding to the engine speed, the transmission input speed and the throttle setting must be in digital form. These input signals are preferably sampled at a rate consistent with the rate of operation of the microcontroller and fast enough to provide the desired control. As previously described, the engine speed, transmission input speed and transmission output speed are preferably detected via multitooth wheels whose teeth rotation is detected by magnetic sensors. The pulse trains detected by the magnetic sensors are counted during predetermined intervals. The respective counts are directly proportional to the measured speed. For proper control the sign of the transmission input speed signal must be negative if the vehicle is moving backwards. Some manner of detecting the direction of rotation of input shaft 25 is needed. Such direction sensing is conventional and will not be further described. The throttle setting is preferably detected via an analog sensor such as a potentiometer. This analog throttle signal is digitized via an analog to-digital converter for use by the microcontroller. The microcontroller executes the processes illustrated in FIGS. 5 by discrete difference equations in a manner known in the art. The control processes illustrated in FIG. 5 should therefore be regarded as an indication of how to program the microcontroller embodying the invention rather than discrete hardware. It is feasible for the same microcontroller, if of sufficient capacity and properly programmed, to act as both clutch actuation controller 60 and as transmission shift controller 33. It is believed that an Intel 80C196 microcontroller has sufficient computation capacity to serve in this manner.
The throttle signal received from throttle 11 is supplied to launch/creep selector 61 and to creep speed reference 62. Launch/creep selector 61 determines from the throttle signal whether to operate in the launch mode or to operate in the creep mode. In the preferred embodiment of the present invention, launch/creep selector 61 selects the launch mode if the throttle signal indicates greater than 25% of the full throttle setting. In other cases launch/creep selector 61 selects the creep mode.
Creep speed reference 62 receives the throttle signal and the engine speed signal and generates a creep speed reference signal. This creep speed reference signal is determined as follows: ##EQU1## where: R crp is the creep speed reference signal; E sp is the measured engine speed; T is the throttle signal; and T ref is a throttle reference constant equal to the throttle signal for 25% full throttle. The creep speed reference signal is the product of the engine speed signal and the ratio of the actual throttle to 25% full throttle. No creep speed reference signal is required for throttle settings above 25% of full throttle because the launch mode is applicable rather than the creep mode. Note that this creep speed reference signal makes the speed reference signal continuous even when switching between the launch mode and the creep mode. Thus no instabilities are induced if changes in the throttle setting causes switching between the two modes.
Mode select switch 63 determines the mode of operation of clutch actuation controller 60. Mode select switch 63 receives the mode selection determination made by launch/creep selector 61. Mode select switch 63 selects either the engine speed signal or the creep speed reference signal depending upon the mode determined by launch/creep selector 61. In the event that the launch mode is selected mode select switch 63 selects the engine speed for control. Thus in the launch mode the clutch engagement is controlled so that the transmission input speed matches the engine speed. In the event that the creep mode is selected mode select switch 63 selects the creep speed reference signal for control. In creep mode the clutch engagement is controlled to match transmission input speed to the creep speed reference signal. This is equivalent to controlling clutch engagement to match the actual clutch slip to desired slip speed. In either mode, the speed reference signal is a transmission input speed reference.
Algebraic summer 64 supplies the input to compensator 65. This input is the difference between the speed reference signal selected by mode select switch 61 and the input speed signal from transmission input speed sensor 31, with the addition of some other terms to be discussed below. Compensator 65 includes a transfer function that is an approximate inverse model of the torsional oscillatory response of the vehicle driveline to torque inputs.
The transfer function of compensator 65 is selected to control clutch engagement via clutch actuator 27 to damp oscillations in the driveline. In the typical heavy truck to which this invention is applicable, the torsional compliance of the driveline causes the driveline transfer function to have a pair of lightly damped poles that may range from 2 to 5 Hz. The exact value depends upon the vehicle characteristics. The transfer function of compensator 65 provides a notch filter in the region of these poles. The frequency band of the notch is sufficiently broad to cover the range of expected vehicle frequency responses. This notch filter preferably includes two complex zeros whose frequency is in the frequency range of the expected poles in the vehicle transfer function. Thus the total response of the closed loop system has highly damped eigen values providing a less oscillatory system.
Compensator 65 also includes an integral function. A pole/zero pair near zero preferably provides this integral function. This type transfer function is known as lag compensation. Provision of this integral function within compensator 65 serves to ensure clutch lockup when operating in the launch mode. The integration rate of compensator 65 can be adjusted by corresponding integration coefficients. The existence of any long term difference between the speed reference signal selected by mode select switch 63 and the transmission input speed cause the integral function of compensator 65 to generate an increasing signal. Any such increasing signal serves to drive the clutch engagement signal toward full clutch engagement. This ensures that clutch 20 is fully engaged at point 101 at some predetermined maximum time following start up of the vehicle when in the launch mode. In the creep mode, this integral function of compensator 65 ensures that there is no long term error between the creep speed reference signal and the transmission input speed.
The transfer function of the compensator 65 preferably follows the form: ##EQU2## where: k is the compensator gain constant; a, b, c, d and e are constants. The term ##EQU3## implements the lag function. The constant a is positive and near zero. The term ##EQU4## implements the notch filter. The roots of (s 2 +bs+c 2 ) provide the complex zeros of the desired notch filter. The constants d and e are positive numbers that are sufficiently large to not interfere with the closed loop stability. Equation (2) is in the form of a continuous time transfer function. In the preferred embodiment a microcontroller implements compensator 65 in discrete difference equations. Those skilled in the are would understand how to convert this continuous time transfer function into appropriate discrete difference equations.
A feedforward signal is provided in the clutch engagement signal via an engine speed differential signal. The engine speed signal is suitably filtered via low pass filter 66 to reduce noise in the differential signal. Differentiator 67 forms a differential signal proportional to the rate of change in the engine speed. This engine speed differential signal and its integral formed by integrator 68 are supplied to algebraic summer 64. Algebraic summer 64 sums the engine speed differential signal from differentiator 67 and the integral signal from integrator 68 with the other signals previously described to form the input to compensator 64.
The feedforward signal permits better response of clutch actuation controller 60 when the engine speed is accelerating. Under conditions of engine speed acceleration the feedforward signal causes rapid engagement of clutch 20 proportional to the rate of engine acceleration. The engine speed can increase rapidly under full throttle conditions before the driveline torque is established. This is because the speed of response of clutch actuation controller 60 without this feedforward response is low compared with the peak engine speed of response. With this feedforward response rapid engine acceleration results in more rapid than otherwise clutch engagement. The additional clutch engagement tends to restrain increase in engine speed by requiring additional torque from the engine. When the engine speed reaches a constant value, the differential term decays to zero and integrator 68 retains the clutch engagement needed to restrain engine speed. Other portions of the control function then serve to provide asymptotic convergence of the transmission input speed to the reference speed.
As noted above, the elements of FIG. 5 are preferably implemented via discrete difference equations in a microcontroller. The present invention can be advantageously employed for clutch re-engagement following shifts of the transmission. In this event the same control processes illustrated in FIG. 5 would be employed, including the discrete difference equations for compensator 65. The control processes for transmission shifts would differ from the preceding description in selection of coefficients in the discrete difference equations embodying clutch actuation controller 60. Coefficients for the discrete difference equations for each selected gear ratio are stored in coefficient memory 69 within the microcontroller embodying clutch actuation controller 60. A particular set of these coefficients would be recalled from coefficient memory 69 depending upon the currently engaged gear ratio. These coefficients are employed in the discrete difference equations forming compensator 65. In other respects the invention would operate the same as described above.
The result of this construction is control of clutch actuation to minimize oscillations in the vehicle driveline. The higher frequency components of clutch actuation controller 60 controls clutch 20 via clutch actuator 27 to damp oscillations in the vehicle driveline. The integral component of clutch actuation controller 60 minimizes long term error and ensures full clutch engagement when operating in the launch mode. | An automatic clutch controller for a vehicle that reduces the oscillatory response to clutch engagement. The automatic clutch controller receives inputs from an engine speed sensor and a transmission input speed sensor and develops a clutch engagement signal controlling a clutch actuator between from disengaged to fully engaged. The clutch engagement signal at least partially engages the friction clutch in a manner to cause the measured transmission input speed to asymptotically approach a reference speed employing an approximate inverse model of this oscillatory response. In a launch mode, corresponding to normal start of the vehicle, the reference speed is the measured engine speed. In a creep mode, corresponding to slow speed creeping of the vehicle, the reference speed is a creep speed reference based on the throttle setting and the engine speed. The two modes are selected based upon the throttle setting. The automatic clutch controller preferably includes an integral error function and a differential engine speed function, which together adaptively adjust clutch engagement corresponding to vehicle loading. | 5 |
This application is a continuation of Ser. No. 09/311,002 filed on May 13, 1999, now U.S. Pat. No. 6,119,119 which is a continuation of Ser. No. 08/760,978 filed on Dec. 5, 1996 now U.S. Pat. No. 5,953,721.
BACKGROUND OF THE INVENTION
The present invention relates to a method for providing data from a data providing side to a data receiving side via a data transmission means, and device thereof.
Data provided from data providers to data receivers via data transmission means such as, for example, communications satellites, telephone lines and optical fiber cables etc. can be roughly divided into two groups. On the one hand, there is data where it is advantageous both for the data provider and the data receiver for the data to have a long or limitless period of validity so that the data can be used for a long period of time. On the other hand, there is data where it is advantageous for both the data provider and the data receiver of the data for the data to have a short valid period so that the data is only used for a short period of time.
Data having a long or limitless period of validity is data such as product summaries occurring in the communications business, while data having a short period of validity is data such as data listing product prices. Data having a valid period is no longer valid once the valid period is over and after the valid period is over data having an updated valid period therefore has to be sent from the data provider to the data receiver via a data transmission means.
However, when data configured so that short period valid data is included as a part of data having a long or indefinite period of validity is provided using related data-providing methods, all of the data for the short period valid data including the long period valid data had to be updated every time the period for the short valid period data expired. This is troublesome with regards to the providing of the data and transmission efficiency is lowered.
As the present invention sets out to resolve the above problems, it is therefore the object of the present invention to provide a data providing method and device thereof capable of providing data easily at a high transmission efficiency.
SUMMARY OF THE INVENTION
A data providing method for providing data according to the present invention therefore comprises the steps of producing and providing first data (e.g. data DTb) having a region including information relating to a valid period of data, receiving the first data, categorizing the first data in accordance with the information relating to the valid period and then storing the first data after being categorized, providing second data (e.g. data DThb) of the same format as the first data, receiving the second data, recognizing the second data with respect to information relating to the valid period and replacing the first data with the second data in accordance with results of the recognition.
The information relating to the valid period of data can include data of the valid period and data showing presence of the data of the valid period.
Further, a data providing method for providing data is therefore provides so as to comprise the steps of combining data (e.g. data DTa) not including data showing a valid period of data and first data (e.g. data DTb) including data showing a valid period of data and then providing the data as being combined, receiving the data as being combined, categorizing the data not including data showing the valid period of data and the first data in accordance with information relating to the valid period of data and then storing the data after being categorized, providing second data (e.g. data DTbb) of the same format as the first data, recognizing the second data with respect to information relating to data showing a valid period of the second data and replacing the first data with the second data in accordance with results of the recognition.
The first data can be replaced with the second data when the second data is determined to be updated data for the first data from the recognition results.
Further, according to the present invention, a data providing device comprises a data provider and a data receiver. The data provider comprises a data producing section for producing first data (e.g. data DTb) having a region including information relating to a valid period of data. The data receiver comprises a storage section for categorizing the first data in accordance with the information relating to the valid period, storing the first data being categorized second data (e.g. data DThb) of the same format as the first data provided by the data provider with respect to information relating to a valid period of the second data and replacing the first data with the second data in accordance with results of the recognition. Here, the data provider provides data therefrom to the data receive via the data transfer means.
The data producing section can provide data of the valid period and data showing presence of the data of the valid period as information relating to the valid period of the data.
Moreover, the storage section can comprise a categorizing section, a storage section, a recognizing section and a replacing section. The categorizing section is for categorizing the first data in accordance with the information relating to the valid period. The storage section is for storing the first data being categorized. The recognizing section is for recognizing the second data of the same format as the first data provided from the data provider with respect to information relating to a valid period of the second data and the replacing section is for replacing the first data with the second data in accordance with results from the recognizing section and storing the second data in the storing section.
The replacing section can replace the first data with the second data when the recognizing section recognizes the second data as being updated data for the first data.
Further, according to the present invention, a data receiving device for receiving data having an area for information relating to a valid period from a data providing device via a data transfer means, comprises a data categorizing means, a data storing means, a data recognition means and a data replacing means. The data categorizing means is for categorizing first data in accordance with information relating to the valid period. The data storing means is for storing the first data being categorized. The data recognition means is for recognizing second data of the same format as the first data with respect to information of a valid period of the second data and the data replacing means is for replacing the first data stored in the data storing means with the second data in accordance with results from the data recognition means.
Further, according to the present invention, a data receiving device for receiving data having an area for information relating to a valid period from a data providing device via a data transfer means, comprises a data categorizing section, a data storage section and a data recognizing section. The data categorizing section is for categorizing data in accordance with information relating to the valid period. The data storage section is for storing the categorized data. The data recognizing section is for recognizing the categorized data with respect to information relating to the valid period. Here, the data categorizing section categorizes data when the data is provided from the data providing device as a combination of data A (e.g. data DTa) and data B (e.g. data DTb). The data A includes data for which the information relating to the valid period is given as showing that the valid period is limitless. The data B includes data for which the information is given as showing that the valid period is short. The categorizing section then transmits the data A to the data storage section and the data B to the data recognizing section on the basis of the information. The data recognizing section recognizes whether or not data to be updated by being replaced with the data B is already stored in the storage section, and the data storage section stores the data B so that the data B is made to correspond to the data A when the data recognizing section recognizes that no data is stored at the storage section.
Moreover, the data receiving device can further comprise a data replacing section for replacing data stored in the storage section and when data is provided from the data providing device as data C (e.g. data DTbb) that includes data for which the information relating to the valid period is given as showing that the valid period is short, the data categorizing section categorizes the data C to be transmitted to the recognizing section on the basis of the information, the recognizing section recognizes whether or not the data C is update data for the data B already stored in the data storage section and the data replacing section replaces the data B with the data C so that the data C is stored in the data storage section when the data C is recognized as being update data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an embodiment of a data providing device of the present invention;
FIG. 2 is a view showing an example of a data format used by the data providing device shown in FIG. 1;
FIG. 3 is a block diagram showing a detailed example of the essential parts of the data providing device shown in FIG. 1;
FIG. 4 is the first part of a flowchart illustrating an example of the operation of the data providing device shown in FIG. 1;
FIG. 5 is the second part of the flowchart illustrating the example of the operation of the data providing device shown in FIG. 1;
FIG. 6 is a view showing an example of data having limitless valid period with the data format shown in FIG. 2;
FIG. 7 is a view showing an example of a first data having short valid period with the format shown in FIG. 2; and
FIG. 8 is a view showing an example of a second data having short valid period with the format shown in FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
The following is a detailed description, with reference to the drawings, of an embodiment of the present invention.
In the embodiment described in the following, the details of a preferred example of this invention is described, with various preferred technological limitations being enforced as a result. However, the scope of the present invention is by no means limited by the following and is particularly by no means limited with respect to the limitations placed in the following.
FIG. 1 is a block diagram showing an embodiment of a data providing device of the present invention.
This data providing device 1 is configured in such a manner that a data providing means 10 on a data providing side and a data receiving means 20 on a data receiving side are connected via a data path 30 constituting a data transmission means.
The data providing means 10 provides data DT made at a data producer 11 from a data provider 12 via the data path 30 .
The data receiving means 20 stores the data DT received at a data receiver 21 at a data storage section 22 via the data path 30 . The data DT stored at the data storage section 22 is then played back at a data playback section 23 in accordance with a data playback instruction SP from a data playback instruction section 24 that came via a user interface 25 .
The services provided by the data providing device 1 are not specified here but can be, for example, data services using communications satellites, data services using the Internet or data services using physical media such as compact disc read-only memories (CD-ROMs). Data transmission means such as, for example, communications satellites, telephone lines, optical fiber cables or the postage system can therefore be used as the data path 30 . The data providing means 10 can include broadcasting stations, data service providers, publishers and post offices. A tuner or decoder can then be provided at the data receiving means 20 when, for example, a broadcast satellite, telephone line, or optical fiber cable etc. is used as the data path 30 .
The format of the data DT provided by the data providing device 1 is as shown, for example, in FIG. 2 . Here, D is the data provided to the user and is referred to as the core data, A differs depending on the service provided but is basically a header containing the type and number etc. of the core data D, B is a bit showing whether or not the core data D possessed by the header A has a valid period and C is a bit showing the valid period when a validity bit is shown to exist at the bit B and is set with the year, month, day, hour, minutes and seconds etc. for the usefulness.
FIG. 3 is a block diagram showing the details of the data storage section 22 .
The data storage section 22 categorizes data DT inputted to a data categorizer 222 from the data receiver 21 via a data input section 221 into data DTa having a long or limitless valid period and data DT 6 having a short valid period using the header A and bit B. The categorized data DTa is stored at a data storage section 223 and the categorized data DTb is outputted to an information recognizer 224 . The data DTb inputted to the information recognizer 224 is recognized with respect to necessity of data replacement using the bit C. The data DTb 1 recognized as having no necessity of being replaced is stored in the data storage section 223 and the data DTb 2 recognized as having necessity of being replaced is outputted to a data replacer 225 to be replaced with replacement data DTb 1 stored in the data storage section 223 . Data DT stored in the data storage section 223 and instructed to be read out is read out in accordance with the data read instruction SR inputted at a data reader 226 from the data playback section 23 and is outputted to the data playback section 23 via a data output section 227 .
An example of the operation of this kind of configuration will now be described with reference to FIG. 4 and FIG. 5 . FIG. 4 is a flowchart of an example operation viewed from the side of the data provider and FIG. 5 is a flowchart of an example operation viewed from the side of the data receiver.
First, at the data producer 11 in the data providing means 10 , a data group DT configured from a combination of, for example, data DTa of a limitless valid period (for example, FIG. 6) and data DTb of a short valid period (for example, FIG. 7) is produced (step STP 1 ) and outputted to the data provider 12 .
At the data provider 12 , the data group DT inputted from the data producer 11 is provided to the data receiver 21 in the data receiving means 20 via the data path 30 (step STP 2 ).
At the data receiver 21 , the data group DT provided via the data path 30 is received (step STP 3 ) and outputted to the data categorizer 222 via the data input section 221 comprising the data storage section 22 in FIG. 3 .
At the data categorizer 222 , the data DTa with the limitless valid period and the data DTb with the short valid period, which constitute the data group DT inputted from the data input section 221 , are categorized by identifying the respective core data Da and Db for the data DTa and DTb with respect to the type and number etc. by using the headers Aa and Ab thereof (step STP 4 ). The core data Da and Db are further identified with respect to whether or not they have a valid period by using the bits Ba and Bb, in accordance with which the data DTa and DTb are further categorized (step STP 5 ).
Since the core data Da for the data DTa in this example is given as having no valid period, the data DTa is then stored in the data storage section 223 (step STP 8 ). On the other hand, the core data Db for the data DTb is given as having a valid period, then the data DTb is outputted to the information recognizer 224 .
At the information recognizer 224 , the presence of corresponding data is recognized for the data stored within the data storage section 223 by using the header Ab and the bit Cb of the data DTb inputted from the data categorizer 222 (step STP 6 ). Here, corresponding data is referred to as being previously supplied data stored in the data storage section 223 for which the valid period has expired, with the type and number etc. of the core data being the same as data DTb supplied this time. in this example no corresponding data is previously stored and the as-inputted data DTb is therefore stored at the data storage section 223 (step STP 8 ).
Next, the presence of other supplied data is recognized (step STP 9 ). When, for example, the valid period of the data DTb has expired so that this core data Db has become invalid, updated data DTbb (for example, shown in FIG. 8) for the short valid period data DTb is produced except the data DTa of a limitless valid period at the data producer 11 in the data providing means 10 in FIG. 1 (step STP 1 ) and outputted to the data provider 12 .
At the data provider 12 , data DTbb inputted from the data producer 11 is provided to the data receiver 21 via the data path 30 (step STP 2 ).
At the data receiver 21 , the data DTbb supplied via the data path 30 is received (step STP 3 ) and then the data DTbb is outputted to the data categorizer 222 via the data input section 221 comprising the data storage section 22 .
At the data categorizer 222 , the type and number etc. of the core data Dbb for the data DTbb is identified using a header Abb of the data DTbb inputted from the data input section 221 and the data DTbb is categorized (step STP 4 ). The core data Dbb is further identified with respect to whether or not the core data Dbb has a valid period by using the bit Bbb, in accordance with which the data DTbb is further categorized (step STP 5 ).
In this example, the core data Dbb of the data DTbb has a valid period, so that the data DTbb is then outputted to the information recognizer 224 . At the information recognizer 224 , the presence of corresponding data is recognized about the data stored within the data storage section 223 using the header Abb and the bit Bbb of the data DTbb inputted from the data categorizer 222 (step STP 6 ). In this example, corresponding data DTb is stored within the data storage section 223 and the data DTbb is outputted to the data replacer 225 . Then, at the data replacer 225 , the data DTb stored at the data storage section 223 is replaced with the data DTbb (step STP 7 ).
As described above, it is sufficient to just provide updated short valid period data as data provided after the valid period of short valid period data has expired even for data configured in such a manner that short valid period data is included as a part within limitless valid period data. It is therefore no longer necessary to provide data including unlimited valid period data in the way that was necessary in the related art and the transmission efficiency can therefore be raised.
When the data receiver wishes to play back the data DTa of a limitless valid period, the data receiver inputs SPa as a data playback instruction SP from the data playback instruction section 24 via the user interface 25 .
The data playback section 23 then recognizes presence of a playback request for the data DTa from the data playback instruction section 24 (step STP 11 in FIG. 5) and when the playback request for the data DTa is presented, a read out instruction SR is outputted as SRa to the data reader 226 for this data DTa.
The data reader 226 then recognizes the cord data Da for the data DTa stored at the data storage section 223 with respect to whether or not the cord data Da has a valid period by using the bit B for the data DTa (step STP 12 ). Then, because the cord data Da of the data DTa in this example has no valid period, the cord data Da for the data DTa stored in the data storage section 223 is read-out and outputted to the data playback section 23 via the data output section 227 . The cord data Da for the data DTa inputted from the data output section 227 is then played-back via the data output section 227 (step STP 14 ).
Next, when the data receiver wishes to play back the short valid period data DTbb, the data receiver inputs SPbb as a data playback instruction SP from the data playback instruction section 24 is inputted via the user interface 25 .
The presence of a playback request for the data DTbb from the data playback instruction section 24 is then recognized at the data playback section 23 (step STP 11 ). When the playback request for the data DTbb is presented, a read out instruction SR for reading out this data DTbb is outputted as SRbb to the data reader 226 in FIG. 3 .
The data reader 226 then recognizes the core data Dbb of the data DTbb stored at the data storage section 223 with respect to whether or not the core data Dbb has a valid period by using the bit Bbb of the data DTb (step STP 12 ). Then, because the core data Dbb of the data DTbb of this example has a valid period, a recognition is made as to whether or not the valid period of the cord data Dbb for the data DTbb has expired by using the bit Cbb of the data DTbb (step STP 13 ). Then, because the valid period of the core data Dbb for the data DTb has not expired in this example, the core data Dbb for the data DTbb stored in the data storage section 223 is read out and outputted to the data playback section 23 via the data output section 227 .
The core data Dbb for the data DTbb inputted from the data output section 227 is played back at the data playback section 23 (step STP 14 ).
The operation for when the data receiver makes a request to playback short valid period data when the updated short valid period data DTbb has not been used for replacing regardless of whether the valid period of the short valid period data has expired so that the core data Db for the data DTb is invalid is carried out in step STP 13 onwards. Namely, whether or not the valid period of the core data Db for the data DTb has expired is recognized using the bit Cb for the data DTb (step STP 13 ). Then, because the valid period of the core data Db for the data DTb has expired in this case, an error signal SE of a message of, for example, “playback is not possible because the valid period of the core data Db for the data DTb has expired” is outputted at the data playback instruction section 24 via the data output section 227 and the data playback section 23 (step STP 15 ), with the data receiver being informed of this via the user interface 25 . It is also possible at the data reader 226 at this time to erase the data DTb for which the valid period has expired from the data storage section 223 . This prevents data for which the valid period has expired from being mistakenly played back.
Then, the presence of a request for playing back of the data DT from the data playback instruction section 24 is recognized at the data playback section 23 in FIG. 1 (step STP 16 ). When a playback request for the data DT is presented, the flow is returned to step STP 12 and the aforementioned operation is repeated.
The data providing side operation described using FIG. 4 and the data receiving side operation described using FIG. 5 are executed independently, i.e. the reading and playing back of other data is possible even while data is being transmitted and stored.
In the aforementioned embodiment, data stored at the data storage section 223 is stored in accordance with the data type, number or valid period, or stored in the sequence received and then arranged during the playing back of the data in accordance with the data type, number or valid period.
According to the present invention, transmission efficiency can be dramatically improved by only providing updated short valid period data after the valid period of short valid period data has expired even for the providing of data configured in such a manner that short valid period data is included as a part of data of a long or limitless valid period. | In a data providing method and device thereof for providing data in a simple manner at a highly efficient transmission rate, first data of a configuration where information relating to a valid period of data is added to the data is made and provided, with the first data being categorized and stored in accordance with the information. Information for second data of the same configuration as the first data is then recognized and the first data is replaced with the second data in accordance with results of the recognition. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to a fermentation process for the preparation of L-amino acids, especially L-threonine, using strains of the family Enterobacteriaceae in which at least the pckA gene is attenuated.
PRIOR ART
[0002] L-Amino acids are used in animal nutrition, in human medicine and in the pharmaceutical industry.
[0003] It is known to prepare L-amino acids by the fermentation of strains of Enterobacteriaceae, especially Escherichia coli and Serratia marcescens. Because of their great importance, attempts are constantly being made to improve the preparative processes. Improvements to the processes may relate to measures involving the fermentation technology, e.g. stirring and oxygen supply, or the composition of the nutrient media, e.g. the sugar concentration during fermentation, or the work-up to the product form, e.g. by ion exchange chromatography, or the intrinsic productivity characteristics of the microorganism itself.
[0004] The productivity characteristics of these microorganisms are improved by using methods of mutagenesis, selection and mutant choice to give strains which are resistant to antimetabolites, e.g. the threonine analogue α-amino-β-hydroxyvaleric acid (AHV) or auxotrophic for metabolites of regulatory significance, and produce L-amino acids, e.g. L-threonine.
[0005] Methods of recombinant DNA technology have also been used for some years to improve L-amino acid-producing strains of the family Enterobacteriaceae by amplifying individual amino acid biosynthesis genes and studying the effect on production.
OBJECT OF THE INVENTION
[0006] The object which the inventors set themselves was to provide novel procedures for improving the preparation of L-amino acids, especially L-threonine, by fermentation.
SUMMARY OF THE INVENTION
[0007] The invention provides a fermentation process for the preparation of L-amino acids, especially L-threonine, using microorganisms of the family Enterobacteriaceae which, in particular, already produce L-threonine and in which the nucleotide sequence (pckA gene) coding for the enzyme phosphoenolpyruvate carboxykinase (PEP carboxykinase) (EC 4.1.1.49) is attenuated.
DETAILED DESCRIPTION OF THE INVENTION
[0008] Where L-amino acids or amino acids are mentioned in the following, this means one or more amino acids, including their salts, chosen from the group consisting of L-asparagine, L-threonine, L-serine, L-glutamate, L-glycine, L-alanine, L-cysteine, L-valine, L-methionine, L-isoleucine, L-leucine, L-tyrosine, L-phenylalanine, L-histidine, L-lysine, L-tryptophan, L-homoserine and L-arginine. L-Threonine is particularly preferred.
[0009] In this context the term “attenuation” describes the reduction or switching-off, in a microorganism, of the intracellular activity of one or more enzymes (proteins) which are coded for by the appropriate DNA, for example by using a weak promoter or a gene or allele which codes for an appropriate enzyme with low activity, or inactivating the appropriate enzyme (protein), and optionally combining these measures.
[0010] By attenuation measures, the activity or concentration of the corresponding protein is in general reduced to 0 to 75%, 0 to 50%, 0 to 25%, 0 to 10% or 0 to 5% of the activity or concentration of the wild-type protein or of the activity or concentration of the protein in the starting microorganism.
[0011] The process is characterized in that the following steps are carried out:
a) fermentation of microorganisms of the family Enterobacteriaceae in which at least the pckA gene is attenuated, b) enrichment of the appropriate L-amino acid in the medium or in the cells of the microorganisms of the family Enterobacteriaceae, and c) isolation of the desired L-amino acid.
[0015] The microorganisms provided by the present invention can produce L-amino acids from glucose, sucrose, lactose, fructose, maltose, molasses, optionally starch or optionally cellulose, or from glycerol and ethanol. Said microorganisms are representatives of the family Enterobacteriaceae selected from the genera Escherichia, Erwinia, Providencia and Serratia. The genera Escherichia and Serratia are preferred. The species Escherichia coli and Serratia marcescens may be mentioned in particular among the genera Escherichia and Serratia respectively.
[0016] Examples of suitable strains, particularly L-threonine-producing strains, of the genus Escherichia, especially of the species Escherichia coli, are:
Escherichia coli TF427 Escherichia coli H4578 Escherichia coli KY10935 Escherichia coli VNIIgenetika MG442 Escherichia coli VNIIgenetika M1 Escherichia coli VNIIgenetika 472T23 Escherichia coli BKIIM B-3996 Escherichia coli kat 13 Escherichia coli KCCM-10132.
[0026] Examples of suitable L-threonine-producing strains of the genus Serratia, especially of the species Serratia marcescens, are:
Serratia marcescens HNr21 Serratia marcescens TLr156 Serratia marcescens T2000.
[0030] L-Threonine-producing strains of the family Enterobacteriaceae preferably possess, inter alia, one or more genetic or phenotypic characteristics selected from the group comprising resistance to α-amino-β-hydroxyvaleric acid, resistance to thialysine, resistance to ethionine, resistance to α-methylserine, resistance to diaminosuccinic acid, resistance to α-aminobutyric acid, resistance to borrelidine, resistance to rifampicin, resistance to valine analogues such as valine hydroxamate, resistance to purine analogues such as 6-dimethylaminopurine, need for L-methionine, optionally partial and compensable need for L-isoleucine, need for meso-diaminopimelic acid, auxotrophy in respect of threonine-containing dipeptides, resistance to L-threonine, resistance to L-homoserine, resistance to L-lysine, resistance to L-methionine, resistance to L-glutamic acid, resistance to L-aspartate, resistance to L-leucine, resistance to L-phenylalanine, resistance to L-serine, resistance to L-cysteine, resistance to L-valine, sensitivity to fluoropyruvate, defective threonine dehydrogenase, optionally capability for sucrose utilization, amplification of the threonine operon, amplification of homoserine dehydrogenase I-aspartate kinase I, preferably of the feedback-resistant form, amplification of homoserine kinase, amplification of threonine synthase, amplification of aspartate kinase, optionally of the feedback-resistant form, amplification of aspartate semialdehyde dehydrogenase, amplification of phosphoenolpyruvate carboxylase, optionally of the feedback-resistant form, amplification of phosphoenolpyruvate synthase, amplification of transhydrogenase, amplification of the RhtB gene product, amplification of the RhtC gene product, amplification of the YfiK gene product, amplification of malate quinone oxidoreductase and amplification of a pyruvate carboxylase and attenuation of acetic acid formation.
[0031] It has been found that the production of L-amino acids, especially L-threonine, by microorganisms of the family Enterobacteriaceae is improved after attenuation and, in particular, switching-off of the pckA gene coding for PEP carboxykinase (EC 4.1.1.49). The nucleotide sequence of the pcka gene of Escherichia coli has been published by Medina et al. (Journal of Bacteriology 172, 7151-7156 (1990)) and can also be taken from the genome sequence of Escherichia coli published by Blattner et al. (Science 277, 1453-1462 (1997)). The nucleotide sequence of the pckA gene of Escherichia coli is represented in SEQ ID No. 1 and the amino acid sequence of the corresponding gene product is represented in SEQ ID No. 2.
[0032] The pckA genes described in the above literature references can be used according to the invention. It is also possible to use alleles of the pckA gene which result from the degeneracy of the genetic code or from neutral sense mutations.
[0033] Attenuation can be achieved for example by reducing or switching off the expression of the pcka gene or the catalytic properties of the enzyme protein. Both measures may optionally be combined.
[0034] Gene expression can be reduced by an appropriate culture technique, by genetic modification (mutation) of the signal structures of gene expression, or by means of antisense RNA technology. Examples of signal structures of gene expression are repressor genes, activator genes, operators, promoters, attenuators, ribosome binding sites, the start codon and terminators. Those skilled in the art will find relevant information inter alia in e.g. Jensen and Hammer (Biotechnology and Bioengineering 58, 191-195 (1998)), Carrier and Keasling (Biotechnology Progress 15, 58-64 (1999)), Franch and Gerdes (Current Opinion in Microbiology 3, 159-164 (2000)) and well-known textbooks on genetics and molecular biology, for example the textbook by Knippers (“Molekulare Genetik” (“Molecular Genetics”), 6th edition, Georg Thieme Verlag, Stuttgart, Germany, 1995) or the textbook by Winnacker (“Gene und Klone” (“From Genes to Clones”), VCH Verlagsgesellschaft, Weinheim, Germany, 1990).
[0035] Mutations which cause a change or reduction in the catalytic properties of enzyme proteins are known from the state of the art. Examples which may be mentioned are the studies of Qiu and Goodman (Journal of Biological Chemistry 272, 8611-8617 (1997)), Yano et al. (Proceedings of the National Academy of Sciences USA 95, 5511-5515 (1998)) and Wente and Schachmann (Journal of Biological Chemistry 266, 20833-20839 (1991)). Surveys can be found in well-known textbooks on genetics and molecular biology, e.g. the textbook by Hagemann (“Allgemeine Genetik” (“General Genetics”), Gustav Fischer Verlag, Stuttgart, 1986).
[0036] Mutations to be taken into consideration are transitions, transversions, insertions and deletions. Depending on the effect of amino acid exchange on the enzyme activity, the term missense mutations or nonsense mutations is used. Insertions or deletions of at least one base pair in a gene cause frame shift mutations, the result of which is that false amino acids are incorporated or translation is terminated prematurely. Deletions of several codons typically lead to a complete loss of enzyme activity. Instructions for the production of such mutations form paft of the state of the art and can be found in well-known textbooks on genetics and molecular biology, e.g. the textbook by Knippers (“Molekulare Genetik” (“Molecular Genetics”), 6th edition, Georg Thieme Verlag, Stuttgart, Germany, 1995), the textbook by Winnacker (“Gene und Klone” (“From Genes to Clones”), VCH Verlagsgesellschaft, Weinheim, Germany, 1990) or the textbook by Hagemann (“Allgemeine Genetik” (“General Genetics”), Gustav Fischer Verlag, Stuttgart, 1986).
[0037] An example of a plasmid by means of which the pckA gene of Escherichia coli can be attenuated and, in particular, switched off by position-specific mutagenesis is plasmid pMAK705ApckA ( FIG. 1 ). It contains only part of the 5′ region and part of the 3′ region of the pckA gene. A 349 bp segment of the coding region is missing (deletion). The sequence of this DNA, which can be used for mutagenesis of the pckA gene, is represented in SEQ ID No. 3.
[0038] The deletion mutation of the pckA gene can be incorporated into suitable strains by gene or allele exchange.
[0039] A common method is the method of gene exchange using a conditionally replicating pSC101 derivative, pMAK705, as described by Hamilton et al. (Journal of Bacteriology 174, 4617-4622 (1989)). Other methods described in the state of the art, for example that of Martinez-Morales et al. (Journal of Bacteriology, 7143-7148 (1999)) or that of Boyd et al. (Journal of Bacteriology 182, 842-847 (2000)), can also be used.
[0040] When exchange has been carried out, the form of the ΔpckA allele represented in SEQ ID No. 4, which is a further subject of the invention, is present in the strain in question.
[0041] Mutations in the pckA gene or mutations involving expression of the pckA gene can also be transferred to different strains by conjugation or transduction.
[0042] Furthermore, for the production of L-amino acids, especially L-threonine, with strains of the family Enterobacteriaceae, it can be advantageous not only to attenuate the pckA gene but also to amplify one or more enzymes of the known threonine biosynthetic pathway, or enzymes of the anaplerotic metabolism, or enzymes for the production of reduced nicotinamide adenine dinucleotide phosphate.
[0043] In this context the term “amplification” describes the increase in the intracellular activity, in a microorganism, of one or more enzymes or proteins which are coded for by the appropriate DNA, for example by increasing the copy number of the gene(s), using a strong promoter or using a gene coding for an appropriate enzyme or protein with a high activity, and optionally combining these measures.
[0044] By amplification measures, in particular over-expression, the activity or concentration of the corresponding protein is in general increased by at least 10%, 25%, 50%, 75%, 100%, 150%, 200%, 300%, 400% or 500%, up to a maximum of 1000% or 2000%, based on that of the wild-type protein or the activity or concentration of the protein in the starting microorganism.
[0045] Thus, for example, one or more genes selected from the group comprising:
the thrABC operon coding for aspartate kinase, homoserine dehydrogenase, homoserine kinase and threonine synthase (U.S. Pat. No. 4,278,765), the pyc gene coding for pyruvate carboxylase DE-A-19 831 609), the pps gene coding for phosphoenolpyruvate synthase (Molecular and General Genetics 231, 332 (1992)), the ppc gene coding for phosphoenolpyruvate carboxylase (Gene 31, 279-283 (1984)), the pntA and pntB genes coding for transhydrogenase (European Journal of Biochemistry 158, 647-653 (1986)), the rhtB gene for homoserine resistance (EP-A-0994190), and the rhtC gene for threonine resistance (EP-A-1013765), the gdhA gene coding for glutamate dehydrogenase (Gene 27:193-199 (1984)
can be simultaneously amplified and, in particular, overexpressed.
[0054] Furthermore, for the production of L-amino acids, especially L-threonine, it can be advantageous not only to attenuate the pckA gene but also to attenuate and, in particular, switch off one or more genes selected from the group comprising:
the tdh gene coding for threonine dehydrogenase (Ravnikar and Somerville, Journal of Bacteriology 169, 4716-4721 (1987)), the mdh gene coding for malate dehydrogenase (EC 1.1.1.37) (Vogel et al., Archives in Microbiology 149, 36-42 (1987)), the gene product of the open reading frame (orf) yjfA (Accession Number AAC77180 of the National Center for Biotechnology Information (NCBI, Bethesda, Md., USA) and SEQ ID No. 5), and the gene product of the open reading frame (orf) ytfP (Accession Number AAC77179 of the National Center for Biotechnology Information (NCBI, Bethesda, Md., USA) and SEQ ID No. 5),
or to reduce the expression.
[0059] It is preferred to attenuate the open reading frame yjfA and/or the open reading frame ytfP.
[0060] It is also possible according to the invention to attenuate the open reading frames yjfA and/or ytfp independently of the pckA gene, in order to achieve an improvement in the amino acids, in particular L-threonine production.
[0061] The invention accordingly also provides a process, characterized in that the following steps are carried out:
d) fermentation of microorganisms of the Enterobacteriaceae family in which at least the open reading frame yjfA and/or ytfP is attenuated, e) enrichment of the L-amino acid in the medium or in the cells of the microorganisms of the Enterobacteriaceae family, and f) isolation of the L-threonine, constituents of the fermentation broth and the biomass in its entirety or portions thereof optionally being isolated as a solid product together with the L-amino acid.
[0065] An example of a plasmid by means of which the open reading frames yjfA and ytfP of Escherichia coli can be attenuated and, in particular, switched off by position-specific mutagenesis is plasmid pMAK705ΔyjfA ( FIG. 2 ). It contains only the 5′ and 3′ flanks of the ytfP-yjfA region, including very short residues of the open reading frames yjfA and ytfp. A 337 bp long part of the ytfP-yjfA region is missing (deletion). The sequence of this DNA, which can be used for mutagenesis of the ytfP-yjfA region, is represented in SEQ ID No. 6.
[0066] An further example of a plasmid by means of which the open reading frames yjfA and ytfP of Escherichia coli can be attenuated and, in particular, switched off by position-specific mutagenesis is the plasmid pMAK705Δ90bp ( FIG. 5 ). It also contains only the 5′ and 31 flanks of the ytfP-yjfA region including very short residues of the open reading frames yjfA and ytfp. A 90 bp long part of the ytfP-yjfA region is missing (deletion). The sequence of this DNA, which can be used for mutagenesis of the ytfP-yjfA region, is represented in SEQ ID No. 7.
[0067] This deletion mutation can be incorporated into suitable strains by gene or allele replacement. It is also possible to transfer mutations in the open reading frames yjfA and/or ytfP or mutations affecting expression of these open reading frames into various strains by conjugation or transduction.
[0068] When replacement has been carried out, the form of the ΔytfP and ΔyjfA allele represented in SEQ ID No. 6 or SEQ ID No. 7, which are a further subject of the invention, is present in the strain in question.
[0069] Furthermore, for the production of L-amino acids, especially L-threonine, it can be advantageous, in addition to the individual or joint attenuation of the pckA gene or of the open reading frames yjfA and/or ytfP, to switch off undesired secondary reactions (Nakayama: “Breeding of Amino Acid Producing Microorganisms”, in: Overproduction of Microbial Products, Krumphanzl, Sikyta, Vanek (eds.), Academic Press, London, UK, 1982).
[0070] The microorganisms prepared according to the invention can be cultivated by the batch process or the fed batch process. A summary of known cultivation methods is provided in the textbook by Chmiel (Bioprozesstechnik 1. Einführung in die Bioverfahrenstechnik (Bioprocess Technology 1. Introduction to Bioengineering) (Gustav Fischer Verlag, Stuttgart, 1991)) or in the textbook by Storhas (Bioreaktoren und periphere Einrichtungen (Bioreactors and Peripheral Equipment) (Vieweg Verlag, Brunswick/Wiesbaden, 1994)).
[0071] The culture medium to be used must appropriately meet the demands of the particular strains. Descriptions of culture media for various microorganisms can be found in the handbook “Manual of Methods for General Bacteriology” of the American Society for Bacteriology (Washington D.C., USA, 1981).
[0072] Carbon sources which can be used are sugars and carbohydrates, e.g. glucose, sucrose, lactose, fructose, maltose, molasses, starch and optionally cellulose, oils and fats, e.g. soya oil, sunflower oil, groundnut oil and coconut fat, fatty acids, e.g. palmitic acid, stearic acid and linoleic acid, alcohols, e.g. glycerol and ethanol, and organic acids, e.g. acetic acid. These substances can be used individually or as a mixture.
[0073] Nitrogen sources which can be used are organic nitrogen-containing compounds such as peptones, yeast extract, meat extract, malt extract, corn steep liquor, soya bean flour and urea, or inorganic compounds such as ammonium sulfate, ammonium chloride, ammonium phosphate, ammonium carbonate and ammonium nitrate. The nitrogen sources can be used individually or as a mixture.
[0074] Phosphorus sources which can be used are phosphoric acid, potassium dihydrogenphosphate or dipotassium hydrogenphosphate or the corresponding sodium salts. The culture medium must also contain metal salts, e.g. magnesium sulfate or iron sulfate, which are necessary for growth. Finally, essential growth-promoting substances such as amino acids and vitamins can be used in addition to the substances mentioned above. Suitable precursors can also be added to the culture medium. Said feed materials can be added to the culture all at once or fed in appropriately during cultivation.
[0075] The pH of the culture is controlled by the appropriate use of basic compounds such as sodium hydroxide, potassium hydroxide, ammonia or aqueous ammonia, or acid compounds such as phosphoric acid or sulfuric acid. Foaming can be controlled using antifoams such as fatty acid polyglycol esters. The stability of plasmids can be maintained by adding suitable selectively acting substances, e.g. antibiotics, to the medium. Aerobic conditions are maintained by introducing oxygen or oxygen-containing gaseous mixtures, e.g. air, into the culture. The temperature of the culture is normally 25° C. to 45° C. and preferably 30° C. to 40° C. The culture is continued until the formation of L-amino acids or L-threonine has reached a maximum. This objective is normally achieved within 10 hours to 160 hours.
[0076] L-Amino acids can be analyzed by means of anion exchange chromatography followed by ninhydrin derivation, as described by Spackman et al. (Analytical Chemistry 30, 1190 (1958)), or by reversed phase HPLC, as described by Lindroth et al. (Analytical Chemistry 51, 1167-1174 (1979)).
[0077] A pure culture of the Escherichia coli K-12 strain DH5α/pMAK705 was deposited on 12th Sep. 2000 at the Deutsche Sammlung fur Mikroorganismen und Zellkulturen (DSMZ=German Collection of Microorganisms and Cell Cultures, Braunschweig, Germany) in accordance with the Budapest Treaty as DSM 13720.
[0078] A pure culture of the Escherichia coli K-12 strain MG442ΔpckA was deposited on 2nd Oct. 2000 at the Deutsche Sammlung fur Mikroorganismen und Zellkulturen (DSMZ=German Collection of Microorganisms and Cell Cultures, Braunschweig, Germany) in accordance with the Budapest Treaty as DSM 13761.
[0079] A pure culture of the Escherichia coli K-12 strain B-3996kurΔtdhΔpckA/pVIC40 was deposited on 9th Mar. 2001 at the Deutsche Sammlung fur Mikroorganismen und Zellkulturen (DSMZ=German Collection of Microorganisms and Cell Cultures, Braunschweig, Germany) in accordance with the Budapest Treaty as DSM 14150.
[0080] A pure culture of the Escherichia coli K-12 strain MG442Δ90yjfA was deposited on 9th May 2001 at the Deutsche Sammlung fur Mikroorganismen und Zellkulturen (DSMZ=German Collection of Microorganisms and Cell Cultures, Braunschweig, Germany) in accordance with the Budapest Treaty as DSM 14289.
[0081] It is also possible according to the invention individually to attenuate the open reading frames ytfP and yjfA in order to improve the production of L-amino acids.
[0082] The process according to the invention is used for the preparation of L-amino acids, e.g. L-threonine, L-isoleucine, L-methionine, L-homoserine and L-lysine, especially L-threonine, by fermentation.
[0083] The present invention is illustrated in greater detail below with the aid of Examples.
[0084] The isolation of plasmid DNA from Escherichia coli and all the techniques for restriction, Klenow treatment and alkaline phosphatase treatment were carried out as described by Sambrook et al. (Molecular cloning—A laboratory manual (1989), Cold Spring Harbor Laboratory Press). Unless indicated otherwise, the transformation of Escherichia coli was carried out as described by Chung et al. (Proceedings of the National Academy of Sciences USA 86, 2172-2175 (1989)).
[0085] The incubation temperature for the preparation of strains and transformants was 37° C. Temperatures of 30° C. and 44° C. were used in the gene exchange process of Hamilton et al.
EXAMPLE 1
[0000] Construction of the deletion mutation of the pckA gene
[0086] Parts of the 5′ and 3′ regions of the pckA gene of Escherichia coli K12 were amplified using the polymerase chain reaction (PCR) and synthetic oligonucleotides. The nucleotide sequence of the pckA gene in E. coli K12 MG1655 (SEQ ID No. 1) was used to synthesize the following PCR primers (MWG Biotech, Ebersberg, Germany):
pckA′5′-1: 5′ - GATCCGAGCCTGACAGGTTA - 3′ pckA′5′-2: 5′ - GCATGCGCTCGGTCAGGTTA - 3′ pckA′3′-1: 5′ - AGGCCTGAAGATGGCACTATCG - 3′ pckA′3′-2: 5′ - CCGGAGAAGCGTAGGTGTTA - 3′.
The chromosomal E. coli K12 MG1655 DNA used for the PCR was isolated with “Qiagen Genomic-tips 100/G” (QIAGEN, Hilden, Germany) according to the manufacturer's instructions. An approx. 500 bp DNA fragment from the 5′ region of the pckA gene (denoted as pckl) and an approx. 600 bp DNA fragment from the 3′ region of the pckA gene (denoted as pck2) could be amplified with the specific primers under standard PCR conditions (Innis et al. (1990), PCR Protocols. A Guide to Methods and Applications, Academic Press) using Taq DNA polymerase (Gibco-BRL, Eggenstein, Germany). The PCR products were each ligated with vector pCR2.1TOPO (TOPO TA Cloning Kit, Invitrogen, Groningen, The Netherlands) according to the manufacturer's instructions and transformed into E. coli strain TOPlOF′. Plasmid-carrying cells were selected on LB agar containing 50 μg/ml of ampicillin. After isolation of the plasmid DNA, vector pCR2.1TOPOpck2 was cleaved with the restriction enzymes StuI and XbaI and, after separation in 0.8% agarose gel, the pck2 fragment was isolated with the aid of the QIAquick Gel Extraction Kit (QIAGEN, Hilden, Germany). After isolation of the plasmid DNA, vector pCR2.1TOPOpck1 was cleaved with the enzymes EcoRV and XbaI and ligated to the isolated pck2 fragment. The E. coli strain DH5α was transformed with the ligation mixture and plasmid-carrying cells were selected on LB agar containing 50 μg/ml of ampicillin. After isolation of the plasmid DNA, control cleavage with the enzymes SpeI and XbaI was used to detect plasmids containing, in cloned form, the mutagenic DNA sequence represented in SEQ ID No. 3. One of the plasmids was denoted as pCR2.lTOPOΔpckA.
EXAMPLE 2
[0000] Construction of exchange vector pMAK705ΔpckA
[0087] After restriction with the enzymes SpeI and XbaI and separation in 0.8% agarose gel, the pckA allele described in Example 1 was isolated from vector pCR2.1TOPOΔpckA and ligated to plasmid pMAK705 (Hamilton et al., Journal of Bacteriology 174, 4617-4622 (1989)) which had been digested with the enzyme XbaI. DH5α was transformed with the ligation mixture and plasmid-carrying cells were selected on LB agar containing 20 μg/ml of chloramphenicol. After isolation of the plasmid DNA and cleavage with the enzymes HpaI, KpnI, HindIII, SalI and PstI, successful cloning was detected. The exchange vector formed, pMAK705ΔpckA (=pMAK705deltapckA), is shown in FIG. 1 .
EXAMPLE 3
[0000] Position-specific mutagenesis of the pckA gene in the E. coli strain MG442
[0088] The L-threonine-producing E. coli strain MG442 is described in patent U.S. Pat. No. 4,278,765 and deposited in the Russian National Collection of Industrial Microorganisms (VKPM, Moscow, Russia) as CMIM B-1628.
[0089] The strain MG442 has a resistance to α-amino-β-hydroxyvaleric acid and has an optionally partial and compensable need for L-isoleucine.
[0090] For exchange of the chromosomal pckA gene for the plasmid-coded deletion construct, MG442 was transformed with plasmid pMAK705ΔpckA. The gene exchange was carried out by the selection method described by Hamilton et al. (Journal of Bacteriology 174, 4617-4622 (1989)) and was verified by standard PCR methods (Innis et al. (1990), PCR Protocols. A Guide to Methods and Applications, Academic Press) using the following oligonucleotide primers:
pckA′5′-1: 5′ - GATCCGAGCCTGACAGGTTA - 3′ pckA′3′-2: 5′ - CCGGAGAAGCGTAGGTGTTA - 3′
[0091] The strain obtained was denoted as MG442ΔpckA.
EXAMPLE 4
[0092] Preparation of L-threonine with the strain MG442ΔpckA MG442ΔpckA was cultivated on minimum medium of the following composition: 3.5 g/l of Na 2 HPO 4 .2H 2 O, 1.5 g/l of KH 2 PO 4, 1 g/l of NH 4 Cl, 0.1 g/l of MgSO 4 .7H 2 O, 2 g/l of glucose and 20 g/l of agar. The formation of L-threonine was checked in 10 ml batch cultures contained in 100 ml Erlenmeyer flasks. These were inoculated with 10 ml of a preculture medium of the following composition: 2 g/l of yeast extract, 10 g/l of (NH 4 ) 2 SO 4 , 1 g/l of KH 2 PO 4 , 0.5 g/l of MgSO 4 . 7H 2 O, 15 g/l of CaCO 3 and 20 g/l of glucose, and incubated for 16 hours at 37° C. and 180 rpm on an ESR incubator from Kühner AG (Birsfelden, Switzerland). 250 μl of this preculture were transferred to 10 ml of a production medium (25 g/l of (NH 4 ) 2 SO 4 , 2 g/l of KH 2 PO 4 , 1 g/l of MgSO 4 .7H 2 O, 0.03 g/l of FeSO 4 7H 2 O, 0.018 g/l of MnSO 4 .1H 2 O, 30 g/l of CaCO 3 , 20 g/l of glucose) and incubated for 48 hours at 37° C. After incubation, the optical density (OD) of the culture suspension was determined with an LP2W photometer from Dr. Lange (Berlin, Germany) at a measurement wavelength of 660 nm.
[0093] The concentration of L-threonine formed was then determined in the sterile-filtered culture supernatant with an amino acid analyzer from Eppendorf-BioTronik (Hamburg, Germany) by means of ion exchange chromatography and postcolumn reaction with ninhydrin detection.
[0094] The result of the experiment is shown in Table 1.
TABLE 1 OD L-Threonine Strain (660 nm) g/l MG442 6.0 1.5 MG442ΔpckA 5.4 3.7
EXAMPLE 5
[0000] Preparation of L-threonine with the strain MG442ΔpckA/pMW218gdhA
[0000] 5.1 Amplification and cloning of the gdhA gene
[0095] The glutamate dehydrogenase gene from Escherichia coli K12 is amplified using the polymerase chain reaction (PCR) and synthetic oligonucleotides. Starting from the nucleotide sequence for the gdhA gene in E. coli K12 MG1655 (gene library: Accession No. AE000270 and No. AE000271) PCR primers are synthesized (MWG Biotech, Ebersberg, Germany):
Gdh1: 5′ - TGAACACTTCTGGCGGTACG - 3′ Gdh2: 5′ - CCTCGGCGAAGCTAATATGG - 3′
[0096] The chromosomal E. coli K12 MG1655 DNA employed for the PCR is isolated according to the manufacturers instructions with “QIAGEN Genomic-tips 100/G” (QIAGEN, Hilden, Germany). A DNA fragment approx. 2150 bp in size, which comprises the gdhA coding region and approx. 350 bp 5′-flanking and approx. 450 bp 3′-flanking sequences, can be amplified with the specific primers under standard PCR conditions (Innis et al.: PCR Protocols. A Guide to Methods and Applications, 1990, Academic Press) with the Pfu-DNA polymerase (Promega Corporation, Madison, USA). The PCR product is cloned in the plasmid pCR2.1TOPO and transformed in the E. coli strain TOP10 (Invitrogen, Leek, The Netherlands, Product Description TOPO TA Cloning Kit, Cat. No. K4500-01). Successful cloning is demonstrated by cleavage of the plasmid pCR2.1TOPOgdhA with the restriction enzymes EcoRI and EcoRV. For this, the plasmid DNA is isolated by means of the “QIAprep Spin Plasmid Kits” (QIAGEN, Hilden, Germany) and, after cleavage, separated in a 0.8 % agarose gel.
[0000] 5.2 Cloning of the gdhA gene in the plasmid vector pMW218
[0097] The plasmid pCR2.1TOPOgdhA is cleaved with the enzyme EcoRI, the cleavage batch is separated on 0.8% agarose gel and the gdhA fragment 2.1 kbp in size is isolated with the aid of the “QIAquick Gel Extraction Kit” (QIAGEN, Hilden, Germany). The plasmid pMW218 (Nippon Gene, Toyama, Japan) is cleaved with the enzyme EcoRI and ligated with the gdhA fragment. The E. coli strain DH5α is transformed with the ligation batch and pMW218-carrying cells are selected by plating out on LB agar (Lennox, Virology 1955, 1: 190), to which 20 μg/ml kanamycin are added.
[0098] Successful cloning of the gdhA gene can be demonstrated after plasmid DNA isolation and control cleavage with EcoRI and EcoRV. The plasmid is called pMW218gdhA ( FIG. 3 ).
[0000] 5.3 Preparation of the strain MG442ΔpckA/pMW218gdhA
[0099] The strain MG442ΔpckA obtained in Example 3 and the strain MG442 are transformed with the plasmid pMW218gdhA and transformants are selected on LB agar, which is supplemented with 20 μg/ml kanamycin. The strains MG442ΔpckA/pMW218gdhA and MG442/pMW218gdhA are formed in this manner.
[0000] 5.4 Preparation of L-threonine
[0100] The preparation of L-threonine by the strains MG442ΔpckA/pMW218gdhA and MG442/pMW218gdhA is tested as described in Example 4. The minimal medium and the preculture medium are additionally supplemented with 20 μg/ml kanamycin.
TABLE 2 OD L-Threonine Strain (660 nm) g/l MG442 6.0 1.5 MG442ΔpckA 5.4 3.7 MG442/pMW218gdhA 5.6 2.6 MG442ΔpckA/pMW218gdhA 5.5 4.0
EXAMPLE 6
[0000] Preparation of L-threonine with the strain MG442ΔpckA/pMW219rhtC
[0000] 6.1 Amplification of the rhtC gene
[0101] The rhtC gene from Escherichia coli K12 is amplified using the polymerase chain reaction (PCR) and synthetic oligonucleotides. Starting from the nucleotide sequence for the rhtC gene in E. coli K12 MG1655 (gene library: Accession No. AE000458, Zakataeva et al. (FEBS Letters 452, 228-232 (1999)), PCR primers are synthesized (MWG Biotech, Ebersberg, Germany):
RhtC1: 5′ - CTGTTAGCATCGGCGAGGCA - 3′ RhtC2: 5′ - GCATGTTGATGGCGATGACG - 3′
[0102] The chromosomal E. coli K12 MG1655 DNA employed for the PCR is isolated according to the manufacturers instructions with “QIAGEN Genomic-tips 100/G” (QIAGEN, Hilden, Germany). A DNA fragment approx. 800 bp in size can be amplified with the specific primers under standard PCR conditions (Innis et al.: PCR Protocols. A Guide to Methods and Applications, 1990, Academic Press) with Pfu-DNA polymerase (Promega Corporation, Madison, USA).
[0000] 6.2 Cloning of the rhtC gene in the plasmid vector pMW219
[0103] The plasmid pMW219 (Nippon Gene, Toyama, Japan) is cleaved with the enzyme SamI and ligated with the rhtC-PCR fragment. The E. coli strain DH5α is transformed with the ligation batch and pMW219-carrying cells are selected on LB agar, which is supplemented with 20 μg/ml kanamycin. Successful cloning can be demonstrated after plasmid DNA isolation and control cleavage with KpnI, HindIII and NcoI. The plasmid pMW219rhtC is shown in FIG. 4 .
[0000] 6.3 Preparation of the strain MG442ΔpckA/pMW219rhtC
[0104] The strain MG442ΔpckA obtained in Example 3 and the strain MG442 are transformed with the plasmid pMW219rhtC and transformants are selected on LB agar, which is supplemented with 20 μg/ml kanamycin. The strains MG442ΔpckA/pMW219rhtC and MG442/pMW219rhtC are formed in this manner.
[0000] 6.4 Preparation of L-threonine
[0105] The preparation of L-threonine by the strains MG442ΔpckA/pMW219rhtC and MG442/pMW219rhtC is tested as described in Example 4. The minimal medium and the preculture medium are additionally supplemented with 20 μg/ml kanamycin.
TABLE 3 OD L-Threonine Strain (660 nm) g/l MG442 6.0 1.5 MG442ΔpckA 5.4 3.7 MG442/pMW219rhtC 5.2 2.9 MG442ΔpckA/pMW219rhtC 4.8 4.4
EXAMPLE 7
[0000] Preparation of L-threonine with the strain B-3996kurΔtdhΔpckA/pVIC40
[0106] The L-threonine-producing E. coli strain B-3996 is described in U.S. Pat. No. 5,175,107 and deposited at the Russian National Collection for Industrial Microorganisms (VKPM, Moscow, Russia).
[0107] The strain B-3996 has, inter alia, a resistance to α-amino-β-hydroxyvaleric acid, has an attenuated, in particular switched-off, or defective threonine dehydrogenase, has an enhanced homoserine dehydrogenase I aspartate kinase I in the feed back resistant form, has an optionally partial and compensable need for L-isoleucine and has the ability to utilize sucrose.
[0000] 7.1 Preparation of the strain B-3996kurΔtdhΔpckA/pVIC40
[0108] After culture in antibiotic-free complete medium for approximately ten generations, a derivative of strain B-3996 which no longer contains the plasmid pVIC40 is isolated. The strain formed is streptomycin-sensitive and is designated B-3996kur.
[0109] The method described by Hamilton et al. (Journal of Bacteriology (1989) 171: 4617-4622), which is based on the use of the plasmid pMAK705 with a temperature-sensitive replicon, was used for incorporation of a deletion into the tdh gene. The plasmid pDR121 (Ravnikar and Somerville, Journal of Bacteriology (1987) 169:4716-4721) contains a DNA fragment from E. coli 3.7 kilo-base pairs (kbp) in size, on which the tdh gene is coded. To generate a deletion of the tdh gene region, pDR121 is cleaved with the restriction enzymes ClaI and EcoRV and the DNA fragment 5 kbp in size isolated is ligated, after treatment with Klenow enzyme. The ligation batch is transformed in the E. coli strain DH5α and plasmid-carrying cells are selected on LB agar, to which 50 μg/ml ampicillin are added.
[0110] Successful deletion of the tdh gene can be demonstrated after plasmid DNA isolation and control cleavage with EcoRI. The EcoRI fragment 1.7 kbp in size is isolated, and ligated with the plasmid pMAK705, which is partly digested with EcoRI. The ligation batch is transformed in DH5α and plasmid-carrying cells are selected on LB agar, to which 20 μg/ml chloramphenicol are added. Successful cloning is demonstrated after isolation of the plasmid DNA and cleavage with EcoRI. The pMAK705 derivative formed is designated pDM32.
[0111] For the gene replacement, B-3996kur is transformed with the plasmid pDM32. The replacement of the chromosomal tdh gene with the plasmid-coded deletion construct is carried out by the selection process described by Hamilton et al. and is verified by standard PCR methods (Innis et al. (1990), PCR Protocols. A Guide to Methods and Applications, Academic Press) with the following oligonucleotide primers:
Tdh1: 5′-TCGCGACCTATAAGTTTGGG-3′ Tdh2: 5′-AATACCAGCCCTTGTTCGTG-3′.
[0112] The strain formed is tested for kanamycin sensitivity and is designated B-3996kurΔtdh.
[0113] For the position-specific mutagenesis of the pckA gene, B-3996kurΔtdh is transformed with the replacement vector pMAK705ΔpckA described in Example 2. The replacement of the chromosomal pckA gene by the plasmid-coded deletion construct is carried out as described in Example 3. The strain obtained is called B-3996kurΔtdhΔpckA.
[0114] B-3996kurΔtdh and B-3996kurΔtdhΔpckA are transformed with the plasmid pVIC40 isolated from B-3996 and plasmid-carrying cells are selected on LB agar with 20 μg/ml streptomycin. In each case a selected individual colony is called B-3996kurΔtdh/pVIC40 and B-3996kurΔtdhΔpckA/pVIC40.
[0000] 7 . 2 Preparation of L-threonine
[0115] The preparation of L-threonine by the strains B-3996kurΔtdh/pVIC40 and B-3996kurΔtdhΔpckA/pVIC40 is tested as described in Example 4. The minimal medium, the preculture medium and the production medium are additionally supplemented with 20 μg/ml streptomycin.
[0116] The result of the experiment is summarized in Table 4.
TABLE 4 OD L-Threonine Strain (660 nm) g/l B-3996kurΔtdh/pVIC40 4.7 6.26 B-3996kurΔtdhΔpckA/pVIC40 4.9 8.92
EXAMPLE 8
[0000] Preparation of L-lysine with the strain TOC21RΔpckA
[0117] The L-lysine-producing E. coli strain pDAl/TOC21R is described in the patent application F-A-2511032 and deposited at the Collection Nationale de Culture de Microorganisme (CNCM=National Microorganism Culture Collection, Pasteur Institute, Paris, France) under number I-167. The strain and the plasmid-free host are also described by Dauce-Le Reverend et al. (European Journal of Applied Microbiology and Biotechnology 15:227-231 (1982)) under the name TOCR21/pDA1.
[0000] 8 . 1 Position-specific mutagenesis of the pckA gene in the E. coli strain TOC21R
[0118] After culture in antibiotic-free LB medium for approximately six generations, a derivative of strain pDA1/TOC21R which no longer contains the plasmid pDA1 is isolated. The strain formed is tetracycline-sensitive and is called TOC21R.
[0119] For replacement of the chromosomal pckA gene by the plasmid-coded deletion construct, TOC21R is transformed with the plasmid pMAK705ΔpckA (Example 2). The gene replacement is carried out by the selection method described by Hamilton et al. (1989) Journal of Bacteriology 174, 4617-4622) and is verified by standard PCR methods (Innis et al. (1990) PCR Protocols. A Guide to Methods and Applications, Academic Press) with the following oligonucleotide primers:
pckA′5′-1: 5′ - GATCCGAGCCTGACAGGTTA - 3′ pckA′3′-2: 5′ - CCGGAGAAGCGTAGGTGTTA - 3′
[0120] The strain obtained is called TOC21RΔpckA.
[0000] 8.2 Preparation of L-lysine with the strain TOC21RΔpckA
[0121] The formation of L-lysine by the strains TOC21RΔ pckA and TOC21R is checked in batch cultures of 10 ml contained in 100 ml conical flasks. For this, 10 ml of preculture medium of the following composition: 2 g/l yeast extract, 10 g/l (NH 4 ) 2 SO 4 , 1 g/l KH 2 PO 4 , 0.5 g/l MgSO 4 *7H 2 O, 15 g/l CaCO 3 , 20 g/l glucose are inoculated and the batch is incubated for 16 hours at 37° C. and 180 rpm on an ESR incubator from Kuhner AG (Birsfelden, Switzerland). 250 μl of this preculture are transinoculated into 10 ml of production medium (25 g/l (NH 4 ) 2 SO 4 , 2 g/l KH 2 PO 4 , 1 g/l MgSO 4 *7H 2 O, 0.03 g/l FeSO 4 *7H 2 O, 0.018 g/l MnSO 4 *1H 2 O, 30 g/l CaCO 3 , 20 g/l glucose, 25 mg/l L-isoleucine and 5 mg/l thiamine) and the batch is incubated for 72 hours at 37° C. After the incubation the optical density (OD) of the culture suspension is determined with an LP2W photometer from Dr. Lange (Berlin, Germany) at a measurement wavelength of 660 nm.
[0122] The concentration of L-lysine formed is then determined in the sterile-filtered culture supernatant with an amino acid analyzer from Eppendorf-BioTronik (Hamburg, Germany) by ion exchange chromatography and post-column reaction with ninhydrin detection.
[0123] The result of the experiment is shown in Table 5.
TABLE 5 OD L-Lysine Strain (660 nm) g/l TOC21R 1.0 1.14 TOC21RΔpckA 1.0 1.27
EXAMPLE 9
[0000] Preparation of L-isoleucine with the strain B-3996kurΔtdhilvA + ΔpckA/pVIC40
[0000] 9 . 1 Preparation of the strain B-3996kurΔtdhilvA + ΔpckA/pVIC40
[0124] The strain B-3996kurΔtdh, which is in need of L-isoleucin, obtained in Example 7.1 is transduced with the aid of the phage Plkc (Lennox, Virology 1, 190-206 (1955); Miller, Experiments in Molecular Genetics, Cold Spring Harbor Laboratory 1972) and L-isoleucine-prototrophic transductants are isolated.
[0125] For this, the phage Plkc is multiplied on the strain MG1655 (Guyer et al., Cold Spring Harbor Symposium of Quantitative Biology 45, 135-140 (1981) and Blattner et al., Science 277, 1453-1462 (1997))and the phage lysate is employed for the transduction of the strain B-3996kurΔtdh. The multiplicity of the infection is approximately 0.2. Selection for L-isoleucine-prototrophic transductants is carried out on minimal agar, which contains 2 g/l glucose and 10 mg/l L-threonine. An L-isoleucine-prototrophic transductant is isolated, smeared on to LB agar for purification or isolation and called B-3996kurΔtdhilvA + .
[0126] The pckA gene of the strain B-3996kurΔtdhilvA + is then replaced, as described in Example 3, by the ΔpckA allele prepared in Example 1 and 2. The strain obtained is called B-3996kurΔtdhilvA + ΔpckA.
[0127] The strains B-3996kurΔtdhilvA + and B-3996kurΔtdhilvA + ΔpckA are transformed with the plasmid pVIC40 isolated from strain B-3996 and plasmid-carrying cells are selected on LB agar, which is supplemented with 20 μg/ml streptomycin. In each case a selected individual colony is called B-3996kurΔtdhilvA + ΔpckA/pVIC40 and B-3996kurΔtdhilvA + /pVIC40.
[0000] 9 . 2 Preparation of L-isoleucine
[0128] The preparation of L-isoleucine by the strains B-3996kurΔtdhilvA + /pVIC40 and B-3996kurΔtdhilvA + ΔpckA/pVIC40 is tested under the test conditions as described in Example 4. The minimal medium, the preculture medium and the production medium are additionally supplemented with 20 μg/ml streptomycin.
TABLE 6 OD L-Isoleucine Strain (660 nm) mg/l B-3996kurΔtdhilvA + /pVIC40 5.8 57 B-3996kurΔtdhilvA + ΔpckA/pVIC40 5.7 70
EXAMPLE 10
[0000] Preparation of L-valine with the strain B-12288ΔpckA
[0129] The L-valine-producing E. coli strain AJ 11502 is described in the patent specification U.S. Pat. No. 439,1907 and deposited at the National Center for Agricultural Utilization Research (Peoria, Ill., USA) as NRRL B-12288.
[0130] 10.1 Position-specific mutagenesis of the pckA gene in the E. coli strain B-1288
[0131] After culture in antibiotic-free LB medium for approximately six generations, a plasmid-free derivative pf strain AJ 11502 is isolated. The strain formed is ampicillin-sensitive and is called AJ11502kur.
[0132] For replacement of the chromosomal pckA gene by the plasmid-coded deletion construct, AJ11502kur is transformed with the plasmid pMAK705ΔpckA (see Example 2). The gene replacement is carried out by the selection method described by Hamilton et al. (1989) Journal of Bacteriology 174, 4617-4622) and is verified by standard PCR methods (Innis et al. (1990) PCR Protocols. A Guide to Methods and Applications, Academic Press) with the following oligonucleotide primers:
pckA′5′-1: 5′ - GATCCGAGCCTGACAGGTTA - 3′ pckA′3′-2: 5′ - CCGGAGAAGCGTAGGTGTTA - 3′
[0133] The strain obtained is called AJ11502kurΔpckA. The plasmid described in the patent specification U.S. Pat. No. 4,391,907, which carries the genetic information in respect of valine production, is isolated from strain NRRL B-12288. The strain AJ11502kurΔpckA is transformed with this plasmid. One of the transformants obtained is called B-12288ΔpckA.
[0000] 10.2 Preparation of L-valine with the strain B-12288ΔpckA
[0134] The formation of L-valine by the strains B-12288ΔpckA and NRRL B-12288 is checked in batch cultures of 10 ml contained in 100 ml conical flasks. For this, 10 ml of preculture medium of the following composition: 2 g/l yeast extract, 10 g/l (NH 4 ) 2 SO 4 , 1 g/l KH 2 PO 4 , 0.5 g/l MgSO 4 *7H 2 O, 15 g/l CaCO 3 , 20 g/l glucose and 50 mg/l ampicillin are inoculated and the batch is incubated for 16 hours at 37° C. and 180 rpm on an ESR incubator from Küthner AG (Birsfelden, Switzerland). 250 pl of this preculture are transinoculated into 10 ml of production medium (25 g/l (NH 4 ) 2 SO 4 , 2 g/l KH 2 PO 4 , 1 g/l MgSO 4 *7H 2 O, 0.03 g/l FeSO 4 *7H 2 O, 0.018 g/l MnSO 4 *1H 2 O, 30 g/l CaCO 3 , 20 g/l glucose, 5 mg/l thiamine and 50 mg/l ampicillin) and the batch is incubated for 72 hours at 37° C. After the incubation the optical density (OD) of the culture suspension is determined with an LP2W photometer from Dr. Lange (Berlin, Germany) at a measurement wavelength of 660 nm.
[0135] The concentration of L-valine formed is then determined in the sterile-filtered culture supernatant with an amino acid analyzer from Eppendorf-BioTronik (Hamburg, Germany) by ion exchange chromatography and post-column reaction with ninhydrin detection.
TABLE 7 OD L-Valine Strain (660 nm) g/l NRRL B-12288 5.6 0.93 B-12288ΔpckA 5.5 1.12
EXAMPLE 11
[0000] Construction of deletion mutations of the ytfP-yjfA gene region
[0136] The ytfP-yjfA gene region is amplified from Escherichia coli K12 using the polymerase chain reaction (PCR) and synthetic oligonucleotides. Starting from the nucleotide sequence of the ytfP-yjfA gene region in E. coli K12 MG1655 (SEQ ID No. 5), the following PCR primers are synthesized (MWG Biotech, Ebersberg, Germany):
ytfP-1: 5′ - GGCGATGTCGCAACAAGCTG - 3′ ytfP-2: 5′ - CTGTTCATGGCCGCTTGCTG - 3′
[0137] The chromosomal E. coli K12 MG1655 DNA employed for the PCR is isolated according to the manufacturers instructions with “Qiagen Genomic-tips 100/G” (QIAGEN, Hilden, Germany). A DNA fragment approx. 1300 bp in size can be amplified with the specific primers under standard PCR conditions (Innis et al. (1990) PCR Protocols. A Guide to Methods and Applications, Academic Press) with Taq-DNA polymerase (Gibco-BRL, Eggenstein, Germany). The PCR product is ligated with the vector pCR2.1TOPO (TOPO TA Cloning Kit, Invitrogen, Groningen, The Netherlands) in accordance with the manufacturers instructions and transformed into the E. coli strain TOP10F′. Selection of plasmid-carrying cells takes place on LB agar, to which 50 μg/ml ampicillin are added. After isolation of the plasmid DNA, successful cloning of the PCR product is checked with the restriction enzymes EcoRI and NsiI.
[0138] To generate a 337 bp deletion in the yftP-yjfA region, the vector pCR2.1TOPOytfP-yjfA is cleaved with the restriction enzymes NdeI and SspI and the DNA fragment 4.8 kbp in size is ligated, after treatment with Klenow enzyme.
[0139] To generate a 90 bp deletion, the vector pCR2.1TOPOytfP-yjfA is cleaved with the enzymes NdeI and SplI and the DNA fragment 5 kbp in size is ligated, after treatment with Klenow enzyme.
[0140] The E. coli strain DH5α is transformed with the ligation batches and plasmid-carrying cells are selected on LB agar, to which 50 μg/ml ampicillin is added. After isolation of the plasmid DNA those plasmids in which the mutagenic DNA sequence shown in SEQ ID No. 6 and SEQ ID No. 7 is cloned are detected by control cleavage with the enzyme EcoRI. The plasmids are called pCR2.1TOPOΔyjfA and pCR2.1TOPOΔ90bp.
EXAMPLE 12
[0000] Construction of the replacement vectors pMAK705ΔyjfA and pMAK705Δ90bp
[0141] The ytfP-yjfA alleles described in Example 11 are isolated from the vectors pCR2.1TOPOΔyjfA and pCR2.1TOPOΔ90bp after restriction with the enzymes SacI and XbaI and separation in 0.8% agarose gel, and ligated with the plasmid pMAK705 (Hamilton et al. (1989) Journal of Bacteriology 174, 4617-4622), which is digested with the enzymes SacI and XbaI. The ligation batches are transformed in DH5α and plasmid-carrying cells are selected on LB agar, to which 20 μg/ml chloramphenicol are added. Successful cloning is demonstrated after isolation of the plasmid DNA and cleavage with the enzymes SacI and XbaI. The replacement vectors formed, pMAK705ΔyjfA (=pMAK705deltayjfA) and pMAK705Δ90bp (=pMAK705delta90bp), are shown in FIG. 2 and in FIG. 5 .
EXAMPLE 13
[0000] Position-specific mutagenesis of the ytfP-yjfA gene region in the E. coli strain MG442
[0142] For replacement of the chromosomal ytfP-yjfA gene region with the plasmid-coded 90 bp deletion construct, MG442 is transformed with the plasmid pMAK705Δ90bp, The gene replacement is carried out by the selection method described by Hamilton et al. (1989) Journal of Bacteriology 174, 4617-4622) and is verified by standard PCR methods (Innis et al. (1990) PCR Protocols. A Guide to Methods and Applications, Academic Press) with the following oligonucleotide primers:
ytfP-1: 5′ - GGCGATGTCGCAACAAGCTG - 3′ ytfP-2: 5′ - CTGTTCATGGCCGCTTGCTG - 3′
The strain obtained is called MG442Δ90yjfA.
EXAMPLE 14
[0000] Preparation of L-threonine with the strain MG442Δ90yjfA
[0143] The preparation of L-threonine by the strain MG442Δ90yjfA is tested as described in Example 4. The result of the experiment is summarized in Table 8.
TABLE 8 OD L-Threonine Strain (660 nm) g/l MG442 6.0 1.5 MG442Δ90yjfA 5.7 2.1
EXAMPLE 15
[0000] Preparation of L-threonine with the strain MG442Δ90yjfAΔpckA
[0000] 15.1 Preparation of the strain MG442Δ90yjfAΔpckA
[0144] The pckA gene of the strain MG442Δ90yjfA is replaced, as described in Example 3, by the ΔpckA allele (see Example 1 and 2). The strain obtained is called MG442Δ90yjfAΔpckA.
[0000] 15.2 Preparation of L-threonine
[0145] The preparation of L-threonine with the strain MG442Δ90yjfAΔpckA is carried out as described in Example 4. The result is shown in Table 9.
TABLE 9 OD L-Threonine Strain (660 nm) g/l MG442Δ90yjfA 5.7 2.1 MG442Δ90yjfAΔpckA 5.3 3.9
BRIEF DESCRIPTION OF THE FIGURES
[0146] FIG. 1 : pMAK705ΔpckA (=pMAK705deltapckA)
[0147] FIG. 2 : pMAK705ΔyjfA (=pMAK705deltayjfA)
[0148] FIG. 3 : pMW218gdhA
[0149] FIG. 4 : pMW219rhtC
[0150] FIG. 5 : pMAK705Δ90bp (=pMAK705delta90bp)
The length data are to be understood as approx. data. The abbreviations and designations used have the following meaning:
[0000]
cat: Chloramphenicol resistance gene
rep-ts: Temperature-sensitive replication region of the plasmid pSC101
pck1: Part of the 5′ region of the pckA gene
pck2: Part of the 3′ region of the pckA gene
ytfP′-yjfA′: DNA sequence containing truncated coding regions of ytfP and yjfA
kan: Kanamycin resistance gene
gdhA: Glutamate dehydrogenase gene
rhtC: Threonine resistance-imparting gene
[0159] The abbreviations for the restriction enzymes have the following meaning
BamHI: restriction endonuclease from Bacillus amyloliquefaciens BglII: restriction endonuclease from Bacillus globigii ClaI: restriction endonuclease from Caryphanon latum EcoRI: restriction endonuclease from Escherichia coli EcoRV: restriction endonuclease from Escherichia coli HindIII: restriction endonuclease from Haemophilus influenzae KpnI: restriction endonuclease from Klebsiella pneumoniae PstI: restriction endonuclease from Providencia stuartii PvuI: restriction endonuclease from Proteus vulgaris SacI: restriction endonuclease from Streptomyces achromogenes SalI: restriction endonuclease from Streptomyces albus SmaI: restriction endonuclease from Serratia marcescens XbaI: restriction endonuclease from Xanthomonas badrii XhoI: restriction endonuclease from Xanthomonas holcicola | The present invention relates to a fermentation process for the preparation of L-amino acids in which the following steps are carried out (a) fermentation of the microorganisms of the family Enterobacteriaceae producing the desired L-amino acid, in which microorganisms' pckA gene, and/or the open reading frames of yjfA and ytfP are individually or jointed inactivated by one or methods of mutagenesis selected from the group consisting of deletion, insertional mutagenesis due to homologous recombination, and transition or tranversion mutagenesis with incorporation of a non-sense mutation in the ytfP and ytfA gene, concentration of the fermentation broth to eliminate water and increase the concentration of said L-amino acids in the broth and E. coli, and isolation of the L-amino acids. | 2 |
[0001] This application is a divisional of application Ser. No. 10/444,225, filed May 23, 2003, U.S. Pat. No. 7,353,571, issued Apr. 8, 2008, and this application incorporates by reference herein the entirety thereof.
FIELD OF THE INVENTION
[0002] The invention relates generally to attachment devices having a fluid-containing cavity.
BACKGROUND OF THE INVENTION
[0003] Attachment devices such as snap hooks and carabiners have long been in use for providing a means for attaching articles to each other. Such devices have numerous applications, such as for example enabling multiple articles to be secured to a backpack, purse, handbag, key chain or the like. As such, these devices are fairly ubiquitous. An example of an attachment device is a carabiner such as is disclosed in U.S. Pat. No. 5,005,266.
[0004] Fluid-filled ornamental articles are known in the art. For example, U.S. Pat. No. 4,148,199 relates to a pierced earring with liquid visible therein. U.S. Pat. No. 4,093,973 relates to a liquid filled ornamental article of jewelry containing an illumination source. U.S. Pat. No. 5,006,375 relates to an ornamental article having a transparent housing shaped into a decorative configuration having a liquid therein and a subatmospheric pressure area between the liquid and housing. However, none of the prior art liquid filled ornamental articles have the utility of providing a means for attaching articles to each other and providing an indicia bearing means on a ubiquitous useful article.
SUMMARY OF THE INVENTION
[0005] The invention provides an attachment device comprising at least one fluid filled cavity formed therein. The attachment device is preferably in the form of a carabiner in which at least a portion of the carabiner body is formed of a transparent material such that the fluid filled cavity is visible. In a preferred embodiment an indicia bearing means is visibly disposed within said cavity.
OBJECTS OF THE INVENTION
[0006] It is an object of the present invention to provide a fluid filled attachment device that is aesthetically pleasing.
[0007] It is a further object of the present invention to provide a novel attachment device that provides an interior fluid filled cavity capable of containing an indicia-bearing medium.
[0008] It is still a further object of the present invention to provide in a novel attachment device a free-floating indicia-bearing medium in said fluid filled cavity.
[0009] It is yet a further object of the present invention to provide in a novel attachment device a fixed indicia-bearing medium in said fluid filled cavity.
[0010] It is still a further object of the present invention to provide a novel attachment device in the form of a carabiner that provides an interior fluid filled cavity capable of containing an indicia-bearing medium.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a front view of a preferred embodiment of the present invention;
[0012] FIG. 2 is a perspective view of a preferred embodiment of the invention of FIG. 1 ;
[0013] FIG. 3A is a cross sectional view of the invention of FIG. 2 taken along the line A-A′;
[0014] FIG. 3B is a cross sectional view of another embodiment of the invention of FIG. 2 taken along the line A-A′;
[0015] FIG. 4 is a perspective view of a further preferred embodiment of the present invention;
[0016] FIG. 5 is a cross sectional view of the invention of FIG. 4 taken along the line B-B′; and
[0017] FIG. 6 is a perspective view of a further preferred embodiment of the present invention.
[0018] FIG. 7 is a perspective view of a further preferred embodiment of the present invention.
[0019] FIG. 8 is a front perspective view of a further preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Now referring to FIGS. 1-3 , a preferred embodiment of the device 2 comprises essentially a body member 10 , at least one openable gate member 20 , at least one cavity 30 formed in the device 2 and a fluid 35 contained in said cavity 30 . Device 2 optionally further includes an indicia-bearing device 40 contained in said cavity 30 .
[0021] Body member 10 comprises an elongated member comprising a first end and a second end and is fabricated of any material suitable for attachment devices such as but not limited to bare or coated metal, wood, rubber or plastic or combinations thereof. Gate member 20 comprises an elongated member pivotally attached at one end to one end of said body member 10 . The other end of gate member 20 contacts the other end of said body member 10 when said gate 20 is in a closed position. Now referring to FIG. 2 , in a preferred embodiment gate member 20 is inwardly openable. Gate member 20 is fabricated of any suitable material as recited above for body member 10 . In a preferred embodiment body 10 is curvilinear. In a most preferred embodiment body member 10 is formed in the shape of a carabiner.
[0022] Cavity 30 is formed in either or both of body member 10 and gate member 20 . Cavity 30 may be formed of a depression or hollow in the material of body member 10 or gate member 20 , for example where the material is formed of a nontransparent material such as metal, wood, rubber or opaque plastic and sealed with a transparent material such as but not limited to readily available plastics or acrylics, polycarbonates, polyimides, methacrylates, polystyrenes or the like such that the interior of the cavity 30 is visible. Now referring to FIGS. 2 and 3 , alternatively, where the material of the portion of the device 2 wherein the cavity 30 is formed is a transparent material the cavity 30 can be a chamber formed therein by thermoforming, blow molding, boring or the like. Now referring to FIGS. 4 and 5 , in yet another embodiment cavity 30 is formed between a portion of body member 10 and a transparent shell member 12 .
[0023] Fluid 35 is any suitable substance that is nonreactive when employed in conjunction with the material of cavity 30 . Suitable fluids 35 include colored or uncolored liquids such as but not limited to water, oil or gel or mixtures thereof, or, as seen in FIG. 2 , small particulate matter 37 such as but not limited to colored or uncolored powders, grains or the like or mixtures thereof; and/or as also seen in FIG. 2 at 35 and 37 mixtures of liquids and solid particles. In a preferred embodiment fluid 35 is transparent. As is also seen in FIG. 2 , those skilled in the art will recognize materials such as reflective or refractive material including but not limited to glitter and/or other insoluble material 37 may be included in fluid 35 for aesthetic purposes. It will also be recognized fluid 35 may contain a colorant. It is to be understood herein that each and every other of the embodiments of the other figures herein may also have the above particulate matter, glitter, etc. 37 within fluid 35 .
[0024] Indicia bearing device 40 is contained in cavity 30 and may be fixedly anchored within said cavity 30 (as seen in FIG. 3B ) or may be unanchored so as to be free-floating or free-moving within said cavity 30 (as seen in FIG. 3A ). Accordingly indicia bearing device 40 may be fabricated of any suitable material that is nonreactive with fluid 35 . Suitable materials are any materials capable of receiving indicia such as ink, engraving, paint, or the like and include but are not limited to metal, wood, laminate, plastic, cork, rubber and the like. Indicia bearing device 40 may have any configuration as long as such configuration can be received and contained in said cavity 30 . Now referring to FIGS. 2 and 3 in a preferred embodiment indicia bearing device 40 is elongated and has a three dimensional cross section, providing more than one indicia bearing surface 42 . As seen in FIG. 3 , in one embodiment indicia bearing device 40 comprises three indicia bearing surfaces 42 and each surface 42 may for example bear different indicia.
[0025] In a preferred embodiment device 2 comprises a curvilinear body 10 , body 10 comprises metal having at least one cavity 30 formed therein, said cavity 30 sealed by a transparent plastic material, said cavity 30 containing a fluid 35 comprising water and further containing indicia bearing device 40 , wherein said indicia bearing device 40 is elongated and is free floating in fluid 35 .
[0026] Now referring to FIG. 6 in a most preferred embodiment device 2 comprises a cavity 30 formed in gate 20 and body 10 is in the shape of a carabiner.
[0027] Now referring to FIG. 7 , in an alternate preferred embodiment body 10 is in the form of a circle.
[0028] Now referring to FIG. 8 , in a further preferred embodiment of the present invention, cavity 30 comprises a significant portion of the device 2 .
[0029] As illustrated in FIGS. 7 and 8 , device 2 is not limited to the form of a carabiner but may take any suitable shape or form.
[0030] While the preferred embodiments have been described and illustrated it will be understood that changes in details and obvious undisclosed variations might be made without departing from the spirit and principle of the invention and therefore the scope of the invention is not to be construed as limited to the preferred embodiment. | An attachment device is provided comprising at least one fluid filled cavity formed therein. The attachment device is preferably in the form of a carabiner in which at least a portion of the carabiner body is formed of a transparent material such that the fluid filled cavity is visible. In a preferred embodiment an indicia bearing means is visibly disposed within said cavity. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of Provisional U.S. Patent Application Ser. No. 61/857,017 filed on Jul. 22, 2013, and Provisional U.S. Patent Application Ser. No. 61/726,207 filed on Nov. 14, 2012, both of which are fully incorporated by reference herein for all purposes. This application is also a continuation in part of the following U.S. patent application Ser. No. 14/080,142 entitled “Automated Control of Spreading Systems”, filed on Nov. 14, 2013, the entirety of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The spreader system, road maintenance equipment, monitoring equipment and methods (“Technology”) described herein, encompass a series of innovations that are aimed at increasing the efficiency of the winter road maintenance industry, improving operational efficiencies, saving money, increasing safety and reducing the impact of chloride on the environment (and infrastructure).
[0003] In the parts of the world that receive various amounts of snow fall each winter, keeping roads clear of ice and snow is a necessity. This is typically achieved by plowing roadways and then spreading deicing and/or abrasive aggregate on road surfaces with spreaders. Chloride based deicers typically come in two different forms, granulated and liquid. Granulated forms (usually chloride based) are typically spread using conveyor type conveyance systems. Liquid based deicers are also used in winter road maintenance operations. Liquid deicers are typically held in liquid storage tanks and use liquid pumps to spray the road ways with brine liquids before winter events occur in order to coat the roadway with a brine solution, thus reducing the ability for ice to form on the road surface.
[0004] There are a large assortment of spreader and spreader controller manufacturers on the market. Existing Spreader Controllers rely on wired connections for connectivity to sensory devices throughout the truck for feedback on system function. These systems are typically controlled manually by the driver, set at a single speed or calibrated for various speeds of the vehicle through a velocity controlled system. Like spreader controllers, plow controller sensors also rely on hardwiring for feedback on plow function.
[0005] According to best management practices in the winter road maintenance industry (for example), certain spread rates should be prescribed for different temperatures and environments. Some spreader controllers take variations in temperature (and environment) into account through the use of externally wired sensors enabling the detection of changes in temperature and in the environment.
[0006] Chloride based deicers are the most widely used of the deicers because of their availability and low cost, however their use has long lasting negative impacts on the areas in which they are used. Such deicers negatively impact at least the following: drinking water quality, aquatic ecosystems, and infrastructure (bridges in particular).
[0007] Winter road maintainers (and plow truck operators in particular) have the propensity to overuse aggregates, this is largely due to the fact that they need to manage many different aspects of the plowing operation concurrently (controlling multiple plow controls, controlling the spreader, driving in tedious driving conditions, navigating traffic, communicating with their supervisor and typically working very long hours). While dispensing material during a winter event, it can be difficult to see where material has been applied, and when in doubt, maintainers typically choose to apply material rather than not applying material (often reapplying it redundantly). The winter road maintenance industry is in need of new technologies that can assist the winter road maintainers in applying deicer and abrasives in the most efficient manner. Furthermore, the installation of wired sensory systems on the maintenance vehicles can be tedious and expensive.
[0008] In addition to driving the vehicle on which a spreading system is mounted, the operators of such systems are typically relied on for activation and volumetric control of the spreader, which commonly results in excessive use of aggregate. Excessive use of material usually is caused by: utilizing open loop control systems, fear of not applying enough material and overcompensating and overlapping (or redundant applications within short time periods).
[0009] Winter road maintenance operations can offer very corrosive and tough environments that tend to damage electrical wiring and connections. Also, many municipalities are slow to adopt new and advantageous technologies because of the lack of technical man-power needed to install and maintain them, especially for hardwired or hardware based systems.
[0010] Furthermore, even absent the operator's other responsibilities, because the operator is generally responsible for using manual throttling controls for activation and volumetric control of the spreading system (e.g., to increase or decrease application rates), it can be very difficult for the operator to provide precise, efficient, optimized application of deicing material. This problem is compounded in systems without mass flow feedback and/or systems with coarse application rate controls.
[0011] The ability to maintain winter roads with an easily-integrated automated spreading system may allow the maintainer to focus on other aspects of the operation and enable material to be spread, for example, based on the trucks location and historical spreading information while using materials in the most economical fashion, thus contributing to safer and more sustainable winter road maintenance.
[0012] A need therefore exists for easy-to-integrate systems and methods of monitoring and automatically dispensing aggregate in order to avoid waste and optimize (winter) road maintenance operations. A system that is easy to integrate into existing vehicles with minimal or no modification to the vehicle would decrease the cost, time, and skill-level required to integrate the monitoring system. Such a system would allow municipalities, for example, with tight budgets to keep their existing vehicle fleet while retrofitting a control system to monitor and control a vehicle's operations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention.
[0014] FIG. 1 is a schematic illustrating a plurality of mobile vehicles having sensors in wireless communication with a database in the cloud which in turn communicates wirelessly with a mobile device.
[0015] FIG. 2 illustrates typical components comprising a wireless sensor.
[0016] FIG. 3 illustrates a schematic of a wireless system for monitoring equipment on a road maintenance truck.
[0017] FIG. 4 illustrates a schematic of a wireless system for monitoring and controlling spreading equipment on a road maintenance truck.
[0018] FIG. 5 illustrates a schematic of a wireless system for monitoring and controlling plowing equipment on a road maintenance truck.
[0019] FIG. 6 illustrates a schematic of a wireless system for monitoring local weather conditions at a vehicle.
[0020] FIG. 7 illustrates a schematic of a wireless system for monitoring weather conditions at a vehicle and automated wireless control of a spreader system based on observed local conditions.
[0021] FIG. 8 illustrates a schematic of a wireless system for monitoring wearable wireless sensor information through a wireless hub, communicating maintenance equipment function at a maintenance vehicle wirelessly to the operator for the control and regulation of maintenance equipment.
[0022] FIG. 9 illustrates a schematic of a wireless system for monitoring wearable wireless sensory information, and communicating maintenance equipment function at a maintenance vehicle wirelessly to the operator for the control and regulation of maintenance equipment.
[0023] FIG. 10 illustrates a schematic of a wireless system for monitoring system and operator information through multiple wireless hubs for the control and regulation of maintenance equipment.
[0024] FIG. 11 illustrates a schematic of a wireless system for monitoring the status of critical switches for the control of maintenance equipment using current sensing and wireless communications for operational monitoring.
[0025] FIG. 12 illustrates a schematic of a wireless system for monitoring the status of critical switches for the control of maintenance equipment using current sensing and wireless Bluetooth (or other forms of wireless) communications for operational monitoring.
[0026] FIG. 13 illustrates a schematic of a wireless system for monitoring wireless sensory information at various locations onboard a vehicle, and communicating maintenance equipment function at a maintenance vehicle wirelessly to a mobile device to communicate information to the operator and for the control of maintenance equipment.
[0027] FIG. 14 illustrates the location, onboard a vehicle, of a wireless rotational rate sensor for sensing the rotation of a conveyance system.
[0028] FIG. 15A illustrates another view of the mounting location of a wireless rotational rate sensor for retrofit mounting on a winter road maintenance vehicle.
[0029] FIG. 15B illustrates an example of a mounting configuration for a wireless rotational rate sensor.
[0030] FIG. 15C is a more detailed view of an embodiment of a wireless rotational rate sensor that is mounted to a conveyor shaft.
[0031] FIG. 15D is an exploded view showing the electronic components inside of a wireless rotational rate sensor that is mounted to a conveyor.
[0032] FIG. 16 is a detailed view of the rear of a spreader hopper illustrating one embodiment of an angle measurement sensor. The angle measurement sensor is shown mounted at one end to the hopper and at the other end to the gate.
[0033] FIG. 17 illustrates an embodiment of a rear view of a gate showing a wireless angle sensor and the associated mounting configuration.
[0034] FIG. 18A illustrates a rear view of a gate showing a wireless angle sensor and the angle created when the gate is at first gate height setting.
[0035] FIG. 18B illustrates rear view of a wireless angle sensor and the angle created when the gate is in an alternative position.
[0036] FIG. 19A illustrates a rear view of a gate showing a wireless angle sensor and the angle created when the gate is at first gate height setting along with a reference angle measurement sensor.
[0037] FIG. 19B illustrates a rear view of a gate showing a wireless angle sensor and the angle created when the gate is at an alternative gate height setting along with a reference angle measurement sensor.
[0038] FIG. 19C is a perspective view of a gate showing a wireless angle sensor and the angle created when the gate is at an alternative gate height setting along with a reference angle measurement sensor.
[0039] FIG. 20 illustrates a detailed view of a wireless angle sensor mounted on a plow frame for measuring the orientation of the plow.
[0040] FIG. 21A illustrates an example of an angle created when the plow is lifted up.
[0041] FIG. 21B illustrates an example of an angle created when the plow is in a down configuration.
[0042] FIG. 22 is a schematic of a wireless sensor for measuring the status of electrical switches communicating wirelessly to a mobile device.
[0043] FIG. 23 is an exploded view of an embodiment of a retrofitted wireless rotational rate sensor attached to the axle shaft of a material spreader.
DETAILED DESCRIPTION OF THE INVENTION
[0044] Several embodiments of the present invention are described in the following detailed description with references to FIGS. 1-23 . Other embodiments may be used and may incorporate changes in structural, logical, software, and hardware elements; such changes may be made without departing from the scope of the present invention. For simplicity, the embodiments of this invention are described with reference to a winter road maintenance vehicle. However, it is within the scope of this invention that the vehicle may be any utility vehicle, for example, a vehicle for use in farming or affecting on or off-road landscapes.
[0045] The present embodiments teach systems that use wireless sensors that wirelessly connect to mobile devices (or other types of computers) using, but not limited to, Bluetooth (and BLE Bluetooth low energy), wifi, ZigBee, and other types of radio communicators to communicate sensor device(s) to mobile device(s).
[0046] Road maintenance operations may be significantly optimized through the use of mobile devices along with wireless sensors capable of communicating these mobile devices (and or computer) for several reasons.
a) Mobile devices are increasingly common and will continue to be at the leading edge of technological advancement. b) The ability to quickly and easily mount sensors throughout a vehicular system is appealing, in contrast to the difficulty in connecting and routing wired sensors throughout a vehicle. c) The combination of sensors and mobile devices (connected to the World Wide Web) allows for the collection, storage, and analysis of stored or real-time data.
[0050] A system connected to the World Wide Web capable of receiving real-time fleet data and also capable of providing real-time fleet data to the vehicle operator will not only help the operator make more informed decisions but will also provide real-time insight to managers of the operation.
[0051] Now with reference to FIG. 1 , it can be seen how information flow may function using wireless sensors with mobile devices in certain embodiments. In FIGS. 1 : 1 a , 1 b , 1 c , 1 d , 1 e , and 5 all represent mobile devices communicating information (flow indicated by the arrows) gathered from wireless sensors and transmitted to a cloud computer 9 communicating with the mobile devices, wherein 1 a through 1 e represent vehicles equipped with wireless communication capabilities. FIG. 1 also illustrates a more detailed schematic 1 e of onboard wireless sensors on a vehicle gathering information and communicating the information wirelessly with a mobile device that may reside in the vehicle (additional detail provided throughout this disclosure). A cellular antenna 7 (or other type of antenna or dish) transmits wireless data to remote servers (as well as to other mobile devices). It will be understood by one skilled in the art that the “antenna” 7 may be any other current or future technology for relaying communications signals, such as a cellular antenna or satellite. Cloud based Servers, Software and Databases 9 which may be capable of collecting, storing, sorting and sharing information from mobile networks and devices, which may in-turn store, analyze, and relay the information to other servers or, for example, back to the vehicle fleet 1 a through 1 e.
[0052] In addition to using wireless devices to communicate to and from vehicles, wireless technology may also be used to communicate between devices within a vehicle. With reference to FIG. 2 a schematic of a wireless device 11 is illustrated. The device, which may for example be a sensor attached to a mechanism on the vehicle comprises a power source 13 , an antenna 15 , a sensor 17 , and optionally a controller 19 . These device elements enable the device to communicate wirelessly with, for example, a mobile device in the passenger compartment of the vehicle. The information communicated therein, may be stored, analyzed, and/or relayed to any other device as illustrated in FIG. 1 .
[0053] The power source 13 illustrated in FIG. 2 may be a storage device such as a battery. Additionally, the power source 13 may comprise a power generating device such as a dynamo, generator, or inertial power generator that takes advantage of a dynamic motion inherent in the vehicle, such as a drive shaft rotation, to generate energy (from kinetic energy) which can be used directly, thus obviating a battery, or used to charge a battery electrically attached to the sensor. The sensor 17 may be used to detect attributes of the vehicle such as the plow angle or the spread rate of material.
[0054] FIG. 3 illustrates an example of wireless sensors incorporated into a winter road maintenance operation. With regard to the Plow Function Sensor 21 , the mobile device 27 may receive information from wireless sensors which may include but are not be limited to: proximity sensors, optical sensors, switch sensors, angle sensors or other types of sensors to detect plow function (plow up and plow down for example). The Spreader Conveyor Speed sensor 23 may be mounted in such a way that it can monitor the actual speed at which the conveyance mechanism is operating. Conveyance speed sensing on a spreader may be achieved utilizing proximity sensors, optical sensors, angle sensors, rotation rate sensors, gravity or other types of sensors. In winter road maintenance operations, the gate height typically controls the amount of material that falls out of the hopper. As such, the Gate Height sensor 25 offers another application where a wireless sensor may be mounted to detect changes in height of the gate which may in turn be used to calculate quantities of material expelled.
[0055] As illustrated in FIG. 4 , additional system components can also be connected wirelessly to communicate with a mobile device 27 in order to improve a winter road maintenance operation (for example). Such additional components may include a wireless GPS antenna 29 for increased position system accuracy. For example, utilizing wireless communication to control the spreader control valve 31 via a conveyor speed sensor 23 may be achieved through the combination of an accurate positioning system and sensory feedback from wireless sensors throughout the vehicle. Additionally a mobile device 27 may be utilized to automate a spreader's hydraulic system based on location, spreading history and the specific environment the vehicle was transiting. Wireless capability may enable easier integration, easier installation, and more direct connection to the mobile device computer. Moreover, in certain embodiments the wireless communication may be “plug and play,” that is, a sensor may be added to a vehicle component, such as a spreader, and when the sensor device is activated the mobile device may automatically communicate with, or “see” the device and automatically configure the device for interaction with the software running on the mobile device.
[0056] Additionally, or alternatively, each of the wireless sensors illustrated in FIGS. 1-23 may contain components similar to those included in the embodiment of FIG. 4 , but it is within the scope of this disclosure that the wireless sensors may have additional (fewer) or other components as well.
[0057] FIG. 5 illustrates an embodiment that is similar to that in FIG. 4 , however it includes the concept of controlling plow controls 33 wirelessly through a mobile device 27 based on the input data from the various wireless sensors, such GPS 29 , plow function 21 , conveyer speed 23 , and gate height 25 . The plow may be controlled concurrently with any other controlled devices such as the spreader ( FIG. 4 ) or it may be controlled individually and independently of any other devices.
[0058] Road maintenance operations are greatly affected by weather conditions. Having the ability to remotely mount multiple weather sensors throughout a maintenance vehicle would be helpful in collecting data as well as in helping operators make better decisions in the field (and remotely) and in real-time. FIG. 6 provides an example of an embodiment comprising sensors mounted to a mobile vehicle for measuring and recording information about the weather which may include but is not limited to: barometric pressure 35 , air temperature 37 , ground temperature 39 , ice detection 41 , thermal sensors 45 as well as optical sensors 43 (utilizing cameras etc.).
[0059] Having real-time weather information wirelessly connected to a mobile device at the vehicle may allow a winter road maintenance system to automatically control equipment thus optimizing spreading quantities appropriately. Both air temperatures and ground temperature sensors may provide useful information to operators engaged in winter road maintenance. For example, when deicing roadways, best management practices suggest that winter road maintainers should apply less material if temperatures are warming and more material if temperatures are cooling and not to apply any material bellow certain temperatures. Also, winter road maintainers may find certain areas of the roadway that may require more material than others (frozen shadow areas, low lands, wind drifts, and bridges as examples). FIG. 7 illustrates an embodiment comprising a number of sensors that may be utilized to observe present road and weather conditions at the vehicle; the sensors 35 , 37 , 39 , 41 , 43 , and 45 may be connected wirelessly to a mobile device 27 , which in turn may have the capability to electronically control the spreader's hydraulic valve 31 wirelessly from the mobile device. Furthermore, this embodiment may comprise sensors allowing it to regulate flow of material depending on the environment that the truck is transiting, for example whether the truck is transiting a typical road section or transiting an area of the road that may stay colder than other sections of roadway such as shadowy streets and bridges.
[0060] With reference now to FIG. 8 ; in certain scenarios the inclusion of a Wireless Sensor Hub 49 may be advantageous in the wireless system. The inclusion of a wireless sensor hub may be included in the system for numerous reasons including (but not limited to) extending the range of transmission/reception of sensor information and/or to increase the number of sensors able to communicate with a given mobile device. FIG. 8 illustrates an embodiment wherein multiple sensors, for example optical sensors 43 or wearable sensors 51 , share a wireless hub which may enable wireless communication to a mobile device 27 . The mobile device 27 may process the information locally or remotely and adjust the control of the system shown using the E-valve 53 , in the embodiment. As an example, electronic valves (or E-Valves) 53 are typically utilized to regulate the hydraulic flow on hydraulic systems. In the case of winter road maintenance vehicles, the E-valve 53 may be used in controlling the hydraulics that controls the spreading system.
[0061] When individuals are working long hours and operating heavy machinery it is important to make sure that they are awake and healthy enough to properly perform the operation. Wearable sensors can help to monitor the state of the driver and adjust the spreader controls appropriately. FIG. 9 shows several examples of wearable sensors that may assist the operator in conducting maintenance operations. Wearable optical sensors 55 are capable of seeing both the perspective of the driver as well as monitoring the state of the drivers eyes and his blink status. This information may also be made available to the operator. Heart rate 57 and blood pressure 59 may also be monitored through wearable sensors. For example, monitoring health status of the operator while operating maintenance equipment may not only be helpful for collecting useful information, but may also be useful in monitoring alertness, assisting in the establishment and regulation of certain minimum alertness and health thresholds, or for controlling the operation of heavy equipment or accessories such as the spreader hydraulic valve 31 .
[0062] FIG. 10 provides an example of how many sensors may be employed though the utilization of multiple wireless hubs 49 a and 49 b with the mobile device 27 for optimization and control of a spreading system, such as for example controlling an electric valve 53 which is typically used to regulate the hydraulic flow on hydraulic systems. These sensors may comprise environmental sensors such as, for example, barometric pressure 35 , ice detection 41 , temperature of the air 37 or ground 39 , and optical sensors 43 . In addition, the sensor array may include onboard sensors that detect various status' and metrics on the vehicle such as plow function 21 , conveyor speed 23 , gate height 25 , gutter broom state 104 , and angle of any structure on the vehicle 71 . Finally, the sensor array may comprise one or more sensors that detect an attribute of the driver such as wearable sensors 105 .
[0063] FIG. 11 provides an example of a current sensor 61 (or voltage sensor) integrated with a mobile device 27 using a wireless communication system (or control system). There are a wide array of switches and control panels on utility vehicles where the easiest way to detect the function of critical switches on a panel may be through the implementation of wireless current (or voltage) sensing retrofits capable of communicating the status of a switch wirelessly to a mobile device. A common application for monitoring the status of a critical switch would be in street sweeping operations, where there are limited areas on the exterior of the truck to mount retrofit sensors, making the voltage monitoring of critical switches a practical alternative for operational monitoring of equipment when integrated with mobile devices and wireless communication capability. The signal from the retrofitted sensor 61 may be transmitted to the mobile device 27 and processed along with the multitude of other signals depicting the status of various systems and devices in or on a vehicle.
[0064] FIG. 12 provides another schematic example of how a current sensor 63 (or voltage sensor) can be retrofit to an existing control switch 65 for continuously communicating status wirelessly to a mobile device 27 .
[0065] FIG. 13 depicts various sensors mounted at locations in and around a winter road maintenance vehicle. For example, a rotational rate sensor 67 may be affixed to an exposed end of the shaft 79 of a conveyor located on a material spreader; the shaft 79 typically being located either near the front or near the rear of the material spreader 106 . 69 depicts a gate height sensor that can be affixed to the rear of a material spreader's hopper 107 and can be capable of measuring adjustments to the height of the gate through angle measurements. 71 depicts the location of an angle measurement sensor for measuring the status of the plow 108 using angle measurements (e.g. plow “up” or plow “down”). 73 depicts switches to be monitored within the cab of the truck using wireless current sensing methods to communicate switch status to a mobile device within the cab. In addition, a mobile device 74 may be located in the passenger compartment for receiving wireless communication from sensors mounted throughout the vehicle.
[0066] FIG. 14 depict the location where a rotational sensor 67 (see FIGS. 15A-D ) may be mounted on a shaft 79 of a material spreader 106 . The sensor (not shown in this figure) may measure rate of rotation and/or absolute angle. The end of the exposed shaft indicated by 79 is a representative location where a rotation rate sensor may be retrofit as this type of shaft 79 arrangement with an exposed end is common in material spreader systems. Mounting in this manner requires that the sensor be wireless, and this mounting location on the shaft 79 provides for easy retrofits on a wide array of spreader types.
[0067] An embodiment of a wireless rotational sensor is depicted in more detail in FIGS. 15 A-D, which depict various components of a rotational rate sensor in perspective views. FIG. 15A depicts a perspective view of the shaft 79 that may be located at a rear end of a conveyer 106 . FIG. 15B depicts a rotational sensor 67 mounted to the end of the conveyor shaft 79 . Likewise, FIG. 15C provides another, more detailed, view of a rotational sensor 67 comprising a mounting back-plate 80 and a mounting bracket 78 for attaching the rotational sensor 67 to the shaft 79 . The bracket 78 may, for example, be welded, bonded, or bolted onto the end of the shaft 79 in order to mount the rotational rate sensor 67 allowing an easy retrofit for the rotational rate sensor 67 onto the exposed portion of spreader shaft 79 . FIG. 15D depicts a rotational rate sensor 67 in an exploded view at the mounting location of wherein a rotational rate sensor would attach to a typical shaft 79 of a material spreader. The rate sensor 67 comprises an electronics module 84 that may be located inside of the back-plate 80 , which is in turn attached to the conveyer shaft 79 via the mounting bracket 78 .
[0068] FIG. 16 is a detail perspective view of the rear end of a material spreader hopper 107 comprising a gate 85 and a conveyer 106 , the gate being positioned open at a height indicated by the arrow h. An angle measurement sensor 82 is configured to measure both absolute gate height h and changes of gate height h on the rear end of the hopper 107 . 81 depicts a wireless angle sensor enabling retrofitting and consisting of a reach arm 83 mounted between the spreader/hopper 107 and the gate 85 ; the reach arm 83 changes its angle respectively with changes in gate height h. The distance that is measured is indicated by h; this opening allows more material to pass along conveyor when gate is in the raised position (increasing h).
[0069] FIG. 17 illustrates one method for mounting an angle sensor 82 to the rear end of a hopper 107 wherein a mounting pin 89 is used with the wireless angle sensing measurement system 82 , in this case depicted on a raised gate. 89 depicts a set pin connection for the sensor 82 as mounted to the gate 85 , and 91 depicts a slot cut into the reach arm 83 or mounting hardware that the sensor is mounted to. As the gate 85 moves up and down, the set pin is able to travel up and down through the slot 91 corresponding to changes in the gate height h, freely altering the angle of the sensor 82 and resulting in different angle measurement readings from the wireless or wired sensor 81 as the sensor 82 pivots on a fixed, but rotatable point 109 on the hopper 107 .
[0070] FIGS. 18A-B illustrates the wireless angle measurement sensor in operation. FIG. 18A shows the gate in the lifted position resulting in a larger gate opening h 1 . As such, the wireless angle measurement sensor 81 orients at a significantly different angle a 1 (up position), than can be seen in FIG. 18B where the orientation of the wireless angle measurement sensor 81 is seen angled in the down position (angle a 2 ) and the gate height h 2 is observed as minimized.
[0071] FIGS. 19A-C illustrate a more detailed view of the wireless angle sensor 81 and the difference of the two angle measurement sensors between FIGS. 19A and 19B with different gate height settings. The figure also illustrates the implementation of a reference angle measurement sensor 97 mounted to measure changes in the truck's orientation on the roadway, in addition to the angle sensor 81 mounted to measure changes in gate height. FIG. 19A demonstrates the orientation of the angle sensor 81 when the gate is elevated to a raised position with a height h 1 , and FIG. 19B indicates the orientation of the angle sensor 81 when the gate is in the lowered position with a height h 2 the reference angle measurement sensor 97 measures the orientation of the truck on the roadway as a reference to the angle sensor system 82 mounted on the gate 85 . FIG. 19C further illustrates, in perspective view, one example of a method to mount the sensor system 82 to the rear of a spreader hopper 107 as well as to an adjustable gate 85 with the gate in the raised position h.
[0072] Now with reference to FIG. 20 which illustrates a potential location of a wireless angle measurement sensor in use on a plow 108 of a plow truck 100 . Typically, proximity sensors 99 are used throughout the industry to indicate whether a plow is up or down, but the use of an angle sensor may be more effective and more easily retrofitted, as indicated by 82 of FIG. 20 . Thus, an angle sensor system 82 may be used in a similar manner as described elsewhere in this disclosure for gate height sensing (see FIGS. 16-19 ). In the configuration illustrated in FIG. 20 , however, the angle sensor system 82 may be pivotally attached on one end 109 to a fixed structure 110 in the front of a vehicle 100 and attached to a movable plow mechanism 103 at the opposite end of a reach arm 83 .
[0073] Plow mechanisms may effectively be equipped with angle sensing to indicate the status of the plow in operational monitoring as shown schematically in FIGS. 21A-B . In FIG. 21A that the plow 108 is up showing a distinct upward angle p 1 of the plow mechanism 103 and FIG. 21B shows the plow 108 oriented in a downward angle p 2 of the plow mechanism 103 , the angle of which may be measured as described elsewhere in this disclosure; see for example the angle sensor system 82 in FIGS. 16-20 .
[0074] With reference to FIG. 22 , which schematically indicates how a voltage or current sensor 65 may be equipped to transmit the status of the voltage flow (or no flow) wirelessly to a mobile device 27 for indicating the status of critical switches 73 , which reside in the cabin of the vehicle, for operational monitoring.
[0075] With reference to FIG. 23 , an exemplar embodiment of a rotational rate sensor 67 that is capable of being retrofitted to a vehicle spreader shaft 79 is shown in an exploded view. The sensor 67 is comprised of a back-plate 80 and a front plate 90 that together house the sensor electronics module 84 and may be attached to each other through an array of bolts 92 . The electronics module 84 contains all of the devices required to sense and transmit the rotational rate, including a printed circuit board, rotational sensor, and a battery or other power source which, in general, would be known to one skilled in the art.
[0076] The rotational rate sensor 67 may be retrofitted to the spreader/conveyer shaft in a variety of arrangements. FIG. 23 illustrates one such arrangement in which two bolts 86 are threaded into the end of the spreader shaft 79 in order to capture and attach a mounting bracket 78 . The mounting bracket is, in turn, attached to the rotational rate sensor 67 via an array of bolts 88 . Thus, the only modification to the truck is the drilling and tapping of holes 111 in the shaft 79 . Furthermore, the sensor 67 may be attached to the shaft 79 via other methods such as, but not limited to, bonding, welding, or clamping.
[0077] While this invention has been particularly shown and described with references to example 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 scope of the invention encompassed by the appended claims. | Described herein are devices and techniques for automating vehicle mounted spreading systems such as deicing systems for winter road maintenance vehicles and/or agricultural spreading systems by use of an electronic control system configured to operate a distribution element drive system. | 6 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to the wrapping of sheet material around cardboard or similar flat material to form an overlay. More specifically, the present invention is directed to apparatus for wrapping an overlay around the leading, trailing and side edges of a flat member such as, for example, the cardboard which may define the cover of a book. Accordingly, the general objects of the present invention are to provide novel and improved methods and apparatus of such character.
(2) Description of the Prior Art
While not limited thereto in its utility, the present invention is particularly well suited for use in the wrapping of overlay material around cardboard or similar flat materials in the manufacture of book covers. In the automatic production of book covers, it is known to wrap the overlay first around the lateral or side edges of the cover and then to subsequently wrap the overlay around the leading and trailing edges of the covers. In the prior art, in order to accomplish the lateral wrapping, the overlay material is laminated to the cardboard with the overlay extending past the edges of the cardboard, the laminate is advanced and gripped by feed chains and is thereafter raised upwardly at an angle of 90°. The overlay is then forced around the edges of the cardboard by inward moving wrapping shafts which travel with the covers. In the prior art apparatus, rotatably mounted wrapping fingers, arranged in a side-by-side relationship, are located across the direction of travel above the plane of motion of the covers for the purpose of folding the overlay around the leading edge. These wrapping fingers are bent at right angles opposite to the direction of travel and, in the ready position, press against a hold down shaft. Thus, the cover will run into the wrapping fingers and, when it overcomes the force of a spring bias thereon, will push the fingers out of the plane of motion. The overlay material is wrapped around the cardboard by the motion of the fingers as they pass over the leading edge of the cover. The trailing edge wrapping in the prior art apparatus is accomplished in the same manner but with wrapping fingers which are transported for a brief period with a considerable higher velocity than the speed of advance of the cover whereby the rear edge wrapping fingers force the overlay material around the cardboard upon overtaking the cover. A catch mechanism is required in order to avoid an extra displacement of the cover in the direction of travel when it is overtaken by the rear edge wrapping fingers.
Previously known methods and apparatus for the wrapping of overlay material around cardboard, the prior art apparatus briefly described above, for example, has not provided a completely satisfactory product. A first deficiency with the prior art apparatus resides in the fact that it is virtually impossible to apply adequate and even pressure to the overlay because of the relatively rapid sliding of the wrapping fingers around the edges of the cardboard and over the glueing area near the edges.
The clamping of the overlay to the cardboard for a significant period of time, the length of which depends on the type of adhesive used and also upon its coating thickness, is a factor which has not been taken into account in the design of prior automatic cover forming equipment. In order to achieve the requisite permanent adhesion of the overlay to the cover, the setting time of the glue is of particular importance. This is particularly critical when using comparatively stiff overlay materials such as Balacron, Skiveitx etc. As a result of the short period of time in which pressure is applied to urge the overlay against to cover in prior art equipment, the overlay often separates from the cardboard. This, of course, will lead to rejection of the cover.
Because of the exertion of only small clamping forces on the edges and on those areas of the covers immediately adjacent the edges, prior art automatic cover forming apparatus has been generally incapable of achieving a tight wrapping of the overlay around the cardboard; this being particularly true when comparatively stiff overlay materials are employed. The problem is not solved by increasing the applied pressure since this will invariably result in damage to the overlay and an unacceptable product. Thus, the well defined edges desired for book covers cannot be achieved using prior art wrapping systems and apparatus.
A further problem which has plagued prior art techniques, and which is attributable to the inability to obtain a tight wrapping, is the entrapment of air between the overlay and the cardboard and/or the production of covers having hollow edges.
As an additional deficiency of the prior art, because of the design of previously available automatic cover forming machines, a relatively short time is available for the clamping process and thus increases in production rate have not been possible.
SUMMARY OF THE INVENTION
The present invention overcomes the above briefly discussed and other deficiencies and disadvantages of the prior art by providing a novel and improved method for the wrapping of overlays around flat members and apparatus for use in the practice of this novel method. Apparatus in accordance with the present invention will automatically produce book covers of high quality and with a production rate substantially higher than previously obtainable.
Apparatus for automatically producing book covers in accordance with the present invention is characterized by a wrapping station through which the covers move subsequent to lamination of the overlay with the cover board. At the wrapping station the overlay material is folded around the leading and trailing edges of the cover and pressed down. A particularly unique feature of the invention resides in the fact that the covers are alternately moved through the wrapping station in two opposite directions and lifting elements are employed for each direction of movement to deflect the overlay material out of the path of motion whereby the overlay material will, by a wrapping tool, be folded around the edges of the cover and pressed tightly against the cover board.
In accordance with another feature of the preferred embodiment of the present invention, again considering the environment of a book cover producing apparatus, the apparatus is characterized by rails located beside the path of motion of the covers for lifting the overlay material which extends outwardly past the side edges of the cover board. Subsequent to the lifting, by means of the action of further rails, the overlay material is folded around the side edges of the cover board. The overlay is subsequently engaged by pressure rolls which are angularly oriented with respect to the direction of motion of the covers whereby the overlay is pressed tightly against the cover board while simultaneously being pulled around the edge thereof.
The present invention makes it possible to wrap overlay material around cardboard or similar flat materials with great precision and at a high operating speed. The overlay material extending beyond the cardboard is bent with sharp corners around the edges of the cardboard and is then pressed down flat to the cardboard surface. The setting time of the glue which bonds the overlay to the cardboard is taken into account by holding the overlay briefly to the cardboard. This brief holding of the overlay to the cardboard to achieve good adherence has a particularly favorable effect with stiff overlay materials having relatively large restoring forces. The pressure rolls which are angularly inclined with respect to the direction of motion of the covers during the side edge wrapping step exert a force perpendicular to the cover edge so that the lateral folds are pasted down perpendicular to the direction of travel as well as in the direction to travel.
Another feature of a book cover producing apparatus in accordance with a preferred embodiment of the present invention is the inclusion of uniquely designed turndown mechanisms for folding the overlay material at the corners of the leading and trailing edges of the cover board. These corner turndown mechanisms include elements which are caused to rotate. These rotating elements are provided with a pressure face which corresponds to the area of the overlay material to be turned down. The turndown elements move along the edges of the cover board with rolling contact on the overlay material which extends beyond the side edges of the cover board; this overlay material having previously been folded around the leading and trailing edges of the cover board. The corner turndown mechanisms act on the overlay during the continuous transport of the covers and the elements which act on the leading edge are driven so as to have a circumferential speed which is slower than the linear speed of the advancing cover. The corner turndown elements which act on the overlay material at the corners of the trailing edge are driven, at least momentarily, so as to have a circumferential speed which is faster than the rate of advancement of the cover. The corner turndown elements accomplish an inward shifting of the upper flap of the contacted overlay material at a sharp angle to the edge of the cover simultaneously with the folding in of the overlay to the side edges of the cover board. The corner turndown elements thus contribute to the manufacture of quality covers by eliminating projections, thick spots, cavities, etc., at the corners of the cover. Additionally, the areas to be turned down can be adjusted thereby reliably preventing glue stains on the inside of the cover.
BRIEF DESCRIPTION OF THE DRAWING
The present invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawing wherein like reference numerals refer to like elements in the several FIGURES and in which:
FIGS. 1a and 1b are schematic side elevation views, partly in section, of a preferred embodiment of the present invention;
FIG. 2 is a top plan view of a portion of the apparatus depicted in FIG. 1b;
FIG. 3 is a view, taken along line C-B, of a portion of the apparatus of FIG. 1a;
FIGS. 4, 5 and 6 are partial views, on an enlarged scale, of the apparatus of FIG. 1a depicting sequential steps in the operation of the embodiment of FIG. 1;
FIG. 7 is a view, taken along line A-B of FIG. 1a, of the preferred embodiment of the present invention with components removed in the interest of clarity;
FIG. 8 is a view of the preferred embodiment of FIG. 1a taken along line E-F; and
FIGS. 9a, 9b and 9c are cross-sectional views of the preferred embodiment of the present invention respectively taken along lines G-H, I-K and L-M of FIG. 1b.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawing, a preferred embodiment of apparatus in accordance with the invention as implemented for the manufacture of book covers is disclosed. As used herein the term book cover refers to the two rectangularly shaped flaps, which form the front and back covers of the book, and the central spine which connects these flaps. A book cover will typically be comprised of a cardboard inner member which is covered by means of a paper overlay. Referring to FIG. 1a, a cover board comprised of cardboard, indicated at 1a, is fed onto a table 3 by means of transporters 2 of a conveyor. The overlay material, indicated at 1b, has glue applied to a first side thereof and is thereafter fed into contact with the cover board 1a, at a laminating station, by means of a feed cylinder 4. A pressure roll 6 is positioned above the feed cylinder 4 and biased toward cylinder 4 by means of a spring 5. The pressure roll 6 is mounted on the end of a pivotal shaft and the clearance between the pressure roll and feed cylinder is adjustable by means of an eccentric 7. Feed cylinder 4 and pressure roll 6 are driven at the same speed and will move a cover board 1a initially to the right as the apparatus is shown in FIG. 1a while simultaneously laminating the overlay 1b thereto.
In order to accomplish the face wrapping of the cover; i.e., the folding of the overlay 1b around the four edges of the cover board 1a; the overlay material extending beyond the leading edge of the board is first deflected upwardly with respect to the board leading edge. For this purpose, the apparatus of FIG. 1 employs a lifting rake 8. The lifting rake 8 is comprised of an angular member which extends from and is connected rigidly to a rotatable shaft 9. Shaft 9 is located in the peripheral area of the side portion of feed cylinder 4 and is operated by means of a crank 10. An idler roll 11, which functions as a cam follower, is positioned intermediate the ends of crank 10. Idler roll 11 follows a stationary cam 12. The end of crank 10 disposed away from shaft 9 is biased toward cam 12 by means of spring 13 to insure that the roll 11 will follow cam 12. The cam 12 is shaped and oriented such that the rake 8 will swing upwardly and bend the overlay in the direction shown in FIG. 1a as the laminate leaves the nip of pressure roll 6 and feed cylinder 4. Due to the shape of cam 12 and the continued rotation of feed cylinder 4, the rake 8 will not act on the cover board 1a. The operation of rake 8 may be clearly seen from consideration of FIGS. 1a and 4-6.
Immediately following the laminating station, defined by pressure roll 6 and feed cylinder 4, the cover will be fed to a first wrapping station. The cover, with the overlay material bent upwardly around the leading edge, is driven by cylinder 4 and pressure roll 6 into the wrapping station. The first wrapping station includes a wrapping tool which extends over the width of the cover and comprises a fixed supporting table 18 and a wrapping rail 19. The wrapping rail 19 is supported above table 18, to thereby define a passageway for the book cover, on a transverse rail 21. As may be seen from joint consideration of FIGS. 1a and 3, wrapping rail 19 is biased away from the support rail 21 and toward table 18 by means of springs 20. By insuring the proper spacing between table 18 and rail 19, the portion of the overlay which is bent upwardly by rake 8 will be folded over and pressed down tightly against the upwardly facing side of cover 1a by means of rail 19 as the cover passes under rail 19 on table 18. The transverse support rail 21 is affixed to vertically movable holding blocks 23. The holding blocks 23 are supported on table 18 by means of compression springs 28 and are provided with through holes which receive a shaft 22. The holding blocks 23 are urged downwardly against the force of springs 28 by means of clamping bars 27. Clamping bars 27 are capable of pivotal motion about a transverse shaft 26 which is supported in the side frames 25 of the apparatus. The clamping bars 27 are held, at the ends thereof opposite to shaft 26, by catches 31 through the action of compression springs 32. Eccentric cams 24 are pinned to shaft 22 at the opposite sides of the blocks 23. The movement of blocks 23 is constrained to the vertical direction by means of guide rail 33, also mounted on the side frames 25, and a lifting frame 34. As will be explained in greater detail below, the lifting frame 34 undergoes vertical reciprocal motion through the supporting table 18. The size of the passageway between rail 19 and table 18 may be varied by rotation of shaft 22, by means not shown in the drawing, whereby the blocks 23 with move vertically with respect to clamping bars 27 as a function of the attitude of the cams 24.
The laminated cover board and overlay, with the overlay folded around the leading edge of the cover board and secured to the upwardly facing side thereof, will be engaged by a transport system including lower and upper rolls 40 and 41 after passage over table 18. The lower transport roll 40 is mounted in the side frames 25 on a shaft 42. A pinion 43 is keyed to shaft 42 and is engaged by a gear segment 45 which rotates about a shaft 44. Segment 45 is provided with an extension 47 which carries an idler roll 46 which functions as a cam follower. Idler roll 46 is in contact with a cam wheel 48 which is attached to the main drive shaft 51 of the apparatus. The movement of cam wheel 48 in response to rotation of shaft 51 imparts, via the idler roll 46 and segment 45, an oscillatory motion to pinion 43 and thus to lower transport roll 40. Thus, the roll 40 will rotate alternately in the clockwise and counterclockwise directions. As may be seen from FIG. 7, the upper transport roll 41 is driven with the same rotational motion as roll 40 through a pair of pinions 49 and a jointed shaft 50.
A second cam wheel 54 is affixed to main drive shaft 51 and is engaged by a follower roll 56 located at the end of a crank arm 55. The crank arm 55 is pinned to shaft 44 whereby the relative motion between cam 54 and follower 56 will result in the rotation of shaft 44. The motion of the shaft 44 is transmitted, via a clamping member 70, to a lift rod 59 which is linked, at its upper end, to an arm 58 which supports the upper transport roll 41. The arm 58 is mounted for rotation about pivot shaft 57 and thus roll 41 is capable of swinging into contact with the cover and acting to clamp the cover against lower transport roll 40. A compression spring 60 is positioned intermediate the clamping member 56 and the lifter rod 59 and biases roll 41 away from roll 40.
The covers passing over table 18 are engaged by rolls 40 and 41 and are moved to the right as the apparatus is shown in FIG. 1a for a distance determined by the size of the various components of the apparatus. This "forward" movement is controlled so that the cover will clear the first wrapping station. By means of the cooperation between cam wheel 48 and follower roll 46, when a limit of motion in the first direction is reached, the direction of rotation of the rolls 40 and 41 will be reversed and the cover will be fed back toward the first wrapping station. Before reintroduction of the cover into the wrapping tool, the overlay material extending beyond the rear edge of the cover board is lifted upwardly and folded around the trailing edge of the cover board by means of a lifting rod 65 which is carried by the previously mentioned lifting frame 34. Vertical motion of the lifting frame 34 in synchronism with the motion of the cover is achieved through the use of a cam wheel 66 which is also keyed to the main drive shaft 51. Cam 66 is engaged by a follower roll 67 attached to a first end of a swivel crank 68, 68' mounted on frame 25. The free end of crank 68 is attached to lifting frame 34 by means of a connecting rod mechanism 69.
The sequence of operations described above, and particularly the wrapping of the overlay around the forward edge of the cover board and subsequently around the trailing edge of the cover board may be seen from consideration of FIGS. 1a, 4, 5 and 6. In order to insure a trouble-free feed of the cover boards and the overlays laminated thereto, as may be seen from FIG. 4, the wrapping rail 19 is provided with a lead-in ramp 19a at a first side and an in-feed ramp 19b at the other side. The introduction of the covers into the wrapping station from both sides in accordance with the present invention, guarantees that the overlay material is drawn tightly around the board edges and is pasted down flat against the upper surface of the cover board.
After the wrapping of the overlay around the rearwardly disposed edge of the cover board has been completed, the clamping bars 27 are raised by means of the lifting frame 34 which continues its upward movement as the cover passes back under the lifting rod 65. Raising of clamping bars 27 enables the passageway between table 18 and wrapping rail 19 to enlarge through the action of the springs 28 (FIG. 3). Accordingly, when the direction of the transport rolls 40 and 41 is reversed, the cover will be again conveyed to the right, as the apparatus is shown in FIG. 1a, without interference from the wrapping tool.
The transport system following the wrapping station is comprised of an endless toothed feed belt 78 which passes about guide rolls 76 and 77; guide roll 76 being coaxial with transport roll 40. The transport system also comprises a pair of support rails 84 which support the covers at either side as they are carried along by belt 78 after being released from transport rolls 40 and 41. The guide roll 76 rotates freely on shaft 42 while guide roll 77 is keyed to a rotatable shaft 82. A pulley 81 is also affixed to shaft 82. Rotation of shaft 82, and thus the driving of belt 78, is accomplished from the main drive shaft 51 by means of a further toothed belt 83 which engages the aforementioned pulley 81 and a further pulley keyed to shaft 51. In order to prevent engagement of the covers by belt 78 in the region of the transport rolls 40 and 41, the conveyor belt 78 is located below the plane of the transport rolls.
In the manufacture of a quality book cover, in the interest of avoiding projections, thick spots and cavities at the corners of the covers, it is necessary that the corners of the overlay be turned down prior to wrapping the overlay around the side edges of the cover board. The apparatus for producing this corner turndown at the leading edge, as depicted in FIGS. 1a and 8, consists a a pair of support elements 91 which are freely rotatable on bushings 94. The bushings 94 rotate about a shaft 92 which is mounted in the side frames 25. The rotating support elements 91 each carry a corner turndown element 93 which is positioned such as to engage the overlay at the corners of the leading edge of the cover. The turndown elements 93 are bolted to the inside of the rotating elements 91 and have a triangular pressure surface which is curved so as to conform with the path of travel of the advancing cover. The elements 93 fold the tabs of the overlay material which extend outwardly past the side edges of the cover board at a sharp angle to the edges of the cover and immediately thereafter press the folded overlay material against the cover board by means of a rolling contact at the edge of the board. This sharp shifting or folding of the overlay material is accomplished by causing the elements 93 to rotate at a circumferential speed which is lower than the speed of linear motion of the covers. Motion is imparted to the elements 91 by means of a chain drive which includes a sprocket 100 attached to each of rotating support elements 91, chains 99, further sprockets 98 and a gear train 97 which drives sprockets 98. The element rotation of the support elements 91 for the corner turndown elements 93 is synchronized with the feed of the covers by means of a further chain drive, including sprocket 96. The details of this further chain drive have been omitted from FIG. 1a in the interest of facilitating understanding of the invention.
In order to permit the apparatus to accomodate book covers of different widths, the position of the rotating support elements 91 on shaft 92 is made adjustable through the use of "pulling plates" 106. The "pulling plates" 106 engage grooves 91a in the support elements 91 and are coupled to further "pulling plates" 110 which engage the grooves 111a of collars 111 affixed to the chain sprocket 98. The sprockets 98 are mounted on a rotatable shaft 112 which is driven by means of the gear train 97. The supporting blocks 107 each include a portion 105 which defines a nut which engages an adjusting spindle 108. Accordingly, by rotating spindle 108, the spacing between the rotating support elements 91 may be varied.
In order to adjust the apparatus to accomodate book covers of varying lengths, the rear edge of the covers is utilized as the reference edge. Thus, the feed cylinder 4 will be rotated about its axis and the forward turndown elements 93 are adjusted relative to trailing edge turndown elements 117, which will be described below, by rotating the support elements 91 about shaft 92. In order to accomodate book covers of varying thickness, the corner turndown elements 93 may be radially adjusted, by means not shown, with respect to the rotating support elements 91.
In order to achieve corner turndown at the corners of the trailing edge of a cover being fed to the right as the apparatus is shown in FIG. 1a, further corner turndown elements 117 are located at both sides of the cover. The turndown elements 117 are mounted on rotating supports 116 as can best be seen from FIG. 8. The rotating supports 116 are affixed to the bushings 94 and, accordingly, have a fixed rotational relationship with regard to shaft 92. In order to achieve a shifting of the tabs in the same manner as described above with regard to the corners of the forward edge of the cover; i.e., in the direction of travel and towards the edge of the board; it is necessary that the corner turndown elements 117 rotate momentarily at a speed which is faster than the linear transport rate of the covers. In order to accomplish the foregoing, a drive system employing a crank slide, of known design which is indicated generally at 118, is employed. The bushings 94, and thus the rotating supports 116 for the turndown elements 117, are driven from the main drive by means of a chain which engages sprocket 119 and the requisite variation in speed of movement of the turndown elements 117 is achieved by coupling sprocket 119 to shaft 92 via the aforementioned crank slide 118 and a feather key connection 120. Because of the momentary increase in the speed of rotation of the supports 116, produced by the crank slide and feather key connection, the rear corner turndown element 117 "overtake" the overlay at the rear corners of the cover and shift the extending tabs of the overlay material at a sharp angle to the edge of the cover and thereafter press the overlay material which has extended beyond the board against the cover board by means of a rolling contact at the edge of the moving cover board. This action is analogous to the wrapping of the forward corners since there is a difference in speed between the turndown elements and the moving cover.
Because of the triangular shape of the corner turndown elements 93 and 117, which can be adapted to a wide variety of sizes of areas to be turned down, glue stains are avoided. A change in the effective pressure area of the corner turndown elements can be made by adjustment thereof relative to the direction of travel of their rotating supports.
With reference now to FIGS. 1b and 9, after completion of the front and rear edge wrapping and the corner turndowns, the covers are fed to a side wrapping station by means of a drive projection 79 on belt 78 (see FIG. 1a). In the side wrapping station the covers are in part supported by a table 130. The overlay material extending beyond the side edges of the board is brought into the vertical position and thereafter pressed and held against the board edges by lifting strips 131 (FIGS. 1a and 9a). The lifting strips 131 are located in U-shaped guide profiles 132 in the support rails 84 and are resiliently urged against the edges of the cover by means of springs 133. The lifting strips 131 are installed on the sides of the path of travel of the cover and include a running surface which starts below the transport plane and rises in the direction of travel. As may be seen from FIG. 9a, the lifting strips also include a running surface 131a which slopes toward the cover.
For format adjustment, the support rails 84 are bolted to carrier blocks 134 which are provided with threaded through holes engaged by adjustment spindles 135. The adjustment spindles 135, in turn, are supported in the side frames 25. A series of freely rotatable support rolls 136 are positioned so as to support the edge areas of the covers. Counter-pressure rolls 138, rotatably mounted in swivel bearings 137, act from above on the edge areas of the covers. The rolls 138 are biased by springs 144 supported in stop members 141; the spring force being transmitted by swivel bearings 137. The amount of pressure exerted on the cover by rolls 138 is adjustable by means of rotating the swivel bearings 137 around freely rotatable shafts 140 extending from carriers 139. The carriers 139, as may be seen from FIG. 9b, engage a threaded section of an adjustment spindle 142 which is supported in the side frames 25. Thus, the format adjustment will be accomplished by rotation of spindles 135 and 142 while a height adjustment for cover materials of various thickness can be made by rotating an eccentric shaft 143 which extends through the carriers 139 and is supported by the side frame 125.
Referring jointly to FIGS. 1b and 2, after the overlay material extending beyond the side edges of the board has been lifted, the cover is transported by means of driven transport rolls 147 and counter-pressure rolls 148; rolls 148 being supported in the same manner as pressure rolls 138. In addition, further support rolls 136 are provided for the edge areas of the covers while the central portion of the covers rests on the support table 130.
Turndown rails 149 are mounted so as to form extensions of strips 131 on both sides of the cover. Turndown rails 149 are mounted from carriers 139 and have guide projections 149a which extend downwardly to be engaged in the guide profiles 132. The rails 84 have a widened support surface 132a in the area of the turndown rails 149. This support surface 132a, along with the bottom of the turndown rails 149 and the guide projections 149a, forms a guide slot which accepts the edges of the covers. This guide slot expands inwardly so as to become wider toward the cover. The turndown rails 149 are also provided with a ramp portion 149b which begins at the lifting strips 131 and extends inwardly across the edge of the cover as may be seen from FIG. 2. The turndown rails 149, accordingly, cause the overlay material to be bent back around the board but do not cause the overlay to be pressed against the board from above.
To press the overlay material down onto the board, angularly oriented pressure rolls 150 are located adjacent the ends of the turndown rails 149 and directly over a pair of the transport rolls 147. The pressure rolls 150 are driven in the direction of travel of the covers. Accordingly, components of force both longitudinally of and perpendicularly to the edges of the covers are exerted on the overlays as they are pressed downwardly so as to adhesively secure them to the cover board.
The pressure rolls 150 are mounted from frames 151 which, as can be seen from joint consideration of FIGS. 2 and 9c, are in turn mounted from the carriers 139. The frames 151 each include a pair of support frames 152 and 153 which support drive shaft 155 on which the pressure role 150 is mounted. The shafts 155 are coupled to drive pinions 154 which are caused to rotate by means not shown.
As a final step, after passing the pressure rolls 150, the covers are fed between a pair of driven pressure rolls 156 wherein they are subjected to a constant pressure which extends over the entire width of the covers.
While a preferred embodiment has been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation. | An overlay is applied to a substrate, for example in the manufacture of book covers, by serially wrapping the overlay around a first pair of oppositely disposed edges of the substrate, folding the corners of the overlay into the substrate and wrapping the overlay around the two remaining edges of the substrate. The first wrapping of the overlay around a pair of edges of the substrate is accomplished by feeding the substrate with the overlay adhered thereto through a wrapping station alternately in opposite directions and deflecting the overhanging portion of the substrate at the leading edge out of the path of motion so that these overhanging portions may be engaged by a wrapping tool. | 1 |
This application is a continuation of application Ser. No. 07/212,959, filed on June 27, 1988, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a thermoplastic elastomer composition which is rich in flexibility and excellent in balance of oil resistance, low-temperature resistance and resistance to permeation of Freon gas (air conditioning refrigerant) and the like, particularly to a thermoplastic elastomer suitable for hose materials.
2. Description of Prior Art
As a refrigerant for air-conditioner in automobiles, FREON gas R-12 (CCl 2 F 2 ) has heretofore been generally used. However, recently, it has been clarified that FREON gas R-12 breaks the ozonosphere in the upper atmosphere and regulation of use of FREON gas R-12 is being internationally strengthened.
As a countermeasure, therefor, the change of the refrigerant from FREON gas R-12 to FREON gas R-22 (CHClF 2 ) is in progress. However, FREON gas R-22 has a greater permeability to hose materials consisting of elastomers than FREON gas R-12 and hence conventional vulcanized rubber materials consisting essentially of a nitrile rubber used for FREON gas R-12 are insufficient in resistance to permeation of FREON gas R-22.
Therefore, use of a metal tube for FREON gas R-22 is taken into consideration; however, this has such problems that noise is made by vibration during the running of a car and the degree of freedom of piping layout in a bonnet is reduced.
Also, the use of resin hoses consisting essentially of nylon is under consideration; however, there are problems similar to those in the case of use of a metal tube. Therefore, materials having excellent resistance to permeation of FREON gas R-22 have been desired.
SUMMARY OF THE INVENTION
The present inventors have made extensive research on the development of materials which are rich in flexibility, excellent in resistance to permeation of FREON gas R-22 and also excellent in low-temperature resistance which is required for FREON gas hose.
According to this invention, there is provided a thermoplastic elastomer composition suitable as a hose material which is excellent in resistance to permeation of FREON gases, particularly FREON gas R-22, and has good oil resistance and low-temperature resistance, and which comprises 25-95% by weight of a polyamide and 75-5% by weight of a halogenated butyl rubber, a chlorosulfonated polyethylene or both of the two.
This invention also provides a FREON gas hose wherein the layer to be contacted with FREON gas is made of the above thermoplastic elastomer composition in which the rubber component has been partially crosslinked.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sketch of a sample of the FREON gas hose of this invention in which 1 refers to an inner tube layer, 2 to a braided reinforcing layer and 3 to an outer tube layer. FIG. 2 is a sketch of another sample of the FREON gas hose of this invention, in which 21 refers to an inner tube layer and 22 to an outer tube layer. FIG. 3 is a sketch of a further sample of the FREON gas hose of this invention, in which 31 refers to the innermost tube layer, 32 to a second inner tube layer, 33 to a braided reinforcing layer and 34 to an outer tube layer. FIG. 4 shows a FREON gas-permeation tester, in which 41 refers to a stainless steel cup, 42 to a stainless steel lid, 43 to a punching board having a permeation area of 1.16 cm 2 , 44 to a test piece of 2 mm in thickness, and 45 to a bolt and 46 to a nut.
The polyamide used in this invention includes homopolymer and copolymers of amide such as nylon 6, nylon 66, nylon 11, nylon 12, nylon 6-9, nylon 6-10, nylon 4-6 and the like; amide resins which are copolymers of amide with other kinds of monomers; polyamide elastomers synthesized by condensation between polyether and polyamide. Among these polyamides, preferred are rubber component and have relatively low melting points.
The halogenated butyl rubber used in this invention includes products of chlorination or bromination of butyl rubbers obtained by cationic polymerization of isobutylene or copolymerization of isobutylene with a small amount of isoprene.
The chlorosulfonated polyethylene includes vulcanizable elastomers which are known in the trade name of HYPALON and have a chlorine content of about 25-45% by weight, preferably 25-40% by weight.
In this invention, the halogenated butyl rubber and/or the chlorosulfonated polyethylene are used, and the use of the former alone is preferred.
In this invention, a crosslinking agent may optionally be used, and this crosslinking agent may be any one usually used in the vulcanization of the halogenated butyl rubber and the chlorosulfonated polyethylene. It includes methylolated alkylphenol-formaldehyde resins, brominated alkylphenol formaldehyde resins, morpholine disulfide, tetramethylthiuram disulfide, sulfur, diamines, organic peroxides and the like. If necessary, co-crosslinking agents may be used.
In the present composition, the proportion of the polyamide is 25-95% by weight, preferably 30-80% by weight and more preferably 40-70% by weight, based on the total weight of all the polymer components. When the polyamide proportion exceeds 95% by weight, the composition is poor in flexibility, and when it is less than 25% by weight, the composition has too low a strength to use as a thermoplastic elastomer in a FREON gas hose, and is inferior in oil resistance and processability.
In the present composition, the proportion of the halogenated butyl rubber and/or the chlorosulfonated polyethylene is 75-5% by weight, preferably 70-20% by weight and more preferably 60-30% by weight, based on the total weight of all the polymer components.
The polyamide and the halogenated butyl rubber and/or the chlorosulfonated polyethylene can be mixed by any mixing method which can be usually used in the production of a compound comprising a resin and a rubber. Specifically, the predetermined amount of the polyamide and the predetermined amount of the halogenated butyl rubber and/or the chlorosulfonated polyethylene are melt-mixed by means of a roll mill, an extruder or a closed type mixer such as Banbury mixer, pressure kneader or the like. In this method, the rubber can be crosslinked by adding a crosslinking agent as mentioned above. The amount of the crosslinking agent added is preferably 0.1-10 parts by weight per 100 parts by weight of the halogenated butyl rubber and/or the chlorosulfonated polyethylene.
Also, if necessary, there may be compounded softening agents and plasticizers for rubber; fillers such as carbon black, white carbon, clay, talc, calcium carbonate and the like; antioxidants; heat stabilizers; ultraviolet absorbers; coloring agents; processing aids; lubricants and the like, which are all known as additives and compounding agents for rubber, in appropriate amounts. Moreover, a part of the halogenated butyl rubber may be replaced by a butyl rubber or chlorinated polyethylene.
When the thermoplastic elastomer composition of this invention is used in a FREON gas hose, the thermoplastic elastomer composition may be used alone or in combination with a braid. Alternative, the thermoplastic elastomer composition may be used as an inner tube layer together with a vulcanized compound of chloroprene rubber or ethylene-propylene rubber which is broadly used as an outer tube layer to form a composite hose. In this case, other thermoplastic elastomer compositions, for example, polypropylene/ethylenepropylene copolymer thermoplastic elastomer, polyesterbased thermoplastic elastomer and the like may be used as the outer tube layer. In addition, the thermoplastic elastomer composition of this invention may be formed into a thin film which may then be bonded as a layer to be contacted with FREON gas to other vulcanized rubber composition or other thermoplastic elastomer tube.
The FREON gas hose of this invention can be produced in a conventional manner. A single tube of the thermoplastic elastomer composition of this invention can be used as the FREON gas hose, and the thermoplastic elastomer of this invention can also be formed into the innermost tube of a composite FREON gas hose.
For example, in FIG. 1 which is a sketch of a sample of the FREON gas hose of this invention, 1 refers to an inner tube layer made of the thermoplastic elastomer composition, 2 to a braided reinforcing layer and 3 to an outer tube layer. In this sample, the rubber material for forming the outer tube layer is not critical, though an ethylene-propylene rubber or chloroprene rubber which has good weather resistance is preferred. The braided reinforcing layer 2 may be made of any fiber such as nylon, polyester, rayon or the like. In FIG. 2, 21 refers to an inner tube layer made of the thermoplastic elastomer composition of this invention, and 22 to an outer tube layer, for which not only vulcanized rubbers but also various weather resistant thermoplastic elastomers may be used. Specifically, polyolefin-based thermoplastic elastomers and polyester-based thermoplastic elastomers are included in the weather resistant thermoplastic elastomers.
The inner and outer diameters of the FREON gas hose of this invention and the wall thicknesses of the inner tube layer and the outer tube layer may be varied depending upon the conditions under which the FREON gas hose is used. As a matter of course, this invention is not limited to the above-mentioned embodiments, and includes other embodiments in which the thermoplastic elastomer composition of this invention is used as the innermost tube layer, such as a three-layer hose in which the innermost tube layer is made of the thermoplastic elastomer composition of this invention, the second inner tube layer is made of a nitrile rubber, chlorosulfonated polyethylene rubber, (halogenated)butyl rubber or the like and the outer tube layer is as mentioned above, or a four-layer hose as shown in FIG. 3 in which 31 refers to the innermost tube layer, 32 to a second inner(intermediate) tube layer, 33 to a braided reinforcing layer and 34 to the outer tube layer made of an ethylene-propylene rubber, a chloroprene rubber or the like, or other various FREON gas hoses.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention is explained in more detail below referring to Examples which are by way of illustration and not by way of limitation.
EXAMPLE 1
In a closed type mixer (HAAKE RHEOCORD SYSTEM 40 RHEOMIX MIXER 300 manufactured by Haake Buchler), 50 parts by weight of nylon 11 (RILSAN BENSNO, a trade name of TORAY INDUSTRIES, INC.) was melt-mixed with 50 parts by weight of chlorinated butyl rubber (EXXON CHLOROBUTYL 1068) at 200° C. for 10 minutes, and thereafter, the resulting mixture was pressed by an electrically heated press at a pressure of 100 kg/cm 2 for 5 minutes to form a sheet having a thickness of 2 mm, a length of 20 cm and a width of 20 cm.
This sheet was subjected to tensile test, oil-resistance test and Gehmann torsional test (low temperature resistance) according to JIS K6301. FREON gas permeability was evaluated by introducing FREON gas R-22 into a stainless steel cup as shown in FIG. 4, putting a circular test piece on the cup as shown in FIG. 4, lidding the cup with a stainless steel lid, thereafter placing the cup in a constant temperature vessel at 50° C., checking the change of the weight with time and determining the amount of FREON gas permeated per unit time per unit area. Flexibility was evaluated by use of JIS A hardness and Shore D hardness. The results obtained are shown in Table 1.
EXAMPLE 2
The same procedure as in Example 1 was repeated, except that 2.0 parts by weight of 4,4'-methylenebiscyclohexylamine and 5.0 parts by weight of magnesium oxide were added as a crosslinking agent in the melt-mixing of 50 parts by weight of nylon 11 with 50 parts by weight of chlorinated butyl rubber, to prepare a test piece, and the test piece was evaluated in the same manner as in Example 1 to obtain the results shown in Table 1.
EXAMPLE 3
The same procedure as in Example 2 was repeated, except that the amounts of the nylon 11 and the chlorinated butyl rubber were changed to 70 parts by weight and 30 parts by weight, respectively, to obtain the results shown in Table 1.
EXAMPLE 4
The same procedure as in Example 2 was repeated, except that the amounts of the nylon 11 and the chlorinated butyl rubber were changed to 40 parts by weight and 60 parts by weight, respectively, to obtain the results shown in Table 1.
EXAMPLE 5
The same procedure as in Example 2 was repeated, except that nylon 12 (RILSAN AESNO, a trade name of TORAY INDUSTRIES, INC). was substituted for the nylon 11 and 1.5 parts by weight of an alkylphenol-formaldehyde resin was used as the crosslinking agent, to obtain the results shown in Table 1.
EXAMPLE 6
The same procedure as in Example 5 was repeated, except that 35 parts by weight of chlorinated butyl a trade name of Japan Synthetic Rubber Co., Ltd.) were substituted for the chlorinated butyl rubber, to obtain the results shown in Table 1.
COMPARATIVE EXAMPLE 1
The same procedure as in Example 1 was repeated, except that the nylon 11 alone was used, to obtain the results shown in Table 1.
COMPARATIVE EXAMPLE 2
The same procedure as in Example 2 was repeated, except that the amounts of the nylon 11 and the chlorinated butyl rubber were changed to 20 parts by weight and 80 parts by weight, respectively, to obtain the results shown in Table 1.
COMPARATIVE EXAMPLE 3
The same procedure as in Example 2 was repeated, except that a vulcanized sheet of an acrylonitrile-butadiene rubber (NBR) which is a conventional material for a FREON gas R-12 hose was substituted for the test piece, to obtain the results shown in Table 1. In this case, the NBR vulcanized sheet was prepared according to the recipe shown in Table 2.
COMPARATIVE EXAMPLE 4
The same procedure as in Example 1 was repeated, except that 50 parts by weight of an acrylonitrilebutadiene rubber (JSR N230S, bound acrylonitrile content: 35% by weight, a product of Japan Synthetic Rubber Co., Ltd.) was substituted for the chlorinated butyl rubber and the melt-mixing was conducted in the presence of 1.0 part by weight of 1,3-bis(t-butylperoxyisopropyl)benzene and 3.0 parts by weight of N,N'-phenylenebismaleimide as a crosslinking agent, to obtain the results shown in Table 1.
EXAMPLE 7
The same procedure as in Example 1 was repeated, except that 50 parts by weight of chlorosulfonated polyethylene (HYPALON 40, a trade name of Showa Neoprene Co., Ltd.) was substituted for the chlorinated butyl rubber, to obtain the results shown in Table 3.
EXAMPLE 8
The same procedure as in Example 7 was repeated, except that the chlorosulfonated polyethylene was previously kneaded with 4 parts by weight of magnesium oxide, 3 parts by weight of pentaerythritol, 1.0 part by weight of sulfur and 2.0 parts by weight of tetramethylthiuram disulfide (TT), per 100 parts by weight of the chlorosulfonated polyethylene, on a twin roll prior to the melt-mixing, to obtain the results shown in Table 3.
EXAMPLE 9
The same procedure as in Example 8 was repeated, except that the amounts of the nylon 11 and the chlorosulfonated polyethylene were changed to 70 parts by weight and 30 parts by weight, respectively, to obtain the results shown in Table 3.
EXAMPLE 10
The same procedure as in Example 8 was repeated, except that the amounts of the nylon 11 and the chlorosulfonated polyethylene were changed to 40 parts by weight and 60 parts by weight, respectively, to obtain the results shown in Table 3.
EXAMPLE 11
The same procedure as in Example 8 was repeated, except that nylon 12 (RILSAN AESNO,,a trade name of TORAY INDUSTRIES, INC.) was substituted for the nylon 11, to obtain the results shown in Table 3.
EXAMPLE 12
The same procedure as in Example 11 was repeated, except that a mixture of 40 parts by weight of chlorosulfonated polyethylene and 10 parts by weight of chlorinated polyethylene (Elasrene 351A, a trade name of Showa Denko K.K.) was substituted for the chlorosulfonated polyethylene, to obtain the results shown in Table 3.
COMPARATIVE EXAMPLE 5
The same procedure as in Example 8 was repeated, except that the amounts of the nylon 11 and the chlorosulfonated polyethylene were changed to 20 parts by weight and 80 parts by weight, respectively, to obtain the results shown in Table 3.
COMPARATIVE EXAMPLE 6
A vulcanized sheet of chlorosulfonated polyethylene was prepared according to the recipe shown in Table 4 and subjected to evaluation in the same manner as in Example 1, to obtain the results shown in Table 3.
EXAMPLE 13
The same procedure as in Example 1 was repeated, except that a 3-liter high temperature kneader manufactured by Moriyama Seisakusho was substituted for the closed type mixer and the melt-mixing was conducted at 210° C. for 10 minutes in the presence of a crosslinking agent consisting of 0.5 part by weight of 1,3-bis(t-butylperoxyisopropyl)benzene (PERKADOX 14/40, a trade name of Kayaku Noury) and 1.0 part by weight of N,N'-phenylenedimaleimide (VULNOC PM, a trade name of Ohuchi Shinko Chemical Industry Co., Ltd.), to obtain the results shown in Table 3.
In addition, hose-extrudability was evaluated by extruding the composition into a hose by means of a 55-mm monoaxial extruder manufactured by Nakatani with a die for tube having an inner diameter of 12 mm and a wall thickness of 1 mm at 200° C. and observing the appearance of the resulting hose. The results obtained are also shown in Table 3.
EXAMPLE 14
The same procedure as in Example 13 was repeated, except that the amounts of the nylon 11 and the halogenated butyl rubber were changed to 30 parts by weight and 70 parts by weight, respectively, to obtain the results shown in Table 3.
TABLE 1__________________________________________________________________________ Example Comparative Example 1 2 3 4 5 6 1 2 3 4__________________________________________________________________________HardnessJIS A 99 99 100 93 98 98 100 87 85 97Shore D 53 55 57 38 50 49 81 29 -- 46Tensile test100% tension -- 164 185 -- -- -- 350 -- 73 140(kgf/cm.sup.2)Tensile strength 130 193 210 104 137 118 420 42 185 185(kgf/cm.sup.2)Elongation (%) 15 155 160 55 80 70 350 95 350 220Oil resistance (JIS oil 9.4 11.0 8.5 12.1 8.2 9.0 3.1 20.1 8.0 7.0No. 3, 100° C. ×70 hrs.)ΔV (%)Low-temp. resistance(Gehmann tortionaltest)T.sub.5 (° C.) -57 <-70 <-70 -55 -67 -57 un- -49 -10 -27T.sub.10 (°C.) -67 <-70 <-70 <-70 <-70 -67 measur- -57 -14 -31 ableFreon gas perme- 0.03 0.03 0.02 0.05 0.01 0.02 0.01 0.50 34.5 20.1ability (Freon gasR-22, 50° C.)ΔW (mm · g/cm.sup.2 · day)__________________________________________________________________________
TABLE 2______________________________________Compounding Recipe (part by weight)______________________________________JSR N222L 100MT brack 20SRF black 80Zinc oxide 5Stearic acid 2Polyester-based plasticizer 10Antioxidant 1Sulfur 2Vulcanization accelerator 1.8Vulcanization ConditionsPress-vulcanized at 150° C. for 20 minutes______________________________________
TABLE 3__________________________________________________________________________ Comparative Example Example 7 8 9 10 11 12 13 14 5 6__________________________________________________________________________HardnessJIS A 98 98 100 94 97 97 90 84 77 79Shore D 48 50 56 37 48 47 33 29 21 23Tensile test100% tension (kgf/cm.sup.2) -- 121 150 -- 116 110 -- -- -- 72Tensile strength (kgf/cm.sup.2) 98 138 182 97 135 127 84 70 39 213Elongation (%) 90 140 170 95 160 130 55 80 450 260Oil resistance (JIS No. 3, 21 17 11.5 30 18 20 10.3 26.2 120 23100° C. × 70 hrs)ΔV (%)Freon gas permeability 0.07 0.06 0.03 0.15 0.06 0.09 0.04 0.10 unmeasurable 1.21(Freon gas R-22, 50° C.)ΔW (mm · g/cm.sup.2 · day)Low-temp. resistance -- -- -- -- -- -- -48 -50 -- --(Gehmann tortional test)T.sub.10 (°C.)Appearance of extruded hose -- -- -- -- -- -- Good Good -- --__________________________________________________________________________ Note: In Comparative Example 5, the Freon gas permeability was unmeasurable because T.sub.B was too small and the hose was broken during the measurement.
TABLE 4______________________________________Compounding Recipe (part by weight)______________________________________Hypalon 40 100Magnesium oxide 4Pentaerythritol 3MT black 50Hard clay 20Polyester-based plasticizer 10Sulfur 1Vulcanization accelerator 2.5Vulcanization ConditionsPress-vulcanized at 165° C. for, 40 minutes.______________________________________ | A thermoplastic elastomer composition which comprises 25-95% by weight of a polyamide and 75-5% by weight of a halogenated butyl rubber, a chlorosulfonated polyethylene or both thereof. Said composition is excellent in resistance to Freon gas permeation and has good oil resistance and low-temperature resistance. A hose wherein the layer to be contacted with a gas is made of the above thermoplastic elastomer composition is suitable as a Freon gas R-22 hose. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to an electrolyte useful for a nonaqueous battery such as a calcium ion battery and a nonaqueous battery containing the electrolyte.
BACKGROUND OF THE INVENTION
[0002] A lithium ion battery has been used practically as a battery having high energy density. As an active material having a high energy density as great as lithium, attention is being paid to calcium and magnesium.
[0003] However, there are few calcium salts and magnesium salts soluble in an organic solvent. Regarding calcium salts, only calcium perchlorate has been studied (J. Electrochem. Soc. Vol. 138, pp. 3356-3545 (1991), D. Surbach, R. Skaletsky and Y. Gofer, “The Electrochemical Behavior of Calcium Electrodes in a Few Organic Electrolytes”).
[0004] A perchlorate is the most stable among chlorates (oxygen acid chloride). Some perchlorates, however, explode by high heat or shock. There also is a risk of an explosion when the perchlorate is heated or is ground in the presence of a combustible material.
[0005] Calcium perchlorate is one of the perchlorates having a characteristic as described above. Therefore, there is a great obstacle to using it as an electrolyte for a battery because of the risk involved. A calcium salt which is capable of being handled safely and of being dissolved in an organic solvent has been looked for use in an electrolyte for a calcium ion battery.
OBJECT OF THE INVENTION
[0006] An object of the present invention is to provide an electrolyte for a nonaqueous battery such as a calcium ion battery and a nonaqueous battery comprising the electrolyte.
SUMMARY OF THE INVENTION
[0007] The present invention is characterized by comprising an electrolyte including calcium bistrifluoromethanesulfonimide [Ca((CF 3 SO 2 ) 2 N) 2]
DETAILED EXPLANATION OF THE INVENTION
[0008] In Japanese Patent Laid-open publication No. 11-209338, calcium bistrifluoromethanesulfonimide is prepared by a reaction of calcium hydroxide and triethylammonium bistrifluoromethanesulfonimide. The publication describes that sulfonimide compounds are useful as a Lewis acid catalyst and ion conductive material in a field of organic synthesis and electrolytes and the like. However, there is no disclosure in the publication that calcium bistrifluoromethanesulfonimide is soluble in an organic solvent.
[0009] The present invention is based on the discovery by the inventors that calcium bistrifluoromethanesulfonimide is soluble in an organic solvent and has a conductivity of 10 −3 Scm −1 which is sufficient for an electrolyte of a battery.
[0010] The electrolyte for a nonaqueous battery of the present invention is a solution of calcium bistrifluoromethanesulfonimide in an organic solvent and/or a molten salt having a melting point of not greater than 60° C.
[0011] The electrolyte of the present invention can be used for a nonaqueous battery including a calcium ion primary battery, a calcium ion secondary battery, and the like.
[0012] As the organic solvent in which calcium bistrifluoromethanesulfonimide can be dissolved, cyclic carbonates, chain carbonates, cyclic ethers, chain ethers, cyclic esters, chain esters, and the like, can be illustrated. They can be used alone or in combinations thereof.
[0013] As the cyclic carbonates, ethylene carbonate (EC), propylene carbonate (PC), butylene carbonate (BC), trifluoropropylene carbonate (TFPC), fluoroethylene carbonate (FEC), and the like, can be illustrated. As the chain carbonates, dimethyl carbonate (DMC), diethyl carbonate (DEC), methylethyl carbonate (MEC), and the like, can be illustrated. As the cyclic ethers, sulfolane(SL), tetrahydrofuran (THF), crown ether (12-crown 4, 15-crown 5,18-crown 6), and the like, can be illustrated. As the chain ethers, dimethoxyethane (DME), ethoxymethoxyethane (EME), diethoxyethane (DEE), diglyme, triglyme, tetraglyme, and the like can be illustrated. As the cyclic esters, γ-butyrolactone (γ-BL), valerolactone (VL), angelicalactone (AL), and the like, can be illustrated. As the chain esters, methyl formate (MF), methyl acetate (MA), methyl propionate (MP) and the like, can be illustrated.
[0014] As the molten salt having a melting point of not greater than 60° C., a salt comprising a cation selected from the group consisting of ammonium, imidazolium, pyrazolium, triazolium, thiazolium, oxazolium, pyridinium, pyridazinium, pyrimidinium and pyrazinium, and an anion selected from BR 4 − , PR 6 − , RSO 3 − , (RSO 2 ) 2 N − and (RSO 2 ) 3 C − (wherein R is alkyl or aryl containing halogen, CF 3 , C 2 F 5 , or other electron attractive group) can be used. Concretely, as the ammonium salt, trimethylpropylammonium-bis (trifluoromethanesulfonyl) imide (TMPA-TFSI), as the imidazolium salt, 1-ethyl-3-methylimidazolium-2,2,2-trifluoro-N-(trifluoronethylslfonyl)acetamide, as the pyrazolium salt, 1,2-dimethyl-4-fluoropyrazolium-tetrafluoroborate, and as the pyridinium salt, 1-ethylpyridinium-2,2,2-trifluoro-N-(trifluoromethylsulfonyl)acetamide, can be illustrated.
[0015] There is no limitation with respect to an amount of calcium bistrifluoromethanesulfonimide dissolved in the organic solvent or molten salt. The amount is that amount which provides necessary conductivity, for example, 10 3 Scm −1 .
[0016] A method of manufacturing calcium bistrifluoromethanesulfonimide used in the present invention is characterized in that calcium carbonate and an imide compound are reacted. Calcium bistrifluoromethanesulfonimide can be prepared by a reaction of calcium carbonate and trifluoromethanesulfonimide.
[0017] In Japanese Patent Laid-open publication No. 11-209338, calcium hydroxide and trifluoromethanesulfonimide are reacted. However, when calcium hydroxide is used, generation of heat is high, handling is complicated and handling of calcium hydroxide itself is dangerous. On the other hand, when calcium carbonate is reacted with trifluoromethanesulfonimide, heat generation is less than that from the reaction of calcium hydroxide and trifluoromethanesulfonimide. Therefore, a process of cooling can be eliminated to simplify the process. Avoiding calcium hydroxide, a strong alkali, significantly reduces danger.
DESCRIPTION OF PREFERRED EMBODIMENT
[0018] Embodiments of the present invention are explained in detail below. It is of course understood that the present invention is not limited to these embodiments and can be modified within the spirit and scope of the appended claims.
EXAMPLE
[0019] Trifluoromethanesulfonimide ((CF 3 SO 2 ) 2 NH, hereinafter HTFSI) was dissolved in water to make a 1 mol/Q (1M) solution. Calcium carbonate (CaCO 3 ) was added to the solution with stirring to a molar ratio of 2:1 (HTFSI:CaCO 3 ). A reaction of calcium carbonate and HTFSI produced calcium bistrifluoromethanesulfonimide, carbon dioxide and water as shown below:
CaCO 3 +HTFSI=Ca(TFSI) 2 +CO 2 +H 2 O
[0020] After confirming that calcium carbonate was completely reacted, water and carbon dioxide were removed by a rotary evaporator under reduced pressure to obtain white calcium bistrifluoromethanesulfonimide. The obtained calcium bistrifluoromethanesulfonimide was dried in a vacuum at 220° C. for eight hours to obtain absolute calcium bistrifluoromethanesulfonimide.
[0021] The obtained calcium bistrifluoromethanesulfonimide was dissolved in each of the organic solvents: propylene carbonate (PC), a mixed solvent of ethylene carbonate (EC) and dimethyl carbonate (DMC) at a mixing ratio of 1:1 by volume, y-butyrolactone (y-BL) and butylene carbonate (BC). It was confirmed that calcium bistrifluoromethanesulfonimide could be dissolved in the solvents. Electrical conductivity of each 1 M (1 mol/l) calcium bistrifluoromethanesulfonimide solution was measured. The results are shown in Table 1. Water content of each 1 M solution was not greater than 100 ppm.
[0022] Calcium bistrifluoromethanesulfonimide was added to trimethylpropylammonium-bis (trifluoromethanesulfonyl) imide (TMPA-TFSI), a molten salt. It was confirmed that calcium bistrifluoromethanesulfonimide was dissolved in TMPA-TFSI. Electrical conductivity of a 0.25 M (0.25 mol/l) calcium bistrifluoromethanesulfonimide molten salt solution was measured. The results are shown in Table 1. The electrical conductivity shown in Table 1 was measured at 25° C.
TABLE 1 Electrical Conductivity Solvent (× 10 −3 Scm −1 ) PC 2.42 EC:DMC 6.55 γ - BL 7.59 BC 1.70 TMPA - TFSI 1.53
[0023] As show in Table 1, the electrical conductivity of each solution was in a range of 1.53×10 −3 ˜7.59×10 −3 Scm −1 . This electrical conductivity range is equal to that of a typical electrolytic solution for a lithium ion battery, i.e., 1 M LiPF 6 in a mixed solvent of EC and DEC at a mixing ratio of 1:1 by volume (7.90×10 −3 Scm −1 ). Therefore, these solutions can be used as an electrolyte for a nonaqueous battery.
ADVANTAGES OF THE INVENTION
[0024] The present invention can provide an electrolyte useful for a nonaqueous battery such as a calcium ion battery. The method of manufacturing calcium bistrifluoromethanesulfonimide used in the present invention can reduce generation of heat during a reaction to make carrying out of the reaction simple and easy and to avoid danger during the reaction. | An electrolyte containing calcium bistrifluoromethanesulfonimide [Ca((CF 3 SO 2 ) 2 N) 2 ] for a nonaqueous battery. The calcium bistrifluoromethanesulfonimide is soluble in an organic solvent and a molten salt having a melting point of not greater than 60° C. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority from Japanese Patent Application No. JP 2009-195506 filed in the Japan Patent Office on Aug. 26, 2009, the entire content of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the technical field of optical elements, imaging optical systems and imaging apparatuses, specifically to the technical field in which the spectral characteristics of incident light on an imaging device are adjusted to desirably improve characteristics such as color reproducibility in the red region.
2. Description of the Related Art
There have been recent demands for miniaturization of imaging apparatuses, such as digital video cameras and digital still cameras, with maintained image quality for pictures and videos.
To meet such demands, imaging apparatuses have been proposed that include a miniaturized imaging optical system, and a high-density CCD (Charge Coupled Device) or a high-density CMOS (Complementary Metal-Oxide Semiconductor) installed as an imaging device.
Generally, a number of techniques are known that realize high resolution to improve image quality in imaging optical systems that use an imaging device. Aside from high resolution, improving image quality involves another important factor—desirable color reproducibility for pictures and videos. The success or failure to ensure desirable color reproducibility is greatly influenced by the spectral characteristics of the optical element disposed on the light path.
For example, in one imaging apparatus of related art, an optical element having an infrared absorbing effect is disposed on the light path of an imaging optical system (see, for example, JP-A-2004-345680). In the imaging apparatus provided with such an optical element, desirable spectral characteristics need to be ensured for the optical element.
In response to the movement toward miniaturization of the imaging optical system or the lens barrel that houses the imaging optical system, there is an increasing tendency of the reflection ghost to occur by the reflection of light at the optical component of the lens barrel, particularly at the optical element including an multilayered film that interferes with ultraviolet rays and infrared rays. Suppression of the reflection ghost is therefore important to realize high image quality and miniaturization at the same time.
FIG. 10 to FIG. 12 are graphical representations of the spectral characteristics of an optical element of related art. In each figure, the upper graph represents the relationship between wavelength and spectral transmittance, and the lower graph represents the relationship between wavelength and the spectral reflectivity on each surface. In the lower graph, the symbols A and B denote the object-side surface and the image-side surface of the optical element, respectively.
FIG. 10 represents measurement values for the optical element that includes a base material formed of a clear glass plate, a spectra adjusting multilayered film formed on the object-side surface of the base material, and an antireflective film formed on the image-side surface of the base material.
FIG. 11 and FIG. 12 represent measurement values for two types of optical elements that include a base material formed of an infrared absorbing glass, a spectra adjusting multilayered film formed on the object-side surface of the base material, and an antireflective film formed on the image-side surface of the base material.
As represented in FIG. 10 , the spectral transmittance abruptly varies near 650 nm in the optical element that uses a clear glass plate for the base material, because the base material does not have an infrared absorbing effect. Thus, unlike the optical elements represented in FIG. 11 and FIG. 12 , unnecessary light is incident on the imaging device.
It is known that the wavelengths of light that tend to contribute to red reflection ghost are from about 600 nm to about 680 nm. The spectral reflectivity is high in this wavelength region in all of the optical elements represented in FIG. 10 to FIG. 12 , and the red reflection ghost is likely to occur.
SUMMARY OF THE INVENTION
The imaging apparatus of related art including an optical element that has an infrared absorbing effect has high resolution with which high image quality can be realized. However, the red reflection ghost makes the color reproducibility insufficient.
Further, because the optical element disposed on the light path of the imaging optical system has a certain thickness, the imaging apparatus is prevented from being sufficiently reduced in size.
Accordingly, there is a need for an optical element, an imaging optical system, and an imaging apparatus with which the foregoing problems can be solved, and that can realize desirable color reproducibility in the red region while achieving miniaturization.
According to an embodiment of the present invention, there is provided an optical element that includes:
a base material formed of a film-like resin material that has an infrared absorbing effect; and
a multilayered film that adjusts spectral characteristics, and is formed on an object-side surface and an image-side surface of the base material.
The optical element is disposed on a light path of an imaging optical system, and of such characteristics that its spectral transmittance, and its spectral reflectivities on the object-side surface and the image-side surface satisfy the following conditions (1) to (4):
0.75< T IRCF (600) /T IRCF (540) <0.95 (1)
615<λ LT50% <670 (2)
| T IRCF (700) /T IRCF (540) |<0.05 (3)
680≦λ LR50% , (4)
where
T IRCF (600) is the spectral transmittance of light with a wavelength of 600 nm, T IRCF (540) is the spectral transmittance of light with a wavelength of 540 nm, λ LT50% is the wavelength of near-infrared light at 50% spectral transmittance, T IRCF (700) is the spectral transmittance of light with a wavelength of 700 nm, and λ LR50% is the wavelength of near-infrared light at 50% spectral reflectivity, wherein the unit of the wavelength is nm.
In this way, in the optical element, the base material absorbs infrared rays, and the multilayered films adjust the spectral characteristics. As a result, the spectral reflectivity decreases in the red region.
It is preferable that the optical element be disposed between an imaging device and a lens disposed closest to an image in the imaging optical system.
By the arrangement in which the optical element is disposed between the imaging device and the lens disposed closest to the image in the imaging optical system, the optical element is disposed at such a position that the principal ray and the peripheral rays are brought close to each other.
In the optical element, it is preferable that the spectral reflectivities on the object-side surface and the image-side surface satisfy the following condition (5):
λ LR50% [A]≧λ LR50% [B], (5)
where λ LR50% [A] is the wavelength of near-infrared light at 50% spectral reflectivity on the object-side surface, and λ LR50% [B] is the wavelength of near-infrared light at 50% spectral reflectivity on the image-side surface.
By satisfying the condition (5), the spectral reflectivity and the reflected wavelength region from the red wavelength region to the near-infrared region become greater on the image-side surface than on the object-side surface.
In the optical element, it is preferable that a total thickness of the base material and the multilayered films formed on the both surfaces of the base material be 120 μm or less.
The thickness can be reduced when the total thickness of the base material and the multilayered films is 120 μm or less.
In the optical element, it is preferable that the base material be made of polyolefinic resin.
With the base material made of polyolefinic resin, excellent optical performance and heat resistance, and low water absorbability can be ensured.
In the optical element, it is preferable that the base material contain at least one kind of organic pigment as a colorant that has an infrared absorbing effect.
In the base material that contains at least one kind of organic pigment as a colorant that has an infrared absorbing effect, the colorant can be desirably mixed with the base material.
According to another embodiment of the present invention, there is provided an imaging optical system that includes at least one lens or lens element, an optical element, and an imaging device that are disposed on a light path.
The optical element includes a base material formed of a film-like resin material that has an infrared absorbing effect, and a multilayered film that adjusts spectral characteristics, and is formed on an object-side surface and an image-side surface of the base material.
The optical element is of such characteristics that its spectral transmittance, and its spectral reflectivities on the object-side surface and the image-side surface satisfy the following conditions (1) to (4):
0.75 <T IRCF (600) /T IRCF (540) <0.95 (1)
615<λ LT50% <670 (2)
| T IRCF (700) /T IRCF (540) |<0.05 (3)
680≦λ LR50% , (4)
where
T IRCF (600) is the spectral transmittance of light with a wavelength of 600 nm, T IRCF (540) is the spectral transmittance of light with a wavelength of 540 nm, λ LT50% is the wavelength of near-infrared light at 50% spectral transmittance, T IRCF (700) is the spectral transmittance of light with a wavelength of 700 nm, and λ LR50% is the wavelength of near-infrared light at 50% spectral reflectivity, wherein the unit of the wavelength is nm.
In this way, in the imaging optical system, the base material absorbs infrared rays, and the multilayered films adjust the spectral characteristics. As a result, the spectral reflectivity decreases in the red region.
According to still another embodiment of the present invention, there is provided an imaging apparatus that includes an imaging optical system that includes at least one lens or lens element, an optical element, and an imaging device that are disposed on a light path.
The optical element includes a base material formed of a film-like resin material that has an infrared absorbing effect, and a multilayered film that adjusts spectral characteristics, and is formed on an object-side surface and an image-side surface of the base material.
The optical element is of such characteristics that its spectral transmittance, and its spectral reflectivities on the object-side surface and the image-side surface satisfy the following conditions (1) to (4):
0.75 <T IRCF (600) /T IRCF (540) <0.95 (1)
615<λ LT50% <670 (2)
| T IRCF (700) /T IRCF (540) |<0.05 (3)
680≦λ LR50% , (4)
where
T IRCF (600) is the spectral transmittance of light with a wavelength of 600 nm, T IRCF (540) is the spectral transmittance of light with a wavelength of 540 nm, λ LT50% is the wavelength of near-infrared light at 50% spectral transmittance, T IRCF (700) is the spectral transmittance of light with a wavelength of 700 nm, and λ LR50% is the wavelength of near-infrared light at 50% spectral reflectivity, wherein the unit of the wavelength is nm.
In this way, in the imaging apparatus, the base material absorbs infrared rays, and the multilayered films adjust the spectral characteristics. As a result, the spectral reflectivity decreases in the red region.
The optical element according to the embodiment of the present invention includes:
a base material formed of a film-like resin material that has an infrared absorbing effect; and a multilayered film that adjusts spectral characteristics, and is formed on an object-side surface and an image-side surface of the base material.
The optical element is disposed on a light path of an imaging optical system, and of such characteristics that its spectral transmittance, and its spectral reflectivities on the object-side surface and the image-side surface satisfy the following conditions (1) to (4):
0.75 <T IRCF (600) /T IRCF (540) <0.95 (1)
615<λ LT50% <670 (2)
| T IRCF (700) /T IRCF (540) |<0.05 (3)
680≦λ LR50% , (4)
where
T IRCF (600) is the spectral transmittance of light with a wavelength of 600 nm, T IRCF (540) is the spectral transmittance of light with a wavelength of 540 nm, λ LT50% is the wavelength of near-infrared light at 50% spectral transmittance, T IRCF (700) is the spectral transmittance of light with a wavelength of 700 nm, and λ LR50% is the wavelength of near-infrared light at 50% spectral reflectivity, wherein the unit of the wavelength is nm.
In this way, desirable color reproducibility can be realized in the red region while achieving miniaturization.
According to the embodiment of the invention, the optical element is disposed between the imaging device and the lens disposed closest to the image in the imaging optical system. In this way, deterioration in the resolution of the imaging optical system can be suppressed, and the amount of back focus deviation that may occur in manufacture or in response to temperature changes can be reduced.
According to the embodiment of the invention, the spectral reflectivities on the object-side surface and the image-side surface satisfy the following condition (5):
λ LR50% [A]≧λ LR50% [B], (5)
where λ LR50% [A] is the wavelength of near-infrared light at 50% spectral reflectivity on the object-side surface, and λ LR50% [B] is the wavelength of near-infrared light at 50% spectral reflectivity on the image-side surface.
In this way, a red ghost can be suppressed, and image quality can be improved.
According to the embodiment of the invention, the total thickness of the base material and the multilayered films formed on the both surfaces of the base material is 120 μm or less. In this way, the thickness can be sufficiently reduced.
According to the embodiment of the invention, the base material is made of polyolefinic resin. In this way, desirable characteristics can be ensured even when used under severe temperature and moisture conditions.
According to the embodiment of the invention, the base material contains at least one kind of organic pigment as a colorant that has an infrared absorbing effect. In this way, the colorant can be desirably mixed with the base material, making it possible to uniformly mix the colorant with the base material.
The imaging optical system according to the embodiment of the invention includes at least one lens or lens element, an optical element, and an imaging device that are disposed on a light path.
The optical element includes a base material formed of a film-like resin material that has an infrared absorbing effect, and a multilayered film that adjusts spectral characteristics, and is formed on an object-side surface and an image-side surface of the base material.
The optical element is of such characteristics that its spectral transmittance, and its spectral reflectivities on the object-side surface and the image-side surface satisfy the following conditions (1) to (4):
0.75 <T IRCF (600) /T IRCF (540) <0.95 (1)
615<λ LT50% <670 (2)
| T IRCF (700) /T IRCF (540) |<0.05 (3)
680≦λ LR50% , (4)
where
T IRCF (600) is the spectral transmittance of light with a wavelength of 600 nm, T IRCF (540) is the spectral transmittance of light with a wavelength of 540 nm, λ LT50% is the wavelength of near-infrared light at 50% spectral transmittance, T IRCF (700) is the spectral transmittance of light with a wavelength of 700 nm, and λ LR50% is the wavelength of near-infrared light at 50% spectral reflectivity, wherein the unit of the wavelength is nm.
In this way, desirable color reproducibility can be realized in the red region while achieving miniaturization.
The imaging apparatus according to the embodiment of the invention includes an imaging optical system that includes at least one lens or lens element, an optical element, and an imaging device that are disposed on a light path.
The optical element includes a base material formed of a film-like resin material that has an infrared absorbing effect, and a multilayered film that adjusts spectral characteristics, and is formed on an object-side surface and an image-side surface of the base material.
The optical element is of such characteristics that its spectral transmittance, and its spectral reflectivities on the object-side surface and the image-side surface satisfy the following conditions (1) to (4):
0.75 <T IRCF (600) /T IRCF (540) <0.95 (1)
615<λ LT50% <670 (2)
| T IRCF (700) /T IRCF (540) |<0.05 (3)
680≦λ LR50% , (4)
where
T IRCF (600) is the spectral transmittance of light with a wavelength of 600 nm, T IRCF (540) is the spectral transmittance of light with a wavelength of 540 nm, λ LT50% is the wavelength of near-infrared light at 50% spectral transmittance, T IRCF (700) is the spectral transmittance of light with a wavelength of 700 nm, and λ LR50% is the wavelength of near-infrared light at 50% spectral reflectivity, wherein the unit of the wavelength is nm.
In this way, desirable color reproducibility can be realized in the red region while achieving miniaturization.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating a configuration of an imaging apparatus according to an embodiment of the present invention, shown in conjunction with FIG. 2 to FIG. 9 .
FIG. 2 is a schematic diagram illustrating a configuration of an optical element.
FIG. 3 is a schematic diagram illustrating another configuration of the imaging apparatus.
FIG. 4 is a schematic diagram illustrating yet another configuration of the imaging apparatus.
FIG. 5 is a graphical representation of the spectral transmission characteristic and the spectral reflectivity characteristic of an optical element of First Example.
FIG. 6 is a graphical representation of the spectral transmission characteristic and the spectral reflectivity characteristic of an optical element of Second Example.
FIG. 7 is a graphical representation of the spectral transmission characteristic and the spectral reflectivity characteristic of an optical element of Third Example.
FIG. 8 is a graphical representation comparing the spectral reflectivity characteristic of the optical element of First Example with that of an optical element of related art.
FIG. 9 is a block diagram illustrating an embodiment of an imaging apparatus of the present invention.
FIG. 10 is a graphical representation of the spectral transmission characteristic and the spectral reflectivity characteristic of an optical element of related art.
FIG. 11 is a graphical representation of the spectral transmission characteristic and the spectral reflectivity characteristic of another optical element of related art.
FIG. 12 is a graphical representation of the spectral transmission characteristic and the spectral reflectivity characteristic of yet another optical element of related art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of an optical element, an imaging optical system, and an imaging apparatus of the present invention are described below with reference to the accompanying drawings.
The embodiments described below are based on application of an imaging apparatus of an embodiment of the present invention to a digital still camera, application of an imaging optical system of an embodiment of the present invention to the imaging optical system of the digital still camera, and application of an optical element of an embodiment of the present invention to the optical element of the imaging optical system.
It should be noted that the applicable areas of the present invention are not just limited to digital still cameras, the imaging optical system of digital still cameras, and the optical element of imaging optical systems. For example, the invention is applicable to a wide range of digital video cameras, cameras incorporated in cellular phones, personal computers, and PDAs (Personal digital Assistants), imaging optical systems provided in a variety of cameras, and optical elements provided in a variety of imaging optical systems.
[Overall Configuration]
As illustrated in FIG. 1 , an imaging apparatus (digital still camera) 1 includes, for example, five lens elements 2 , and an imaging device 3 , such as a CCD and a CMOS, disposed on a light path. The imaging apparatus 1 illustrated in FIG. 1 is of a five-element configuration; however, this is merely an example, and the imaging apparatus 1 may include any number of lens elements 2 . The lens element (first lens element) 2 closest to the object has a prism 2 a that bends the light path 90°.
The imaging device 3 is disposed closest to the image on the light path.
An optical element 4 is disposed between the imaging device 3 and a lens 2 b disposed closest to the image in the lens element (fifth lens element) 2 closest to the image.
A cover glass 5 is disposed between the optical element 4 and the imaging device 3 . An aperture stop 6 is disposed on the image side of the lens element (third lens element) 2 , disposed thirdly in the order of the lens elements 2 relative to the direction from the object side to the image side.
The lens elements 2 , the imaging device 3 , the optical element 4 , the cover glass 5 , and the aperture stop 6 are among the members of the imaging apparatus 1 that realize the imaging optical system.
The imaging apparatus 1 including the prism 2 a can be reduced in thickness, because the prism 2 a bends the light path at right angle.
[Configuration of Optical Element]
The optical element 4 has an infrared absorbing effect, and, as illustrated in FIG. 2 , includes a base material 8 formed of a film-like resin material, and multilayered films 9 and 10 formed on the object-side surface and the image-side surface, respectively, of the base material 8 .
The optical element 4 can have a sufficiently reduced thickness because the base material 8 is formed of a film-like material. This enables the imaging optical system and the imaging apparatus 1 to be reduced in size, particularly in the normal thickness of the imaging apparatus of a so-called retractable type, in which the lens barrel is retracted when not in use, and extends for shooting.
The total thickness of the base material 8 and the multilayered films 9 and 10 in the optical element 4 is preferably 120 μm or less, because it makes the advantageous effect of thickness reduction more prominent.
The base material 8 has an infrared absorbing effect, specifically an absorbing characteristic from the red wavelength region to the near infrared ray region (about 540 nm to about 700 nm).
This enables the balance of the spectral intensities of incident light on the imaging device 3 (for example, the balance of the light intensities of the blue region, green region, and red region) to be optimally adjusted, making it possible to desirably perform the white balance adjustment and color reproduction of pictures and videos.
Chromatic noise due to over electrical color adjustment also can be prevented.
Further, the red reflection ghost generated in the imaging optical system by the reflection of unnecessary light and that may cause deterioration of image quality can be suppressed to improve image quality.
Further, because the optical element 4 includes the multilayered films 9 and 10 that adjust spectral characteristics on the both surfaces of the base material 8 , the spectral characteristics, which cannot be adjusted sufficiently with the near-infrared region absorbing characteristic of the base material 8 alone, can be adjusted more delicately. As a result, transmission spectral characteristics can be ensured with which the color adjustment of pictures and videos can be optimally performed.
Further, because the multilayered films 9 and 10 are formed on the both surfaces of the base material 8 , the stress due to the multilayered films 9 and 10 can balance on the both surfaces of the base material 8 , even when the base material 8 is formed using a low rigid film-like resin material. It is therefore possible to minimize the extent of warpage or bending, and thus to improve the surface precision of the optical element 4 . As a result, the optical performance of the imaging optical system can be prevented from deteriorating, and the occurrence of reflection ghost can be suppressed.
In order to maximize the effect of improving the surface precision of the optical element 4 , it is preferable to provide essentially the same number of layers for the multilayered films 9 and 10 so that the stress can balance on the both surfaces of the base material 8 .
The optical element 4 is configured so that the spectral transmittance and the spectral reflectivities on the object-side surface and the image-side surface satisfy the following conditions (1) to (4).
0.75 <T IRCF (600) /T IRCF (540) <0.95 (1)
615<λ LT50% <670 (2)
| T IRCF (700) /T IRCF (540) |<0.05 (3)
680≦λ LR50% , (4)
where
T IRCF (600) is the spectral transmittance of light with a wavelength of 600 nm, T IRCF (540) is the spectral transmittance of light with a wavelength of 540 nm, λ LT50% is the wavelength of near-infrared light at 50% spectral transmittance, T IRCF (700) is the spectral transmittance of light with a wavelength of 700 nm, and λ LR50% is the wavelength of near-infrared light at 50% spectral reflectivity.
The unit of wavelength is nm.
The conditions (1) to (3) specify the spectral transmission characteristic of the optical element 4 from the red wavelength region to the near-infrared region.
Above and below the range of condition (1), the light quantity near the wavelength 600 nm becomes overly unbalanced with respect to the light quantity in the other visible light region, making it difficult to adjust the white balance in color reproduction. Further, there will be a substantial incidence of chromic noise because of the excess electrical signal gain involved in image processing, leading to image quality deterioration.
Above the upper limit of condition (2), the transmission cutoff wavelength of infrared rays in the optical element 4 becomes too long, and the quantity of transmitted light and the transmitted wavelength region become too large in the near-infrared region, making it difficult to sufficiently perform the color adjustment of pictures and videos. For example, white balance adjustment becomes difficult. Another problem is the exposure of the imaging device 3 with the infrared region light, which cannot be visually perceived.
On the other hand, below the lower limit of condition (2), the transmission cutoff wavelength of infrared rays in the optical element 4 becomes too short, and the quantity of transmitted light and the transmitted wavelength region become too small in the red region, making it difficult to sufficiently perform the color adjustment of pictures and videos. The reproducibility of red and purple colors is particularly affected.
Above the upper limit of condition (3), the quantity of light near the wavelength 700 nm becomes too large, and the quantity of light in the near-infrared region incident on the imaging device 3 becomes excessive. This is detrimental to the color reproducibility of the output pictures and videos, particularly in red and black. For example, white balance adjustment becomes difficult. Another problem is the exposure of the imaging device 3 with the infrared region light, which cannot be visually perceived.
Condition (4) specifies the spectral reflectivity characteristic of the optical element 4 from the red wavelength region to the near-infrared region.
Below the lower limit of condition (4), the spectral reflectivity and the reflected wavelength region of the optical element 4 become too large from the red region to the infrared ray region. In this case, the red reflection ghost due to the reflected light off the optical element 4 becomes notable, leading to a serious deterioration in image quality. The red reflection ghost occurs by the reflection, for example, between the imaging device 3 or the lenses of the imaging optical system and the optical element 4 .
The red reflection ghost becomes more frequent as the incident angle of the ghost-causing light on the optical element 4 increases, because it increases the interference of the multilayered films 9 and 10 on the incident light on the optical element 4 . Thus, the red reflection ghost, in particular, is more likely to occur when the incident angle of the ghost-causing light on the optical element 4 , or the density of the incident light on the optical element 4 is increased as a result of reducing the size of the imaging optical system and the imaging apparatus 1 .
As described above, with the optical element 4 satisfying the conditions (1) to (4), the red reflection ghost can be suppressed. In addition, a desirable white balance can be ensured, and desirable color reproducibility can be realized concerning the red region. As a result, image quality can be greatly improved. Specifically, desirable color reproducibility can be ensured concerning the red region by satisfying the conditions (1) to (4), even when the incident angle of the ghost-causing light on the optical element 4 , or the density of the incident light on the optical element 4 is increased as a result of reducing the size of the imaging apparatus 1 , as described above.
In the imaging apparatus 1 , the optical element 4 is disposed between the imaging device 3 and the lens 2 b disposed closest to the image in the imaging optical system.
With the optical element 4 disposed between the lens 2 b and the imaging device 3 , disturbance or deterioration due to spherical aberration can be reduced more than when the optical element 4 is disposed in the vicinity of the aperture stop 6 where the principal ray and the peripheral rays are distant apart. As a result, deterioration in the resolution of the imaging optical system can be suppressed, and the amount of back focus deviation that may occur in manufacture or in response to temperature changes can be reduced.
Generally, an imaging apparatus including an imaging device is designed like an image-side telecentric system, in order to make the field illuminance of the imaging optical system uniform. Designed like an image-side telecentric system, the size of the imaging optical system can be reduced by the optical design that allows a space to be formed relatively easily between the imaging device and the lens disposed closest to the image in the imaging optical system.
Such a space can be used to dispose the optical element 4 between the imaging device 3 and the lens 2 b disposed closest to the image on the light path as in the imaging apparatus 1 , making it possible to readily reduce the size of the imaging apparatus 1 .
In the imaging apparatus 1 , it is preferable that the spectral reflectivities of the optical element 4 on the object-side and image-side surfaces satisfy the following condition (5):
λ LR50% [A]≧λ LR50% [B] (5)
where λ LR50% [A] is the wavelength of near-infrared light at 50% spectral reflectivity on the object-side surface, and λ LR50% [B] is the wavelength of near-infrared light at 50% spectral reflectivity on the image-side surface.
Condition (5) specifies the orientation of the optical element 4 . Specifically, it specifies that the surface of the optical element 4 having a higher spectral reflectivity from the red wavelength region to the near-infrared region is on the side of the imaging device 3 .
When the optical element 4 is disposed oppositely so as not to satisfy condition (5), the spectral reflectivity and the reflected wavelength region from the red wavelength region to the near-infrared region become greater on the object-side surface than on the image-side surface. In this case, the red reflection ghost due to the reflection between the optical element 4 and the optical members, such as the lenses 2 , disposed on the object side of the optical element 4 becomes more frequent, and image quality deteriorates.
Reflection ghost still may occur between the image-side surface of the optical element 4 and the imaging device 3 , even when the optical element 4 is disposed so as to satisfy condition (5). However, considering the number of reflection ghost patterns associated with the number of components that reflect light, the conditions of incident light angle, and the size and shape of the ghost image that appears in pictures and videos, the orientation of the optical element 4 satisfying the condition (5) yields better image quality than when the optical element 4 is disposed oppositely so as not to satisfy the condition (5).
Further, any reduction in image quality caused by the reflection ghost when the optical element 4 is disposed so as to satisfy condition (5) can be prevented when the optical element 4 satisfies conditions (1) to (4).
The base material 8 of the optical element 4 is formed using a film-like resin material. It is preferable to use, for example, polyolefinic resin as the material of the base material 8 .
Polyolefinic resin is a material with a number of advantages, including excellent optical properties (high transmissivity, low birefringence, high Abbe number, etc.), high heat resistance, and low water absorbability. Thus, by using polyolefinic resin for the base material 8 , the desirable characteristics of the optical element 4 can be maintained even when the imaging apparatus 1 is used under severe temperature and moisture conditions.
Further, polyolefinic resin is less expensive than the infrared absorbing glass used as the material of the base material in related art. Thus, by forming the base material 8 using polyolefinic resin, the manufacturing cost of the imaging apparatus 1 and the imaging optical system can be reduced.
Further, because polyolefinic resin has excellent moldability, the optical element 4 can be formed with a reduced thickness compared with using, for example, the infrared absorbing glass as the base material. For example, the thickness can be reduced to 120 μm or less to reduce the size of the imaging apparatus 1 and the imaging optical system.
When using polyolefinic resin for the base material 8 of the optical element 4 as above, it is preferable to mix the resin with an organic pigment colorant having optical absorption properties in the near-infrared region, for example, such as an anthocyanin pigment and a cyanine pigment, as the infrared absorbing material.
For example, there are many reports concerning improvements of heat resistance and light resistance in regard to anthocyanin pigments (see, for example, JP-A-2003-292810). Further, because anthocyanin pigments are natural colorants and are expected to have stable reliability even under extreme temperature conditions, anthocyanin pigments, unlike synthetic colorants, can easily overcome environmental concerns.
Further, with the use of an organic pigment as the infrared absorbing material, the colorant can be desirably mixed with the polyolefinic resin.
The imaging apparatus 1 has been described as including, for example, five lens elements 2 . However, the optical element 4 may be provided in, for example, an imaging apparatus 1 A or an imaging apparatus 1 B, as described below (see FIG. 3 and FIG. 4 ).
As illustrated in FIG. 3 , the imaging apparatus 1 A includes, for example, three lens elements 2 A, and an imaging device 3 , such as a CCD and a CMOS, disposed on the light path. The optical element 4 is disposed between the imaging device 3 and a lens 2 c disposed closest to the image in the lens element (third lens element) 2 A closest to the image.
A cover glass 5 is disposed between the optical element 4 and the imaging device 3 . An aperture stop 6 is disposed on the image side of the lens element (second lens element) 2 A, disposed secondary in the order of the lens elements 2 A relative to the direction from the object side to the image side.
The lens elements 2 A, the imaging device 3 , the optical element 4 , the cover glass 5 , and the aperture stop 6 are among the members of the imaging apparatus 1 A that realize the imaging optical system.
As illustrated in FIG. 4 , the imaging apparatus 1 B includes, for example, four lens elements 2 B, and an imaging device 3 , such as a CCD and a CMOS, disposed on the light path.
The optical element 4 is disposed between the imaging device 3 and a lens 2 d disposed closest to the image in the lens element (fourth lens element) 2 B closest to the image.
A low-pass filter 7 and a cover glass 5 are disposed in this order from the object side between the optical element 4 and the imaging device 3 . An aperture stop 6 is disposed on the object side of the lens element (third lens element) 2 B, disposed thirdly in the order of the lens elements 2 B relative to the direction from the object side to the image side.
The lens elements 2 B, the imaging device 3 , the optical element 4 , the cover glass 5 , the aperture stop 6 , and the low-pass filter 7 are among the members of the imaging apparatus 1 B that realize the imaging optical system.
In the imaging apparatus 1 B provided with the low-pass filter 7 , the low-pass filter 7 can prevent the production of moire fringes.
EXAMPLES
Specific examples of the optical element 4 are described below with reference to FIG. 5 to FIG. 7 . Note that, in the following First, Second, and Third Examples, the thickness of the optical element 4 is 100 μm. In the graphical representations of FIG. 5 to FIG. 7 , the upper graph represents the relationship between wavelength and spectral transmittance, and the lower graph represents the relationship between wavelength and the spectral reflectivity on each surface. In the lower graph, surface A is the surface of the optical element 4 on the side of the object, and surface B is the surface of the optical element 4 on the side of the image.
FIG. 5 is a graphical representation of First Example.
In First Example, the following conditions (1) to (5) are satisfied.
T IRCF (600) /T IRCF (540) =0.906 (1)
λ LT50% =650 nm (2)
| T IRCF (700) /T IRCF (540) |=0.002 (3)
λ LR50% =729 nm, 697 nm (4)
λ LR50% [A]=729 nm, λ LR50% [B]=697 nm (5)
As represented in FIG. 5 , in First Example, the spectral transmittance gradually decreases toward the longer wavelength side in the red region (wavelengths of about 600 nm to about 700 nm).
On both surface A and surface B, the spectral reflectivity is low at the wavelengths of about 600 nm to about 680 nm—a wavelength region of light that tends to contribute to red reflection ghost—, and is high in the region on the longer wavelength side.
Thus, in First Example, a desirable white balance can be ensured, and desirable color reproducibility can be realized in the red region.
FIG. 6 is a graphical representation of Second Example.
In Second Example, the following conditions (1) to (5) are satisfied.
T IRCF (600) /T IRCF (540) =0.946 (1)
λ LT50% =655 nm (2)
| T IRCF (700) /T IRCF (540) |=0.002 (3)
λ LR50% =729 nm, 697 nm (4)
λ LR50% [A]=729 nm, λ LR50% [B]=697 nm (5)
As represented in FIG. 6 , in Second Example, the spectral transmittance gradually decreases toward the longer wavelength side in the red region (wavelengths of about 600 nm to about 700 nm).
On both surface A and surface B, the spectral reflectivity is low at the wavelengths of about 600 nm to about 680 nm—a wavelength region of light that tends to contribute to red reflection ghost—, and is high in the region on the longer wavelength side.
Thus, in Second Example, a desirable white balance can be ensured, and desirable color reproducibility can be realized in the red region.
FIG. 7 is a graphical representation of Third Example.
In Third Example, the following conditions (1) to (5) are satisfied.
T IRCF (600) /T IRCF (540) =0.807 (1)
λ LT50% =622 nm (2)
| T IRCF (700) /T IRCF (540) |=0.0001 (3)
λ LR50% =739 nm, 694 nm (4)
λ LR50% [A]=739 nm, λ LR50% [B]=694 nm (5)
As represented in FIG. 7 , in Third Example, the spectral transmittance gradually decreases toward the longer wavelength side in the red region (wavelengths of about 600 nm to about 700 nm).
On both surface A and surface B, the spectral reflectivity is low at the wavelengths of about 600 nm to about 680 nm—a wavelength region of light that tends to contribute to red reflection ghost—, and is high in the region on the longer wavelength side.
Thus, in Third Example, a desirable white balance can be ensured, and desirable color reproducibility can be realized in the red region.
As an example, FIG. 8 compares the spectral reflectivity of the optical element 4 of First Example with that of an optical element of related art (example represented in FIG. 10 ).
As represented in FIG. 8 , the optical element of related art has high spectral reflectivity at the wavelengths of about 600 nm to about 680 nm—a wavelength region of light that tends to contribute to red reflection ghost—, whereas the optical element 4 has high spectral reflectivity on the longer wavelength side of the region of from about 600 nm to about 680 nm.
Thus, with the use of the optical element 4 , the spectral reflectivity becomes high on the longer wavelength side of the wavelength region of light that tends to contribute to red reflection ghost. Accordingly, the red reflection ghost can be suppressed. As a result, a desirable white balance can be ensured, and desirable color reproducibility can be realized in the red region.
[Exemplary Configuration of Multilayered Film]
Table 1 presents an exemplary configuration of the multilayered films. In the table, the symbols A and B denote the surfaces of the optical element 4 on the object side and the image side, respectively. The multilayered film 9 and the multilayered film 10 of the optical element 4 represented in Table 1 have 19 layers and 17 layers, respectively.
TABLE 1 Physical Optical Layer Film thickness thickness Surface number material (nm) (nd) A 1 SiO 2 101.81 0.269 λ 0 2 Ta 2 O 5 40.56 0.160 λ 0 3 SiO 2 210.19 0.556 λ 0 4 Ta 2 O 5 32.74 0.129 λ 0 5 SiO 2 220.62 0.584 λ 0 6 Ta 2 O 5 31.61 0.125 λ 0 7 SiO 2 221.29 0.585 λ 0 8 Ta 2 O 5 32.42 0.128 λ 0 9 SiO 2 216.62 0.573 λ 0 10 Ta 2 O 5 32.99 0.130 λ 0 11 SiO 2 187.10 0.495 λ 0 12 Ta 2 O 5 89.85 0.354 λ 0 13 SiO 2 158.41 0.419 λ 0 14 Ta 2 O 5 88.20 0.347 λ 0 15 SiO 2 157.49 0.417 λ 0 16 Ta 2 O 5 88.33 0.348 λ 0 17 SiO 2 163.34 0.432 λ 0 18 Ta 2 O 5 112.65 0.444 λ 0 19 SiO 2 139.97 0.370 λ 0 Base Material B 20 SiO 2 163.76 0.433 λ 0 21 Ta 2 O 5 98.89 0.389 λ 0 22 SiO 2 151.72 0.401 λ 0 23 Ta 2 O 5 87.94 0.346 λ 0 24 SiO 2 151.21 0.400 λ 0 25 Ta 2 O 5 80.23 0.316 λ 0 26 SiO 2 158.32 0.419 λ 0 27 Ta 2 O 5 73.35 0.289 λ 0 28 SiO 2 162.99 0.431 λ 0 29 Ta 2 O 5 72.29 0.285 λ 0 30 SiO 2 161.26 0.427 λ 0 31 Ta 2 O 5 77.01 0.303 λ 0 32 SiO 2 156.40 0.414 λ 0 33 Ta 2 O 5 83.25 0.328 λ 0 34 SiO 2 155.75 0.412 λ 0 35 Ta 2 O 5 80.93 0.319 λ 0 36 SiO 2 73.50 0.194 λ 0 * λ 0 = 550 nm
[Embodiment of Imaging Apparatus]
FIG. 9 is a block diagram illustrating a digital still camera as an embodiment of an imaging apparatus of the present invention.
A imaging apparatus (digital still camera) 100 includes a camera block 10 , a camera signal processor 20 , an image processor 30 , an LCD (Liquid Crystal display) 40 , a R/W (reader/writer) 50 , a CPU (Central Processing Unit) 60 , an input section 70 , and a lens drive controller 80 .
The camera block 10 has imaging functions. The camera signal processor 20 performs signal processing such as the analog-digital conversion of captured image signals. The image processor 30 performs recording and reproduction of image signals. The LCD 40 is provided to display information such as captured images. The R/W 50 performs the write and read of image signals to and from a memory card 1000 . The CPU 60 controls the entire operation of the imaging apparatus 100 . The input section 70 includes, for example, various switches manipulated by a user to perform necessary operations. The lens drive controller 80 controls the driving of the lenses disposed in the camera block 10 .
The camera block 10 includes, for example, an imaging optical system including a zoom lens 11 , and an imaging device 12 such as a CCD and a CMOS.
The camera signal processor 20 performs various types of signal processing, including digital conversion of output signals from the imaging device 12 , noise removal, image quality compensation, and conversion into brightness and color-difference signals.
The image processor 30 performs, for example, compression coding and decompression decoding of image signals based on a predetermined image data format, and conversion of data specification such as resolution.
The LCD 40 displays information such as the state of user manipulation on the input section 70 , and captured images.
The R/W 50 writes the image data encoded by the image processor 30 into the memory card 1000 , and reads the recorded image data from the memory card 1000 .
The CPU 60 serves as a control processor, controlling each circuit block of the imaging apparatus 100 based on, for example, input command signals from the input section 70 .
The input section 70 includes, for example, a shutter release button with which a shutter is manipulated, and a select switch used to select an operation mode, and outputs input command signals to the CPU 60 in response to user manipulation.
The lens drive controller 80 controls, for example, motors that drive the lenses in the zoom lens 11 , based on control signals from the CPU 60 .
The memory card 1000 is, for example, a semiconductor memory detachably provided for the slot connected to the R/W 50 .
The operation of the imaging apparatus 100 is described below.
During a standby mode for capturing, the captured image signals in the camera block 10 are output to the LCD 40 via the camera signal processor 20 , and displayed as a camera through image, under the control of the CPU 60 . Upon input of input command signals for zooming from the input section 70 , the CPU 60 outputs control signals to the lens drive controller 80 , and a predetermined lens in the zoom lens 11 is moved under the control of the lens drive controller 80 .
When the shutter (not illustrated) of the camera block 10 is operated in response to the input command signal from the input section 70 , the camera signal processor 20 outputs the captured image signals to the image processor 30 for compression coding, and the signals are converted into digital data of a predetermined data format. The converted data is output to the R/W 50 , and written into the memory card 1000 .
Note that focusing is performed when, for example, the shutter release button of the input section 50 is pressed halfway, or all the way for recording (capturing), upon which the lens drive controller 80 moves a predetermined lens in the zoom lens 11 for focusing based on control signals from the CPU 60 .
For reproduction of the image data recorded in the memory card 1000 , the R/W 50 reads predetermined image data from the memory card 1000 according to manipulation of the input section 70 , and after decompression decoding by the image processor 30 , reproduction image signals are output to the LCD 40 and the reproduced image is displayed.
The specific shapes and configurations of the members described in the preferred embodiments are merely exemplary in nature and have been described to simply embody the present invention. The foregoing description of the invention is thus not to be construed as being limiting the technical scope of the present invention. | An optical element includes: a base material formed of a film-like resin material that has an infrared absorbing effect; and a multilayered film that adjusts spectral characteristics, and is formed on an object-side surface and an image-side surface of the base material. The optical element is disposed on a light path of an imaging optical system, and of such characteristics that its spectral transmittance, and its spectral reflectivities on the object-side surface and the image-side surface satisfy the conditions (1) to (4)
0.75< T IRCF (600) /T IRCF (540) <0.95 (1)
615<λ LT50% <670 (2)
| T IRCF (700) /T IRCF (540) |<0.05 (3)
680≦λ LR50% , (4)
where
T IRCF (600) , T IRCF (540) , and T IRCF (700) are the spectral transmittances of light with wavelength of 600 nm, 540 nm, and 700 nm, respectively, and λ LT50% and λ LR50% are the wavelengths of near-infrared light at 50% spectral transmittance and 50% spectral reflectivity, respectively. | 6 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates in general to sewing machines and in particular to a new and useful embroidering machine wherein groups of threaded needles are utilized, one at a time, to produce embroidery.
To obtain an embroidery having a neat appearance, it is desirable to conceal the ends of both the locking threads and the needle threads on the underside of the embroidered work. To this end, the embroidering threads are cut in such a way that the cut needle-thread ends carried by the needles are sufficiently, but not too long, so that during the formation of the initial stitch of a stitch group including several stitches, the needle threads securely interlock with the locking threads and the ends of the needle threads are completely pulled through the work to the underside thereof. In embroidering machines having embroidering heads equipped with a plurality of needles assembled into a group and where each needle is threaded with a thread of its own and only one needle can be brought into the working position at a time, it is further required to keep the thread ends carried by needles in a rest position, away from the working area, to avoid their inadvertent being picked up during the operation.
In another prior art embroidering machine (Swiss Pat. No. 65,330), the presser feet are designed as thread clamps. After making an embroidery stitch group, the embroidering frame carrying the work is displaced until the needle threads extending from the needle to the work come to lie in front of a receiving slot of the presser feet. Then, by means of an elongated slide moved along the presser feet, the needle threads are pushed, one after the other, into the clamps of the presser feet and immediately cut. Since in this embroidering machine all the needles are moved simultaneously, the device is not suitable for embroidering machines having embroidering head with a group of individually operable needles. Further, since the pressure feet are provided at locations which are laterally spaced from the respective needles, they cannot satisfactorily keep the work down in the close proximity of the needles, so that at the withdrawal of the needles from the work, the work may partly be taken along and thus flutter. Another disadvantage is that due to the use of an elongated slide traveling along the presser feet, the embroidering machine requires much space.
Still another prior art embroidering machine (U.S. Pat. No. 3,349,733) comprises a plurality of needles, drivable by groups, and an equal number of clamping or holding devices for the needle threads, which are provided laterally of the needles and closely spaced from the work. With the last stitch of a stitch group done, the frame carrying the work is displaced through a relatively long distance, whereby the needle thread portions extending from the needles to the work are brought into the proximity of the clamping devices. At the same time, further thread lengths are pulled off the supply bobbins. To bring the needle threads into the open clamping jaws of the clamping devices, all clamping devices are moved in the direction of the needle threads and then closed. Upon cutting the threads, the needle-thread ends carried by needles which will not be used in the next embroidering operation are retained in the respective clamping devices, while the other needle-thread ends are released prior to the start of the initial stitch.
Since the clamping devices are closely spaced from the work, there is a risk, even with a work stretched in a vertical plane and horizontally reciprocating needles, that the needle-thread ends hanging from the closed clamping devices will be picked up during the embroidering operation by the adjacent, driven needles and worked into the embroidery. Clamping devices in such arrangement are therefore, unsuitable for embroidering machines in which the work extends horizontally and the needles are moved vertically. Another disadvantage is that after the last stitch in a stitch group, the frame carrying the work must be displaced through a relatively large distance, to get the needle thread to the clamping devices. If, for example, after a change to another color of the needle threads, the next stitch is to be made in close proximity of the last stitch, the frame or work must first be returned into its initial position.
SUMMARY OF THE INVENTION
The present invention is directed to an embroidering machine in which the devices holding the needle-thread ends are relatively remote from the work, and in which, during the further pull, clamping, and cutting of the needle threads, the work remains in its position occupied at the termination of the last stitch of a stitch group.
An object of the present invention is thus the provision of an embroidering machine comprising a plurality of embroidering heads equipped with a number of needles which form a group and are threaded each with a thread of its own, with only one threaded needle being operable to sew at a time, a presser foot mechanism with presser foot which is cyclically movable upwardly and downwardly and provided with holes for the passage of the needles. A thread cutting device and holding device for the needle threads is provided and, upon termination of an embroidering operation, the presser foot is movable substantially transversely to a longitudinal axis of the needles so that, after a thread cutting operation, the presser feet can be lifted into a position above their usual top dead center position.
By the provided movement of the presser feet in a direction transverse to the longitudinal axis of the needles, a pull is exerted on the thread portions extending vertically between the needles and the work, whereby a further thread portion is pulled off the respective supplies. This ensures that upon cutting the threads, the needle-thread end portions carried by the needles are sufficiently long for the next stitch-forming operation. Then, after the thread cutting operation, the presser feet are lifted so far beyond their upper dead center position of their cyclic up and down motion, that they introduce the needle thread ends into the holding or clamping devices which are relatively remote from the work. The needle threads are thus further pulled off and introduced into the holding devices due to the respective motion of the presser feet. The work can therefore, remain in this position, occupied at the termination of the last formed stitch, with the further favorable result that the control program for the advance of the work or the frame is not interrupted by the thread pulling, cutting, and clamping operations.
In their uppermost position, the presser feet are lifted above the edge of the frame carrying the work. Therefore, with the simultaneous use of a plurality of small frames, the frames can be displaced from one embroidering head to the other while passing under the presser feet in their uppermost position.
Another object of the invention is to provide an embroidering machine wherein the supports of the presser feet are mounted on a shaft and two different alternately effective drive mechanisms are provided for driving this shaft. The presser feet thus execute all their motions in a manner most simple to achieve in design, namely along a circular path. Since during this motion, the presser feet are displaced not only in the direction of the longitudinal axis of the needle, but also transversely thereto, the intermittent pulling of the needle threads is effected by the pivotal motion of the presser feet alone.
During the formation of initial stitches, the minimum length of the needle thread end portions needed for securely interlock the needle threads with the locking threads is not a constant dimension, it depends on the thickness of the work and the elasticity of the threads. Another object of the invention is thus to provide a second drive mechanism of the presser foot shaft with a controllable, geared motor which can be stopped as desired, that makes it possible to adjust the height of the presser feet stroke, determining the extenstion of the needle thread pulling, and thus to exactly adjust the length of the needle-thread end portions.
By using a tie rod provided with an idle-stroke device, for example a pin-and-slot joint, the drive motions produced by the first drive mechanism to move the presser feet cyclcally up and down are taken up by the idle-stroke device and prevented from being transmitted to the geared motor.
A further object of the present invention is to provide an embroidering machine wherein the drive mechanism includes a toggle joint having two arms, with one arm being pivotally connected to an adjusting lever for adjusting the one arms position. This makes it possible to vertically displace the range of the cyclic up and down stroke of the presser feet and thus to adapt to different thicknesses of the work.
A still further object is to provide clutch means between the presser feet and support so that the supports of the presser feet can be disengaged from the presser foot shaft, if needed.
Another object of the present invention is to provide an embroidering machine wherein the holding device for the ends of the needle threads comprise a plate which shields the ends of the needles in their raised or rest positions and which includes at least one chamber with an open downwardly extending and upwardly extending end with means for directing compressed air through a compressed air nozzle upwardly through the chamber.
In the holding device for needle thread ends, the compressed air flowing into the chamber from the air nozzle and has the effect of producing an underpressure at the lower end of the chamber, so that the needle-thread ends lifted by the presser feet are pulled into the chamber by suction and are retained therein as long as the air flows through the chamber. The chamber is so dimensioned that the needle thread ends of all of the needles of an embroidering head can be received and retained. The holding power of the air stream, however, is small enough to make it possible to withdraw the needle thread of the driven needle, during the downward motion thereof, from the chamber without an appreciable force, in order to make an initial stitch.
The needle-thread ends retained by the holding device and belonging to needles which are not used during an embroidering operation are prevented from getting into the path of motion of the driven needles due to the provision that the holding devices are disposed at a relatively large distance from the work. This precautionary measure is now further supported by the fact that the needle thread ends extend in the chambers from below upwardly thus in a direction away from the work.
To reduce the consumption of compressed air, a clamping element is accommodated in the chamber of each holding device, which is non-positively held in clamping position but can be moved into a way-clearing position by the air flowing therethrough. The clamping element may be designed as a hinged flap, for example, or a freely movable pin applying by gravity against extensions provided in the chamber.
An object of the present invention is also to mount the plate of the holding device on a horizontal axis and connect jump action means to the plate. Accordingly, each holding device can be swung from a working position in which the plates shield the points of the needles which are in rest position, into a rest position in which these needles are freely accessible for threading.
Another object of the invention is to provide an embroidering machine which is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference 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 invention is explained in the following with reference to the drawings in which:
FIG. 1 is a partial view of an embroidering machine, with the shown needle being disengaged from the needle bar, i.e in its rest position;
FIG. 2 is a partly sectional view of a clutch by which the presser foot supports are connected to the presser foot shaft;
FIG. 3 is an enlarged view of a holding device and of the needle bar drive which is turned through 90° to clearly illustrate the design; and
FIG. 4 is a sectional view taken along the line IV--IV of FIG. 3, with the needle in rest position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to the drawings, the embroidering machine of the invention comprises a housing 1 with a plurality of embroidering heads 2 of which only one is shown in FIGS. 1 and 3.
Each embroidering head 2 is equipped with a plurality of needles 3 which are to be threaded with different threads and form together a needle group. Needles 3 are clamped in needle holders 4 which are received in a horizontally displaceable magazine 5.
Each embroidering head 2 is provided with a single needle bar 6 which is driven from an oscillating shaft 7 through a crank 8 and a link 9. Needle bar 6 can be connected to one of needle holders 4 by means of a coupling mechanism 10 disclosed in German patent application Pat. No. 29 27 142.9. To engage or disengage needle holders 4, needle bar 6 is lifted, by means of an air cylinder 11 which is connected through a forked head 12 to crank 8, into an engagement-stroke position which is higher than the upper working-stroke end position. That is why the needle holders 4 and needles 3 disengaged from the needle bar 6 are kept in a lifted position which is more remote from the workpiece W placed on a bed plate 13, than their upper dead center position during an embroidering operation.
The needle 3 which is connected to needle bar 6, thus in working position, cooperates with a rotary hook 14 mounted below bed plate 13. Bed plate 13 is provided with a needle hole 15 for the passage of needle 3. A horizontally movable thread catcher 16 of a thread cutting device 17 is disposed between bed plate 13 and rotary hook 14. Each needle 3 carries a needle thread N which is delivered to the needle from a supply device, for example a spool of yarn (not shown) and passed therebetween about an engageable and disengageable thread tightener 18 and a thread guide 21, and through the eye 19 of an oscillating thread take-up lever 20.
To hold the workpiece W flat in the stitch forming area, each embroidering head 2 is associated with a pressure foot 22 having a hole 23 for the passage of the vertically reciprocating needle 3. Presser foot 22 is secured to a support 24 mounted for pivoting about a presser foot shaft 25 which is common to all the presser feet 22. As shown in FIG. 2, support 24 is associated with a crank 26 which is non-rotatably fixed to shaft 25 and can be connected to support 24 through a clutch 27. Clutch 27 comprises a spring-loaded pin 29 which is displaceably received in an extension 28 of support 24 and, in engaged position of the clutch, engages a bore 30 of crank 26. Presser foot shaft 25 further carries a helical torsion spring 31 holding presser foot 22 in a lifted position as long as pin 29 is retracted.
To reciprocate presser feet 22 periodically up and down during the embroidering operation, presser foot shaft 25 is connected to a drive mechanism 32 receiving its motion from a motor 33. Motor 33 also drives the take-up levers 20 and needle bars 6 of embroidering heads 2 and the rotary hooks 14, through suitable transmission elements (not shown). The motor shaft carries a crank disc 34 secured thereto and drives a link 35. Link 35 acts on the toggle joint 36 of a toggle mechanism 37 having arms 38 and 39. Arm 38 is hinged at a fixed location to housing 1, while arm 39 acts on the toggle joint 40 of another toggle mechanism 43 formed by two arms 41 and 42. Arm 41 is hinged to the adjusting lever 44 of an adjusting device 45 comprising a spindle 46 and an axially fixed set wheel 47.
Arm 42 of toggle mechanism 43 has a slot 48 receiving a pin 49 which is provided on a crank 50 secured to presser foot shaft 25. Arm 42 and crank 50 are thus connected to each other through a pin-and-slot joint 51. A tension spring 52 is attached by one of its ends to pin 49 and its other end to a pin 53 which is secured to a tension adjusting bolt 55 adjustable by a nut 54. Arm 41 is thus an adjustment arm and arm 42 is thus a motion accepting arm.
Presser foot shaft 25 is further associated with a drive mechanism 56. Drive mechanism 56 comprises a drive motor 57 with an output shaft 58 to which a crank disc 59 and a control disc 60 with an extension 61, are secured. Crank disc 59 is connected, through a two-part tie rod 62, to a crank 63 which is secured to presser foot shaft 25. The two parts of tie rod 62 are connected to each other by an idle-stroke joint 64 comprising a slot 65 provided in one part of the tie rod and a pin 66 secured to the other tie rod part and engaging slot 65. In the path of motion of extension 61, three slot-type proximity switches 67, 68 and 69 which are known per se, are provided, for switching drive motor 57 on and off in a controlled mannerwith the location of the intermediate switch 68 being adjustable.
To each embroidering head, 2, a holding plate 70 is secured carrying a plate 72 hinged thereto at 71. Plate 72 has an L-shaped lower end. Along with two springs 73 attached by one end to plate 70 and by their other end to plate 72, plate 70 and 72 form a jump-action switching mechanism 74. Plate 72 is provided with a stepped aperture 75, so that needle bar 6 with needle holder 4 and needle 3, can freely pass therethrough, and support 24 carrying presser foot 22 can swing upwardly.
At either side of aperture 75, a chamber 76,77, respectively, is formed on the front side of plate 72. chambers 76,77 have an inlet 78 on their lower end and an outlet 79 on their upper end. At the lower end of each chamber 76, 77 a tube 80 is provided, having one end closed and the other end connected to a compressed-air source (not shown). On their side facing chamber 76 or 77, the two tubes 80 are provided with a plurality of bores 81 which act as air nozzles 82 turned in the direction of chambers 76, 77, thus upwardly. Each chamber 76,77 accommodated a hinged flap 83 resting by gravity on the bottom 84 of chamber 76 or 77.
Plate 72, chambers 76,77, air nozzles 82 including tubes 80, and flaps 83 form together a holding device 85 for the end E of needle threads N. Holding device 85 can be pivoted by hand into two different positions in which it is held by the spring force of a jump-action switching mechanism. In the working position of holding device 85 shown in the drawing, L-shaped plate 72 shields the points of needles 3 which are in rest position, so that holding device 85 at the same time acts as a needle guard reducing the risk of injuries. In its rest position (not shown), holding device 85 is pivoted rearwardly and the needles 3 in rest position are freely accessible for threading.
The embroidering machine operates as follows:
Since the motions of the different mechanical parts are identical in all embroidering heads 2, the operation of a single embroidering head is discussed.
To perform an embroidering operation, motor 33 is started. In a manner known per se, the motor drives needle bar 6, thread take-up lever 20, and rotary hook 14, as well as link 35 of drive mechanism 32. The motions of link 35 are transmitted, through the toggle mechanisms 37, 43 and the pin-and-slot joint 51 which is held in its upper end position by tension spring 52, to crank 50, so that presser foot shaft 25 executes rotary oscillatory motions.
If foot presser 22 is operatively connected through clutch 27 to presser foot shaft 25, the rotary oscillatory motion of shaft 25 causes a reciprocating up and down motion of presser foot 22, the stroke being about 4 mm. This motion of presser foot 22 is synchronized with the motion of needle bar 6 of the effect that as needle 3 is engaged in workpiece W, the presser foot passes through the lower dead center of its motion in which it bears against the workpiece W, so that the workpiece is prevented from being taken along at the withdrawal of needle 3. During the period in which needle 3 is withdrawn from workpiece W, the presser foot passes through the upper dead center of its motion so that it does not hinder the feed motion of workpiece W taking place during this period. By turning set wheel 47, the vertical range of motion of presser foot 22 can be displaced and thus adjusted to the thickness of the work.
The rotary oscillatory motion imparted to the presser foot shaft 25 by drive mechanism 32 is also transmitted to crank 63 and the lower part of tie rod 62. This oscillatory motion however, is not transmitted farther since it is taken up by idle-stroke joint 64. Therefore, the upper part of tie rod 62, and drive motor 57, remain unaffected by the oscillatory motion of presser foot shaft 25.
Upon termination of the last stitch of a stitch group including a plurality of stitches, motor 33 is switched off, and needle bar 6 is stopped in the upper dead center position of its working stroke. The stopping of motor 33 also stops take-up lever 20 and presser foot 22. Further, thread tightener 18 is opened.
Following the opening of thread tightener 18, drive motor 57 is started, so that the upper part of tie rod 62 is lifted by crank disc 59. As soon as the lower end of slot 65 butts against pin 66, the lower part of tie rod 62 is also lifted whereby crank 63 and presser foot shaft 25 are swung in the counterclockwise direction, as viewed in FIG. 1. This displaces pin 49 away from the upper end of slot 48, against the action of tension spring 52, while presser foot 22 is lifted above the upper dead center of its periodic up and down motion, into the mid-position indicated in dash-dotted lines in FIG. 1. Since during the upward motion, presser foot 22 follows a circular path, the lateral component of this motion, which is transverse the longitudinal axis of needle 3, causes the needle thread portion N extending from needle 3 to work W to be withdrawn sidewardly. Thereby, a further length of the thread is pulled off the supply around or through thread guide 21, bore 19 of take-up lever 20, and thread tightener 18.
The distance through which presser foot 22 is lifted to pull off the further length of thread is controlled by slot-type proximity switch 68. As extension 61 enters the slot of switch 68, drive motor 57 and, thereby, the upward motion of presser foot 22, are stopped. After the thread portion is pulled off, the locking thread and the needle thread are cut by means of a thread cutting device 17. The cut thread ends connected to work W remain at the underside thereof and are relatively short. The length of the thread end E carried by needle 3 depends on the length of the portion previously pulled off and is dimensioned to obtain a secure interlocking of the locking thread with the needle thread N during formation of the next stitch. Should it turn out that the thread end E carried by needle 3 is too short or too long, its length can be adjusted by resetting slot-type proximity switch 68.
If, after cutting the thread, it is intended to make with the same needle thread N a new stitch group, drive motor 57 is restarted to rotate in the opposite direction until extension 61 enters the slot of proximity switch 67 whereby motor 57 is stopped again. Due to the reversal of motor 57, presser foot 22 returns to its normal working position and a new stitch forming operation can start.
If, after cutting the thread, it is intended to continue the embroidering with another needle thread N, drive motor 57 is restarted in the same direction as before during the pulling out the thread portion, until extension 61 enters the slot of proximity switch 69, whereby motor 57 is stopped. This rotation of motor 57 moves presser foot 22 into its upper position indicated in dash-dotted lines in FIG. 1, in which the needle thread end E still extending through hole 23 of the presser foot is brought into a position favorable for catching it by means of holding device 85.
After presser foot 22 has reached this upper position, air nozzles 82 are supplied with compressed air, so that an air stream is forced through chambers 76,77. This air stream produces an underpressure in the zone of inlets 78 of chamber 76, 77, causing the needle thread end E lifted by presser foot 22 to be pulled out of hole 23 and taken by suction into one of the two chambers 76,77. Needle-thread end E is thus moved past and beyond flap 83 which is lifted by the air stream, to protrude from outlet 79 along with those needle-thread ends E which are carried by the needles 3 which are in rest position in front of the respective chambers 76 or 77. Upon introducing needle-thread end E, the compressed air supply is switched off, so that flaps 83 sink under their own weight and clamp the needle-thread ends E extending through chambers 76,77 against the bottom 84 of the chambers. In this way, needle-thread ends E are prevented from slipping out of chambers 76,77.
As soon as the needle thread E carried by the needle 3 which is connected to needle bar 6 is clamped in holding device 85, motor 57 is started again and presser foot 22 returns into its normal working position i.e. the lowermost position according to FIG. 1. This pivotal return motion ends at the instant at which extension 61 enters the slot of proximity switch 67 and motor 57 is stopped. Needle bar 6 is then lifted by air cylinder 11 into engagement-stroke position which is higher than its upper end position during a working stroke. As comprehensively described in the mentioned German patent application Pat. No. 29 27 142.9, this stroke in excess of needle bar 6 causes needle holder 4 to disengage from needle bar 6. Thereupon, by shifting magazine 5, the needle holder 4 carrying the needle with the thread N provided for the next stich forming operation is brought into the path of motion of needle bar 6 and operatively connected thereto by lowering the needle bar. The needle-thread end E carried by the presently driven needle 3 is thereby pulled back from below the respective flap 83 without a particular effort, and thereby withdrawn from holding device 85.
Since while shifting magazine 5 it may happen that some of the needle-thread ends E clamped by flaps 83 are pulled out of chamber 76, 77 and come to lie in the trough formed on plate 72, air nozzles 82 are supplied with compressed air once more for a short period of time after the thread change, so that needle threads E which might have slipped out of chambers 76, 77 are taken in again.
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. | An embroidering machine comprises a plurality of embroidering head each equipped with a plurality of needles formed into a group each with its thread. A needle bar is engageable with one needle at a time in the group to bring the needle from a rest position thereof into an operating position. A presser foot mechanism with a presser foot attached cyclically moves the presser foot upwardly and downwardly from an upper dead center position to a lower dead center position. The presser foot is provided with a hole for the passage of the one needle. Thread cutting and holding devices are provided for cutting the thread of the one needle to form a thread end portion and hold the thread end portion. Upon the termination of an embroidering operation with the one needle, the presser foot mechanism is operable to move the presser foot substantially transversely to a longitudinal axis of the needles and, after the thread is cut, to lift the presser foot upwardly beyond its upper dead center position. The holding device includes a shield for shielding the points of the needles in a rest position and a chamber having an open bottom and top end with compressed air nozzle for directing the thread end portions into the chamber to secure the thread end portions. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation-in-part of Ser. No. 10/465,975, entitled “Detachable Self-Expanding Aneurysm Cover Device”, filed Jun. 27, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a repositionable self-expanding intravascular aneurysm cover device and a hydraulic deployment system for placing the device at a preselected location within a vessel of the human body, and more particularly, relates to a device and hydraulic deployment system for the device which may be used to initially place the aneurysm cover device at a first location within a vessel and if it is desirable to reposition the device, the device may be withdrawn into the deployment system and subsequently repositioned at a different location.
[0004] 2. Description of the Prior Art
[0005] For many years flexible catheters have been used to place various devices within the vessels of the human body. Such devices include dilatation balloons, stents, embolic coils and aneurysm covers. Examples of such catheter devices are disclosed in U.S. Pat. No. 5,108,407, entitled, “A Method And Apparatus For Placement Of An Embolic Coil”; U.S. Pat. No. 5,122,136, entitled, “Endovascular Electrolytically Detachable Guidewire Tip For The Electroformation Of Thrombus In Arteries, Veins, Aneurysms, Vascular Malformations And Arteriovenous Fistulas.” These patents disclose devices for delivering an embolic coil to a preselected position within a vessel of the human body in order to treat aneurysms, or alternatively, to occlude the blood vessel at the particular location.
[0006] Devices, such as stents, which are placed in vessels may take the form of helically wound wire, or tubular like structures, with numerous patterns defining the walls. Examples of various stent configurations are disclosed in U.S. Pat. No. 4,512,338, entitled, “Process For Restoring Patentcy To Body Vessels”; U.S. Pat. No. 5,551,954, entitled, “Biodegradable Drug Delivery Vascular Stent”; and U.S. Pat. No. 4,994,071, entitled, “Bifurcating Stent Apparatus And Method.” Stents are generally formed of materials which retain their shape under the pulsatile flow conditions encountered when placed within the body vessel. Some materials that have been used to make such stents include metals and alloys, such as, stainless steel, tantalum, tungsten and nitinol, as well as polymers such as polyvinyl alcohol (PVA), polyglycolic acid (PGA) and collagen. On occasion multiple stents are placed at a given location to provide the desired vascular support.
[0007] In the past, the deployment of stents has been accomplished by numerous techniques. One such technique used to deploy a typical wire stent uses a pusher wire to push the wire stent through the lumen of a properly positioned cannula. As the stent exits the cannula it takes a predetermined shape until completely deposited in the vessel. This procedure is usually conducted under fluoroscopic visualization, such that the movement of the stent through the vasculature can be monitored. With these placements systems there is very little control over the exact placement of the stent since the stent may be ejected to a position some distance beyond the end of the cannula. As is apparent, with these latter systems, when the stent has been released from the cannula it is difficult, if not impossible, to retrieve the stent or to reposition the stent.
[0008] Numerous procedures have been developed to enable more accurate positioning of stents within a vessel. One such procedure utilizes a helically wound wire loop stent with a relaxed diameter. The stent is wound on a smaller diameter delivery while fixing the ends of the stent. This keeps the stent in a small diameter, tightly wound coil. This system is then delivered through the lumen of a properly positioned catheter exiting at a desired location. Once the delivery wire is activated to release the ends of the stent, the stent radially expands to its relaxed larger diameter. Such a stent positioning method is disclosed in U.S. Pat. No. 5,772,668, entitled, “Apparatus For Placing An Endoprosthesis.”
[0009] Another stent positioning system utilizes a self-expanding tubular stent. This stent has a relaxed diameter that approximates the diameter of the vessel to be supported. For transport through the catheter, the stent is positioned on a smaller diameter delivery wire. A sheath is positioned over the stent/delivery wire assembly constraining the stent to a smaller diameter. Once the assembly is placed at the desired location in the vasculature, the sheath is withdrawn exposing the stent allowing the stent to return to its predetermined larger size. The expansion of the stent uncouples the stent from the delivery wire while depositing the stent in the vessel at the desired location.
[0010] Still another stent positioning system utilizes a hydraulic stent deployment system for placing a self-expandable stent into the vessels of the body, and in particular into the small vessels of the brain. More particularly, this stent positioning system utilizes a catheter having a distal tip for retaining the stent in order to transport the stent to a predetermined position within a vessel and a control mechanism for releasing the stent at the preselected position. The control mechanism generally takes the form of a pressure generating device, such as a syringe, which is used to apply pressure to the catheter to thereby cause the distal end of the catheter to expand radially which in turn causes the stent to be released from the distal tip of the catheter. An example of such a stent positioning system is illustrated in U.S. Pat. No. 6,254,612, entitled, “Hydraulic Stent Deployment Systems,” and assigned to the same assignee as the present invention.
[0011] An example of a self-expanding tubular stent is illustrated in U.S. Pat. No. 6,267,783, entitled, “Stent Which Is Easily Recaptured And Repositioned Within The Body.” This self-expanding stent is formed by cutting and removing diamond shaped sections from the wall of a thin-walled nitinol tube to thereby form a relatively flexible, skeletal, tubular stent. The stent may be compressed to a smaller size for insertion into a vessel and then may be permitted to expand to a size where the stent contacts the walls of a vessel. The disclosed stent may also be recaptured and repositioned within a vessel.
[0012] An example of a self-expanding aneurysm cover is shown in U.S. Pat. No. 5,591,195 entitled, “Apparatus And Method For Engrafting A Blood Vessel.” The aneurysm cover illustrated in this patent is comprised of an expandable wire frame, which upon expansion, supports a fabric material which covers the mouth of an aneurysm.
SUMMARY OF THE INVENTION
[0013] The present invention is directed toward a deployment system and a aneurysm cover device which may be delivered at a site within a vessel and may be withdrawn after placement and to reposition the device at another site within the vessel.
[0014] In accordance with one aspect of the present invention, the self-expanding aneurysm cover device deployment system also includes a delivery catheter through with the device is delivered to the predetermined location. Initially, the device is retained by the deployment catheter within a delivery catheter and the device is positioned within the lumen of the distal section of the delivery catheter. The deployment catheter and the delivery catheter are moved to a desired position within a vessel and the deployment catheter is moved distally to permit the device to be pushed out of the distal end of the delivery catheter. The aneurysm cover device, being a self-expanding device, expands radially and contacts the walls of the vessel. If, prior to the final release of the aneurysm cover device from the deployment catheter it is determined that the device should be repositioned to another position within the vessel, the deployment catheter may be moved proximally back into the delivery catheter. As the aneurysm cover device is withdrawn into the delivery catheter, the device collapses to fit within the lumen of the delivery catheter. Once the device has been withdrawn into the delivery catheter, the delivery catheter may be moved into another position within the vessel for repositioning and subsequent release of the device. Accordingly, with this aneurysm cover device design is possible to permit the self-expanding device to completely expand at a first location, to then withdraw the device back into the delivery catheter, to move the delivery catheter to a second position and to again expand the device at the second position for subsequent release of the device.
[0015] In accordance with another aspect of the present invention, the self-expanding aneurysm cover device includes a generally cylindrical skeletal frame in which the frame includes a proximal loop portion, a positioning tab attached to the proximal loop portion and extending from the loop portion in a direction generally parallel to the longitudinal axis of the skeletal frame, and also includes a distal spring biased portion connected to the loop portion along at least two spaced apart locations on the loop portion. The skeletal frame is adapted to assume a first expanded position in which the spring portion is expanded to thereby cause the loop portion to be expanded to form a generally cylindrical loop configuration which lies in a plane extending in an oblique angle to the longitudinal axis of the skeletal frame. When the tab is moved proximally, the skeletal frame becomes compressed so that the loop portion lies in a plane extending closer to parallel to the longitudinal axis of the skeletal frame thereby causing the spring-biased portion to collapse which in turn causes the loop portion to collapse for easy withdrawal of the aneurysm cover device from a vessel.
[0016] In accordance with still another aspect of the present invention, the self-expandable aneurysm cover device includes an outwardly biased cylindrical skeletal frame in which the skeletal frame defines a proximal loop portion which lies in a plane extending at an oblique angle to the longitudinal axis of the cylindrical skeletal frame. The cover device also includes a positioning tab attached to the proximal end of the skeletal frame such that when force is applied to the positioning tab to cause the tab to move in a direction proximally of the cylindrical skeletal frame, the frame is caused to collapse radially for easy removal of the aneurysm cover device from a vessel.
[0017] In accordance with still another aspect of the present invention, the aneurysm cover device includes a generally cylindrical frame having a first condition in which said cylindrical skeletal frame may be compressed to have an overall small outside diameter and a normally biased second condition in which the cylindrical skeletal frame has an overall larger diameter. The cylindrical skeletal frame defines a loop portion at its proximal end in which the loop portion lies in a plane extending at an oblique angle to the longitudinal axis of the cylindrical skeletal frame. Also the device includes a positioning tab attached to the loop portion and extending from the proximal end of the loop portion in a direction generally parallel to the longitudinal axis of the skeletal frame. When a pulling force is applied to the positioning tab in a direction proximal to the cylindrical frame, the cylindrical frame is caused to collapse to form a device which has a reduced outside diameter therefore which may be easily removed from a vessel.
[0018] In accordance with another aspect of the present invention, the deployment system includes an elongated flexible deployment catheter having a distal section for retaining the aneurysm cover device so the device may be moved to a preselected position within the vessel. The catheter has a lumen which extends throughout the length of the catheter and also includes a distal section which is formed of a material having a durometer such that when sufficient fluid pressure is applied to the interior of the deployment catheter, the walls of the distal tip expand outwardly, or radially, to thereby increase the size of the lumen at the distal section of the catheter. A headpiece element, or protruding tab, of the aneurysm cover device is placed into the lumen at the distal section of the catheter and is retained by the distal section of the catheter. A hydraulic injector, such as a syringe, is coupled to the proximate section of the catheter for applying a fluid pressure to the interior of the catheter. When the device is placed at the desired position within the vessel, fluid pressure is applied to the interior of the deployment catheter by the hydraulic injector to thereby cause the walls of the distal section to expand outwardly thereby releasing the device for placement in the vessel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is an enlarged, partially sectioned view of an embodiment of the hydraulic deployment system and aneurysm cover device in accordance with the present invention;
[0020] FIG. 2 is an enlarged elevational view showing the aneurysm cover device of the present invention in an expanded configuration;
[0021] FIG. 3 is an enlarged elevational view of the aneurysm cover device shown in FIG. 2 when viewed from the bottom;
[0022] FIG. 4 is an enlarged oblique view of the aneurysm cover device as shown in FIG. 2 ;
[0023] FIG. 5 illustrates the aneurysm cover device of the present invention positioned within a delivery catheter prior to delivery of the aneurysm cover device into a vessel;
[0024] FIG. 6 is an enlarged partially sectioned view illustrating the aneurysm cover device of FIG. 5 after expansion of the device in a vessel; and,
[0025] FIG. 7 is an enlarged partial sectioned view illustrating the aneurysm cover device partially withdrawn into the delivery catheter and partially collapsed for subsequent repositioning within a vessel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] FIG. 1 generally illustrates the intravascular aneurysm cover device deployment system 100 which is comprised of a hydraulic injector or syringe 102 , coupled to the proximal end of a deployment catheter 104 . An intravascular aneurysm cover device is disposed within the lumen of the distal section 108 of the catheter 104 . The proximal end of the aneurysm cover device is tightly held within the lumen of the distal section 108 of the catheter 104 until the deployment system is activated for release of the aneurysm cover device. As may be seen, the syringe 102 includes a threaded piston 110 which is controlled by a handle 112 for infusing fluid into the interior of the catheter 104 . Also as illustrated, the catheter 104 includes a winged hub 114 which aids in the insertion of the catheter into the access catheter 116 which has a proximal hub 118 that is placed in the vascular system of the body. The intravascular aneurysm cover device deployment system 100 is described in more detail in U.S. Pat. No. 6,254,612, entitled, “Hydraulic Stent Deployment System” and assigned to the assignee of the present invention. This patent and the disclosure thereof is incorporated herein by reference.
[0027] FIGS. 2, 3 and 4 illustrate in more detail the intravascular self-expanding aneurysm cover device. The aneurysm cover device is comprised of a headpiece element 122 which extends from the proximal end of a self-expanding skeletal tubular section 124 .
[0028] The tubular section 124 is preferably formed from a thin-walled cylindrical tube formed from a super elastic alloy of nickel and titanium, such as nitinol. A description of medical devices which utilize such alloys may be found in U.S. Pat. No. 4,665,906, entitled, “Medical Devices Incorporating Sim Alloy Elements,” which is hereby incorporated by reference. The tubular section 124 is preferably laser cut from a nitinol tube and thereafter treated so as to exhibit super elastic properties at body temperature. As illustrated, tubular section 124 is formed by removing diamond patterned sections from the sidewalls of the nitinol tube, and when the aneurysm cover device is fully expanded, the diamonds would have angles of between 20 and 70 degrees at their distal and proximal ends. As is apparent, the tubular section 124 may be formed with various other patterns or configurations.
[0029] Also, and as illustrated in FIGS. 2 through 4 subsequent to cutting the diamond patterned sections from the tubular section 124 , the proximal end of the tube is cut to form a loop configuration 125 which extends in a plane which is oblique to the longitudinal axis of the tubular section 124 . This angle is preferably between about 10 and 70 degrees to the longitudinal axis of the aneurysm cover device. The preferred angle is 20 degrees to the longitudinal axis. After the diamond patterned sections are cut, there is formed a continuous proximal oval shaped loop 126 . The headpiece element 122 is connected to the most proximal edge of the proximal oval shaped loop 126 . The headpiece element 122 is retained by the deployment catheter 104 . FIGS. 2 through 4 illustrate the aneurysm cover device in its normal or expanded state prior to insertion into a delivery catheter for insertion into a vessel of the body.
[0030] As may be noted in FIGS. 2 and 4 , the pattern is constructed such that the diamonds which are in the lower portion of this Figure, i.e., diamonds on opposite side of aneurysm cover device from the portion of the aneurysm cover device which covers the aneurysm, are larger in size than the diamonds in the upper portion of this Figure which results in a denser mesh existing in the portion of the aneurysm cover device which covers the aneurysm.
[0031] As also may be noted in FIG. 2 and FIG. 4 , the aneurysm cover device includes outer struts 129 which are cut of a wider thickness than the inner struts 131 which causes the outer structure of the aneurysm cover device to provide a more rigid structure for holding the aneurysm cover device into the vessel and across the aneurysm. The rigid outer struts 129 also provide additional rigidity to improve “pushability” of the aneurysm cover device through the delivery catheter 128 .
[0032] As further noted in FIG. 3 , the aneurysm cover device includes four radiopaque markers 133 a, 133 b, 133 c and 133 d which aide in the positioning of the aneurysm cover device across an aneurysm. The radiopaque markers 133 a through 133 d are preferably formed by electroplating the distal portions of the struts with a radiopaque material, such as gold. As may be observed in FIGS. 2 and 3 , the radiopaque markers 133 d and 133 c do not extend distally as far as marker 133 a and 133 d. The longer markers 133 a and 133 b provide an indication of the more dense (upper portion of FIG. 2 ) portion of the aneurysm cover device to thereby aide in placement of the aneurysm cover device across the aneurysm in two respects. The longer markers 133 a and 133 b assist in placing the more dense portion of the aneurysm cover device at a position across the aneurysm and also provide an indication of the width of the more dense portion of the aneurysm cover device relative to the aneurysm.
[0033] As may be appreciated the aneurysm cover device may be delivered using various types of delivery systems other than the hydraulic delivery system disclosed in the present patent application. Such other devices may use heat, electric or mechanical systems to release the aneurysm cover device into a vessel with or without other embolic devices, such as embolic coils.
[0034] The aneurysm cover device may be treated by applying a coating to reduce the occurrence of a stenosis or to improve compatibility with other embolic devices. An example of a coating to reduce the occurrence of a stenosis is rapamycine. U.S. Pat. Nos. 5,288,711; 5,516,781; 5,563,146; 5,646,160 and 5,665,728 all disclose techniques for applying this coating to medical devices. The disclosures of these patents are incorporated by reference herein. In addition, the aneurysm cover device may be covered by a fabric covering, such as a polymer mesh, to more completely seal the opening of an aneurysm.
[0035] As illustrated in FIG. 5 , the self-expanding aneurysm cover device is placed within a delivery catheter 128 which serves to compress the aneurysm cover device to a size sufficiently small so that it may be inserted into a vessel and across an aneurysm. As may be noted in FIG. 5 , upon compression, the proximal loop portion 125 of the tubular section 124 is caused to move into a plane which extends closer to parallel to the longitudinal axis of the tubular section 124 . Once the delivery catheter 128 is properly positioned within a vessel adjacent the aneurysm, the deployment catheter 104 may be moved distally relative to the delivery catheter, or alternatively the delivery catheter 128 may be moved proximally relative to the deployment catheter 104 , thereby causing the aneurysm cover device to move out of the distal end of the delivery catheter and thereafter expand into contact with the walls of the vessel and across the neck of the aneurysm. At this point the hydraulic deployment system may be actuated to release the aneurysm cover device. Alternatively, if the aneurysm cover device is not positioned at a correct location, the deployment catheter 104 may be withdrawn proximally relative to the delivery catheter to thereby withdraw the aneurysm cover device back into the delivery catheter. As the aneurysm cover device is withdrawn into the catheter it collapses to fit within the distal portion of the delivery catheter 128 . After the aneurysm cover device is withdrawn back into the delivery catheter 128 , the delivery catheter may be moved into a new position and the aneurysm cover device may once again be deployed.
[0036] As may be noted, because of the construction of the aneurysm cover device which results in the proximal edge of the device lying in a plane which is oblique to the longitudinal axis of the device, the device collapses easily as the device is withdrawn back to the delivery catheter 128 . If this edge, or loop 126 , were to be positioned at right angles to the longitudinal axis of the aneurysm cover device, as is the case with prior art devices, it would be very difficult, if not impossible, to withdraw the device back into the delivery catheter 128 once the device had been moved entirely out of the distal end of the catheter. The “ramp” configuration at the proximal edge of the aneurysm cover device 106 of the present invention causes the aneurysm cover device to collapse easily within the delivery catheter 128 thereby providing a device which may be very easily repositioned after initially being placed at a selected location.
[0037] Although a particular embodiment of the present invention has been shown and described, modifications may be made to the device and/or method of use without departing from the spirit and scope of the present invention. The terms used in describing the invention are used in their descriptive sense and not as terms of limitations. | A self-expanding aneurysm cover device which takes the form of an outwardly biased cylindrical skeletal frame in which the proximal end of the cylindrical skeletal frame forms a loop which extends at an oblique angle to the axis of the cylindrical skeletal frame. A positioning tab extends from the proximal end of the skeletal frame which when pulled causes the cylindrical skeletal frame to collapse to a reduced diameter for removal of the device from a vessel. | 0 |
BACKGROUND
[0001] The present disclosure relates generally to a design structure, and more specifically to a design structure for dissipating thermal energy generated by semiconductor devices utilizing backside thermoelectric devices.
[0002] The cooling of integrated circuits becomes increasingly difficult with scaling, as there are more devices per unit area per die. There are a variety of cooling solutions, for example, servers may be cooled by using large metal heat sinks, fins, and water cooling. However, for portable devices, a small form-factor cooling device is desirable. One solution involves thermoelectric cooling (hereinafter “TEC”), which uses the Peltier effect to create a heat flux between the junction of two different types of thermoelectric materials. TEC devices are solid-state active heat pumps which transfer heat from one side of the device to the other.
[0003] Thermoelectric devices formed from semiconductor thermoelectric materials do not need any liquid or gas as coolant and have the advantages of continuous work capabilities, no pollution, no moving parts, no noise, long life, small volume and light weight. However, traditional thermoelectric devices have a large volume and require a separate power supply circuit. As such, they can only be attached to an outside of 3D stacked integrated circuits, which may have issues with effectively cooling the interior high temperature areas.
SUMMARY
[0004] Embodiments of the present invention provide a semiconductor structure and method to dissipate heat generated by semiconductor devices by utilizing backside thermoelectric devices. In certain embodiments, the semiconductor structure comprises an electronic device formed on a first side of the semiconductor structure. The semiconductor structure also comprises a thermoelectric cooling device formed on a second side of the semiconductor structure in close proximity to a region of the semiconductor structure where heat dissipation is desired, wherein the thermoelectric cooling device includes a Peltier junction. In other embodiments, the method comprises forming an electronic device on a first side of a semiconductor structure. The method also comprises forming a thermoelectric cooling device on a second side of the semiconductor structure in close proximity to a region of the semiconductor structure where heat dissipation is desired, wherein the thermoelectric cooling device includes a Peltier junction.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0005] FIG. 1 depicts fabrication steps, in accordance with an embodiment of the present invention.
[0006] FIG. 2 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0007] FIG. 3 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0008] FIG. 4 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0009] FIG. 5 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0010] FIG. 6 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0011] FIG. 7 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0012] FIG. 8 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0013] FIG. 9 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0014] FIG. 10 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0015] FIG. 11 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0016] FIG. 12 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0017] FIG. 13 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0018] FIG. 14 depicts additional fabrication steps, in accordance with an embodiment of the present invention.
[0019] FIG. 15 is a flow chart of a design process used in semiconductor design, manufacture, and/or test.
DETAILED DESCRIPTION
[0020] FIGS. 1-3 illustrate the steps for fabricating an integrated circuit having embedded thermoelectric cooling (hereinafter “TEC”) devices. FIG. 1 depicts fabrication steps, in accordance with an embodiment of the present invention. Wafer 105 is a semiconductor wafer that includes layers 110 , 120 , and 130 . In an embodiment, wafer 105 is a silicon on insulator (hereinafter “SOI”) wafer. Layers 110 and/or 130 include semiconductor material, such as silicon, germanium, and gallium arsenide. In another embodiment, layer 120 is a buried dielectric layer, such as silicon oxide. In certain embodiments, layer 130 is a device layer. In other embodiments, layer 110 is a handle wafer. Although a SOI wafer is used, bulk semiconductor substrates may be used in place of SOI substrates. In certain embodiments, dielectric material, insulating material, and/or conductive material is deposited using an appropriate deposition process, for example, physical vapor deposition, chemical deposition, electrochemical deposition, molecular beam epitaxy, and atomic layer deposition. Likewise, conductive material can be deposited using an appropriate deposition process, such as sputtering.
[0021] Trenches 140 , which are shallow trench isolations, are etched in to layer 130 , for example, by wet and/or dry etching. In certain embodiments, dielectric material is deposited in trenches 140 . The excess dielectric is removed by mechanical and chemical planarization.
[0022] In an embodiment, layer 150 includes dielectric material deposited using an appropriate deposition process, such as CVD. A gate oxide is grown by thermo oxidation, poly silicon is deposited by CVD, and a resist mask is formed on top of the polysilicon. Transistors 155 and 157 are patterned by an appropriate process, such as reactive ion etching. Spacers are formed on the gates by CVD and reactive ion etching. Transistors 155 and 157 are formed using appropriate processes, such as ion implantation, annealing, and silicide implantation. Layer 150 is deposited on layer 130 and trenches 140 , for example, by CVD. In an embodiment, layer 150 is silicon oxide. Layer 150 is then planarized to remove excess material. A mask is applied and reactive ion etching is applied to etch contacts 152 and 156 . Metal is deposited in contacts 152 and 156 with the excess removed by CMP. TSV 154 and 158 are formed using appropriate processes, such as lithography and etching. A predefined lithography pattern is applied to non TSV areas of layer 150 and TSV 154 and 158 are etched. Dielectric material is deposited to form barriers 115 a and 115 b . Metal is subsequently deposited to form TSVs 154 and 158 with the excess removed, for example by CMP.
[0023] Layer 160 , which includes dielectric material, is formed on layer 150 , for example, by CVD. A resist is formed on non-trench areas of layer 160 and trenches are formed therein, for example, by etching. The resist is subsequently removed. Metal is deposited in the trenches forming metal contacts 162 , 164 , 166 , and 168 . The excess metal from metal contacts 162 , 164 , 166 , and 168 is removed, for example, by CMP. FIG. 2 illustrates additional fabrication steps, in accordance with an embodiment of the present invention. Layer 110 is thinned to expose TSVs 154 and 158 . In an embodiment, an additional silicon etch is performed to ensure that the TSVs 154 and 158 protrude from layer 110 . Layer 200 , which includes dielectric material, is deposited on layer 110 , for example, by CVD. In an embodiment, layer 200 includes polyimide, silicon oxide, and SiN. Layer 200 is planarized by CMP to expose the TSVs 154 and 158 . In an embodiment, bond pads 205 and 210 , which include conductive material, such as barium and copper, are formed on layer 200 by first depositing a titanium barrier layer and/or copper seed layer on to layer 200 , for example, by sputter deposition. Resist is formed on non-TEC areas of layer 200 and solder is plated to form metal contacts 220 and 225 . The resist is then removed, for example, by an oxygen plasma or solvent, and the barrier and/or seed layer is etched by wet etching. In an embodiment, metal contacts 220 and 225 also include additives, such as copper and/or silver. Subsequently, the resist is removed.
[0024] Thermoelectric cooling (hereinafter “TEC”) devices are non-mechanical cooling devices that attract heat when an electric current is applied to it. TEC devices use the Peltier effect to create a heat flux between the junction of n-type and p-type semiconductor materials. TEC devices can be constructed by placing the dielectric material in parallel thermally and in series electrically. TEC elements 230 and 235 are attached to bond pads 205 and 210 by metal contacts 220 and 225 , respectively. In an embodiment, TEC elements 230 and 235 are grown on a separate substrate, such as gallium arsenide, and are then attached to bond pads 205 and 210 , for example, by solder reflow. In other embodiments, bond pads 205 and 210 may be formed on TEC elements 230 and 235 to improve adhesion to metal contacts 220 and 225
[0025] TEC elements 230 and 235 include n-type and/or p-type TEC material, such as bismuth telluride, lead telluride, cobalt triantimonide, and silicon germanium. TEC elements 230 and 235 include TEC materials that have dissimilar electron concentrations. For example, if TEC element 230 includes a n-type TEC material, then TEC element 235 includes a p-type TEC material and vice-versa.
[0026] FIG. 3 depicts additional fabrication steps, in accordance with an embodiment of the present invention. Another mask is formed on the non-wire areas of layer 300 and vias 311 and 312 are patterned therein using, for example, conventional lithography and etching. The mask is removed. Wire 310 , which includes conducting material, such as TiN/Al, is formed on TEC elements 235 and 230 and wire portions of layer 300 , for example, by sputter deposition or electroplating.
[0027] TEC device 340 is energized via metal contacts 164 and 168 and TSVs 154 and 158 . When energized, heat is drawn towards TEC elements 230 and 235 and dissipates in to layer 300 . FIG. 3 illustrates a multi-layered semiconductor device that includes electronic devices formed on a side of the semiconductor device, in accordance with an embodiment of the present invention. Wherein the semiconductor device is formed on a SOI wafer and cooled via a TEC device that is affixed to the opposite side of the SOI wafer that the electronic devices are formed on. The TEC device is affixed to the semiconductor device via solder bumps and, in response to being energized via TSVs that are connected to metal contacts, attracts heat generated by the electronic devices.
[0028] FIGS. 4 and 5 depict fabrication steps for additional embodiments of the present invention wherein the TEC device connects to the wafer via metal contacts instead of solder bumps. FIG. 4 depicts additional fabrication steps, in accordance with embodiments of the present invention. FIG. 4 uses the fabrication steps depicted in FIG. 1 ; however, instead of forming metal contacts 205 and 210 on layers 200 , layer 400 , which is a metal layer that includes conducting material, is formed on layer 200 . In an embodiment, layer 400 includes titanium and/or copper. In an embodiment, layer 400 is a bond pad layer. A mask is formed on the first non-TEC area of layer 400 and TEC element 410 is formed on layer 400 , for example, by electroplating. Subsequently, the mask is removed. Another mask (not shown) is formed on the second non-TEC area of layer 400 and TEC element 415 , which include TEC material, is formed on layer 400 . TEC elements 410 and 415 function similarly to TEC elements 230 and 235 (discussed above), respectively. TEC elements 410 and 415 also include the same TEC material as TEC elements 230 and 235 (discussed above).
[0029] FIG. 5 depicts additional fabrication steps, in accordance with an embodiment of the present invention. Non-TEC areas of layer 400 are removed using an appropriate process, such as wet etching, which results in contacts 510 and 515 . Layer 500 , which includes insulator material, is formed on layer 200 . Vias 511 a and 511 b are formed in layer 500 in the same fashion as vias 311 and 312 , respectively, are formed in layer 300 . Wire 520 is formed in the same fashion as wire 310 (discussed above). TEC device 540 functions in the same fashion as TEC device 340 . In addition, wire 520 function is a similar fashion to wire 310 . FIG. 5 illustrates a multi-layered semiconductor device that includes electronic devices formed on a side of structure, in accordance with an embodiment of the present invention. Wherein the semiconductor device, which is formed on a SOI wafer, is cooled via a TEC device that is affixed to the opposite side of the semiconductor device that the electronic devices are formed on. The TEC device is affixed to the semiconductor device via metal contacts and, in response to being energized via TSVs that are connected to other metal contacts, attracts heat generated by the electronic devices.
[0030] FIG. 6 illustrates an additional embodiment of the present invention. FIG. 6 depicts additional fabrication steps, in accordance with an embodiment of the present invention. Specifically, FIG. 6 illustrates an alternative embodiment wherein layer 200 is not formed on layer 110 , which itself is completely removed during the wafer thinning step described in FIG. 1 .
[0031] In an embodiment, bond pads 610 and 620 , which include conductive material, are formed on layer 120 in the same fashion that bond pads 205 and 210 (discussed above) are formed on layer 200 . In another embodiment, bond pads 610 and 620 are formed on layer 120 in the same fashion that metal contacts 510 and 515 are formed on layer 110 . In yet another embodiment, metal contacts 610 , 620 , 205 , and 210 include the same conductive material. In other embodiments, metal contacts 630 and 640 are formed on bond pads 610 and 620 , respectively, in the same fashion that metal contacts 220 and 225 are formed on bond pads 205 and 210 , respectively. In still other embodiments, metal contacts 630 , 640 , 320 , and 325 include the same conductive material.
[0032] TEC elements 650 and 660 are formed on metal contacts 630 and 640 , respectively, in the same fashion that TEC elements 230 and 235 are formed on metal contacts 220 and 225 , respectively. In an embodiment, TEC elements 650 and 660 include the same TEC material as TEC devices 230 and 235 , respectively. Layer 600 , which includes insulator material, is formed on layer 120 in the same fashion that layer 300 is formed on layer 200 . In an embodiment, layers 600 and 300 include the same material. Wire 670 , which includes conducting material, is formed on layer 600 in the same fashion that wire 310 is formed on layer 300 .
[0033] In an embodiment, wires 670 and 310 include the same conducting material. TEC device 601 functions in the same fashion as TEC device 340 . The IC structure depicted in FIG. 6 illustrates a multi-layered semiconductor device that includes electronic devices formed on a side of the semiconductor device, in accordance with an embodiment of the present invention. Wherein the semiconductor device is cooled via a TEC device that is affixed to the opposite side of the semiconductor device that the electronic devices are formed on. The TEC device, which is embedded in insulator material, is affixed to the semiconductor device via metal contacts and, in response to being energized via TSVs that are connected to other metal contacts, attracts heat generated by the electronic devices.
[0034] FIG. 7 depicts additional fabrication steps, in accordance with an embodiment of the present invention. Specifically, FIG. 7 describes additional fabrication steps that utilize the structure described in FIG. 1 . A mask is formed on the non-TEC device areas of layer 110 . Excess layer 110 is removed, for example, by lithography and etching. Bond pads 205 and 210 , which include conducting material, are formed on layer 120 in the same fashion that bond pads 205 and 210 are formed on layer 120 (discussed above).
[0035] In an embodiment, metal contacts 710 , 720 , 205 , and 210 include the same conducting material. Metal contacts 730 and 740 , which include conducting material, are formed on bond pads 710 and 720 , respectively, in the same fashion that metal contacts 220 and 225 are formed on bond pads 205 and 210 , respectively.
[0036] In an embodiment, metal contacts 730 , and 740 include the same conducting material as metal contacts 220 and 225 , respectively. TEC elements 750 and 760 , which include TEC material, are formed on metal contacts 730 and 740 in the same fashion that TEC elements 230 and 235 are formed on metal contacts 220 and 225 , respectively. In an embodiment, TEC elements 750 and 760 include the same thermoelectric material as TEC elements 230 and 235 , respectively.
[0037] FIG. 8 depicts additional fabrication steps, in accordance with an embodiment of the present invention. Layer 810 , which includes insulator material, is formed on layer 120 in the same fashion that layer 500 is formed on layer 200 . Layers 810 and 500 include the same insulator material. Wire 870 is formed in layer 810 in the same fashion that wire 310 is formed in layer 300 . FIG. 8 illustrates a multi-layered semiconductor device that includes electronic devices formed on a side of semiconductor device, in accordance with an embodiment of the present invention. Wherein the semiconductor device is cooled via a TEC device that is affixed to the opposite side of the semiconductor device that the electronic devices are formed on. The TEC device, which is embedded in insulator material, is affixed to the semiconductor device via solder bumps and, in response to being energized via TSVs that are connected to other metal contacts, attracts heat generated by the electronic devices.
[0038] FIGS. 9 through 14 depict an embodiment of the present invention that is incorporated into a multi-chip stack. FIG. 9 depicts additional fabrication steps, in accordance with an embodiment of the present invention. Specifically, FIG. 9 describes additional fabrication steps that utilize the structure described in FIG. 1 . Here, prior to the formation of layer 160 on layer 150 , TSV 970 and barrier 915 are formed in layers 150 , 140 , 120 , and 110 in addition to and in the same manner that TSVs 154 and 158 as well as barriers 115 a and 115 b are formed therein.
[0039] Layer 980 , which includes insulator material, is formed on layer 160 . In an embodiment, layer 980 is an insulation and/or passivation layer that includes insulation and/or passivation material, such as polymide. In certain embodiments, a mask is applied on the non-bond pad areas of layer 980 . Bond pad 932 , which includes a conducting material, is formed on layer 980 . In an embodiment, bond pad 932 includes copper. Subsequently, the mask is removed. Contact 940 , which includes a conducting metal, is formed on bond pad 930 . In certain embodiments, contact 940 is a solder contact formed by solder reflow.
[0040] The wafer undergoes backside processing wherein layer 900 is formed on layer 110 in the same manner that layer 200 is formed on layer 110 (discussed above). Layer 902 , which includes conducting material, is formed on layer 900 . TEC elements 930 and 935 , which include TEC material, are formed on layer 902 in the same fashion that TEC elements 230 and 235 are formed on metal contacts 220 and 225 , respectively. TEC elements 930 and 935 function in the same fashion as TEC elements 230 and 235 , respectively.
[0041] FIG. 10 depicts additional fabrication steps, in accordance with an embodiment of the present invention. Metal contacts 903 , 905 , and 910 are formed from layer 902 in the same fashion that metal contacts 510 and 515 are formed from layer 400 (discussed above). FIG. 11 depicts additional fabrication steps, in accordance with an embodiment of the present invention. Layer 1100 , which includes dielectric material, is formed on layer 900 . Bond pad 1130 , which includes conducting material, is formed in layer 900 over metal contact 903 in the same fashion that bond pad 932 is formed in layer 980 over contact 162 . In certain embodiment, bond pads 932 and 1130 include the same conducting material.
[0042] Wire 1110 , which includes conducting material, is formed on TEC elements 930 and 935 in the same fashion that wire 310 is formed on TEC elements 230 and 235 . Layer 1120 , which includes dielectric material, is formed on wire 1110 and layer 1100 . FIG. 12 depicts additional fabrication steps, in according to an embodiment of the present invention. Specifically, FIG. 12 illustrates fabrication steps for the second chip of a two chip stack embodiment of the present invention. In an embodiment, wafer 1205 is a SOI wafer that includes layers 1200 , 1220 , and 1230 . Wafer 1205 is formed in the same fashion that wafer 105 is formed (discussed above). Layers 1200 , 1220 , and 1230 included the same dielectric material as layers 110 , 120 , and 130 . Trenches 1240 are formed in layer 1230 in the same fashion and include the same dielectric material as trenches 140 . Layer 1250 is formed on layer 1230 in the same fashion that layer 150 is formed on layer 130 . Layers 1250 and 150 include the same dielectric material. TSVs 1270 and 1275 are formed in layer 1250 in the same fashion that TSV 152 and 156 are formed in layer 150 . Devices 1255 and 1275 are formed in layer 1250 in the same fashion that devices 155 and 157 are formed in layer 150 . In an embodiment, devices 1255 , 1257 , 155 , and/or 157 are the same type of device, such as a FET. Layer 1260 , which includes low-K dielectric material, is formed on layer 1250 in the same fashion that layer 160 is formed on layer 150 . In certain embodiment, layers 1260 and 160 include the same low-K dielectric material.
[0043] Metal contacts 1262 , 1264 , 1266 , and 1268 , which include conducting material, are formed on layer 1260 in the same fashion that metal contacts 162 , 164 , 166 , and 168 are formed on layer 160 . In an embodiment, metal contacts 1262 , 1264 , 1266 , 1268 , 162 , 164 , 166 , and/or 168 include the same conducting material.
[0044] FIG. 13 depicts additional fabrication steps, in accordance with an embodiment of the present invention. The wafer undergoes additional front side processing wherein layer 1300 , which includes insulator material, is formed on metal contacts 1262 , 1264 , 1266 , 1268 and layer 1260 in the same fashion that layer 980 is formed on metal contacts 162 , 164 , 166 , 168 and layer 160 (discussed above). Bond pad 1330 , which includes conducting material, is formed on layer 1300 in the same fashion that bond pad 930 is formed in layer 980 . Layer 1310 , which includes thermal interface material (hereinafter “TIM”), is formed on layer 1200 , for example, by screen printing or deposition by syringe. TIM may consist of silicon of epoxy binders impregnated with thermally conductive particles, such as silver ceramics and/or diamonds. Heat sink 1300 , which is a metal heat sink, is affixed to layer 1200 by layer 1310 . In an embodiment, heat sink 1300 includes one or more of the following metals: silicon, copper, aluminum, silver, gold, aluminum nitride, and diamond.
[0045] FIG. 14 depicts additional fabrication steps, in accordance with an embodiment of the present invention. Specifically, FIG. 14 depicts a chip stack that includes the semiconductor structures from FIGS. 11 and 13 affixed to each other. Heat sink 1410 is a heat sink that draws thermal energy from wire 1110 . Heat sink 1410 includes heat sink material, such as copper, diamond, and/or composite materials, such as copper-titanium pseudo alloy, aluminum silicon carbide, Dymalloy, and E-material. In an embodiment, heat sink 1410 extends to the edge of the die.
[0046] FIG. 14 illustrates a multi-stacked multi-layered semiconductor device that includes electronic devices formed on a side of the first stack, in accordance with an embodiment of the present invention. Bond pads 1130 and 1330 are connected by metal contact 1340 (discussed above). In an embodiment, voids between the semiconductor devices are filled, for example, by epoxy injection. The semiconductor device depicted herein, which is formed on a SOI wafer, is cooled via a TEC device that is affixed to the opposite side of the semiconductor device that the electronic devices are formed on. The TEC device is affixed to the semiconductor device via metal contacts and, in response to being energized via TSVs that are connected to other metal contacts, attracts heat generated by the electronic devices. The second stack is attached to the first stack by a solder bump and includes a heat sink adhered to the side of the stack that is opposite if the solder bump.
[0047] FIG. 15 shows a block diagram of an exemplary design flow 1500 used for example, in semiconductor IC logic design, simulation, test, layout, and manufacture. Design flow 1500 includes processes, machines and/or mechanisms for processing design structures or devices to generate logically or otherwise functionally equivalent representations of the design structures and/or devices described above and shown in FIGS. 1-14 . The design structures processed and/or generated by design flow 1500 may be encoded on machine-readable transmission or storage media to include data and/or instructions that when executed or otherwise processed on a data processing system generate a logically, structurally, mechanically, or otherwise functionally equivalent representation of hardware components, circuits, devices, or systems. Machines include, but are not limited to, any machine used in an IC design process, such as designing, manufacturing, or simulating a circuit, component, device, or system. For example, machines may include: lithography machines, machines and/or equipment for generating masks (e.g. e-beam writers), computers or equipment for simulating design structures, any apparatus used in the manufacturing or test process, or any machines for programming functionally equivalent representations of the design structures into any medium (e.g. a machine for programming a programmable gate array). Design flow 1500 may vary depending on the type of representation being designed. For example, a design flow 1500 for building an application specific IC (ASIC) may differ from a design flow 1500 for designing a standard component or from a design flow 1500 for instantiating the design into a programmable array, for example a programmable gate array (PGA) or a field programmable gate array (FPGA) offered by Altera® Inc. or Xilinx® Inc.
[0048] FIG. 15 illustrates multiple such design structures including an input design structure 1520 that is preferably processed by a design process 1510 . Design structure 1520 may be a logical simulation design structure generated and processed by design process 1510 to produce a logically equivalent functional representation of a hardware device. Design structure 1520 may also or alternatively comprise data and/or program instructions that when processed by design process 1510 , generate a functional representation of the physical structure of a hardware device. Whether representing functional and/or structural design features, design structure 1520 may be generated using electronic computer-aided design (ECAD) such as implemented by a core developer/designer. When encoded on a machine-readable data transmission, gate array, or storage medium, design structure 1520 may be accessed and processed by one or more hardware and/or software modules within design process 1510 to simulate or otherwise functionally represent an electronic component, circuit, electronic or logic module, apparatus, device, or system such as those shown in FIGS. 1-14 . As such, design structure 1520 may comprise files or other data structures including human and/or machine-readable source code, compiled structures, and computer-executable code structures that when processed by a design or simulation data processing system, functionally simulate or otherwise represent circuits or other levels of hardware logic design. Such data structures may include hardware-description language (HDL) design entities or other data structures conforming to and/or compatible with lower-level HDL design languages such as Verilog and VHDL, and/or higher level design languages such as C or C++.
[0049] Design process 1510 preferably employs and incorporates hardware and/or software modules for synthesizing, translating, or otherwise processing a design/simulation functional equivalent of the components, circuits, devices, or logic structures shown in FIGS. 1-15 to generate a Netlist 1580 which may contain design structures such as design structure 1520 . Netlist 1580 may comprise, for example, compiled or otherwise processed data structures representing a list of wires, discrete components, logic gates, control circuits, I/O devices, models, etc. that describes the connections to other elements and circuits in an integrated circuit design. Netlist 1580 may be synthesized using an iterative process in which netlist 1580 is resynthesized one or more times depending on design specifications and parameters for the device. As with other design structure types described herein, netlist 1580 may be recorded on a machine-readable data storage medium or programmed into a programmable gate array. The medium may be a non-volatile storage medium such as a magnetic or optical disk drive, a programmable gate array, a compact flash, or other flash memory. Additionally, or in the alternative, the medium may be a system or cache memory, buffer space, or electrically or optically conductive devices and materials on which data packets may be transmitted and intermediately stored via the Internet, or other networking suitable means.
[0050] Design process 1510 may include hardware and software modules for processing a variety of input data structure types including Netlist 1580 . Such data structure types may reside, for example, within library elements 1530 and include a set of commonly used elements, circuits, and devices, including models, layouts, and symbolic representations, for a given manufacturing technology (e.g., different technology nodes, 32 nm, 45 nm, 90 nm, etc.). The data structure types may further include design specifications 1540 , characterization data 1550 , verification data 1560 , design rules 1570 , and test data files 1585 which may include input test patterns, output test results, and other testing information. Design process 1510 may further include, for example, standard mechanical design processes such as stress analysis, thermal analysis, mechanical event simulation, process simulation for operations such as casting, molding, and die press forming, etc. One of ordinary skill in the art of mechanical design can appreciate the extent of possible mechanical design tools and applications used in design process 1510 without deviating from the scope and spirit of the invention. Design process 1510 may also include modules for performing standard circuit design processes such as timing analysis, verification, design rule checking, place and route operations, etc.
[0051] Design process 1510 employs and incorporates logic and physical design tools such as HDL compilers and simulation model build tools to process design structure 1520 together with some or all of the depicted supporting data structures along with any additional mechanical design or data (if applicable), to generate a second design structure 1590 . Design structure 1590 resides on a storage medium or programmable gate array in a data format used for the exchange of data of mechanical devices and structures (e.g. information stored in a IGES, DXF, Parasolid XT, JT, DRG, or any other suitable format for storing or rendering such mechanical design structures). Similar to design structure 1520 , design structure 1590 preferably comprises one or more files, data structures, or other computer-encoded data or instructions that reside on transmission or data storage media and that when processed by an ECAD system generate a logically or otherwise functionally equivalent form of one or more of the embodiments of the invention shown in FIGS. 1-14 . In one embodiment, design structure 1590 may comprise a compiled, executable HDL simulation model that functionally simulates the devices shown in FIGS. 1-14 .
[0052] Design structure 1590 may also employ a data format used for the exchange of layout data of integrated circuits and/or symbolic data format (e.g. information stored in a GDSII (GDS2), GL1, OASIS, map files, or any other suitable format for storing such design data structures). Design structure 1590 may comprise information such as, for example, symbolic data, map files, test data files, design content files, manufacturing data, layout parameters, wires, levels of metal, vias, shapes, data for routing through the manufacturing line, and any other data required by a manufacturer or other designer/developer to produce a device or structure as described above and shown in FIGS. 1-14 . Design structure 1590 may then proceed to a stage 1595 where, for example, design structure 1590 : proceeds to tape-out, is released to manufacturing, is released to a mask house, is sent to another design house, is sent back to the customer, etc.
[0053] 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” and/or “comprising,” when used in this specification, 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.
[0054] The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein. | Embodiments of the present invention provide a semiconductor structure and method to dissipate heat generated by semiconductor devices by utilizing backside thermoelectric devices. In certain embodiments, the semiconductor structure comprises an electronic device formed on a first side of the semiconductor structure. The semiconductor structure also comprises a thermoelectric cooling device formed on a second side of the semiconductor structure in close proximity to a region of the semiconductor structure where heat dissipation is desired, wherein the thermoelectric cooling device includes a Peltier junction. In other embodiments, the method comprises forming an electronic device on a first side of a semiconductor structure. The method also comprises forming a thermoelectric cooling device on a second side of the semiconductor structure in close proximity to a region of the semiconductor structure where heat dissipation is desired, wherein the thermoelectric cooling device includes a Peltier junction. | 7 |
This is a division of application Ser. No. 681,252, filed Apr. 28, 1976, now U.S. Pat. No. 4,095,317 which in turn is a divisional of Ser. No. 517,802, filed Oct. 24, 1974, now U.S. Pat. No. 3,983,610.
BACKGROUND OF THE INVENTION
This invention relates to the production of texturized yarns or like multifilament groups of synthetic polymeric materials, e.g. tows, and more particularly to an apparatus and process for texturizing yarn to provide uniform random crimps in the filaments of the yarn by pneumatically conveying the yarn into a bulking chamber to form an elongated uniformly compacted yarn mass and to the yarn products resulting from the process.
Heretofore, many apparatus and processes have been developed for texturizing yarn made of thermoplastic polymeric materials by the use of fluid jets or like pneumatic means. Many of these prior developments have been relatively successful in providing bulky voluminous yarn having a degree of crimp uniformity and improved dyeing characteristics suitable for use in the production of textile fabrics, carpets and the like. However, the apparatus employed for carrying out many of these known processes is complex and requires elaborate machining techniques to produce. This apparatus is costly and for this reason elaborate and slower stuffer box crimping systems, wherein relatively straight feeder yarn is forced into a compression chamber by a pair of driven rolls and is accumulated within the chamber by pressure developed within the chamber, are often employed. In these systems the feeder yarn forms wads of yarn in the compression chamber and a regular crimp is imparted to the individual filaments of the yarn during this accumulation. Also heated fluids such as steam or hot air are often utilized to moisten and/or heat-set the yarn while in a crimped state within the compression chamber.
Because of the advantage found in the yarns produced by the pneumatic bulking or texturizing systems, particularly the high yarn processing speeds, and random crimping of the filaments, the difficulties in producing the necessary apparatus as well as the complex controls required for operating such apparatus have been accepted by the industry. In these known processes an initially straight and pre-drawn yarn which may be untwisted or slightly twisted is subjected to a turbulent fluid such as steam in such a manner that the individual filaments of the yarn are looped, coiled, or crimped and the yarn is heat-set in this condition. The individual filaments are in this manner formed into a bulky wool-like product wherein each of the filaments in a relaxed condition exhibit a plurality of crimps or loops along a given length. These crimps are usually offset and out of phase with each other in a random manner.
One difficulty encountered in these known pneumatic processes is a requirement to provide a sufficient number of crimps to a given length of yarn. Often it is difficult to obtain consistently more than 10 crimps per inch in the filaments of the resulting yarn product.
Many prior attempts to improve the crimp count involve procedures to impinge, fold or coil the yarn in such a manner that the yarn filaments are highly crimped while allowing the yarn to be subsequently removed from the apparatus without loss of desired yarn properties.
Also, the procedures used for separating the yarn from the fluid stream, usually hot air or steam, are important to the success of the crimping process. Various devices such as angled baffles, bulking tubes with reverse exhaust, bulking chambers with lateral exhaust ports, rotating screen drums and the like have been employed. The use of such devices often imposes limitations of yarn speed, yarn uniformity or process flexibility on the known processes.
In order to overcome a number of drawbacks attendant to these pneumatic bulking techniques, several developments have been made. For example, U.S. Pat. No. 2,982,082 discloses a process and apparatus for producing voluminous yarn wherein a continuous filament yarn is fed into a jet by a pair of rollers. The jet has an inlet tube extending through a chamber and is provided with a jet tip which faces and enters the mouth of a venturi passage. The outer surface of the jet and the mouth of the venturi cooperate to form an annular passage for a fluid stream under pressure to be blown into the chamber and out through the venturi. The yarn is drawn out of the jet by an additional pair of rollers at such a rate that the yarn is overfed to the jet so that the individual filaments of the yarn are formed into loops and curls by the turbulence of the air stream beyond the annular passage within the jet.
U.S. Pat. No. 3,373,470 describes a process for stuffer-type crimping of thermoplastic filaments wherein the filaments are introduced into one end of an elongated confined space by a stream of fluid such as steam under pressure and at a temperature sufficient to set the filaments. The filaments are tightly packed within the confined space by controllably releasing part of the fluid from the confined space laterally of the confined space at a position spaced from the other end and the packed filaments are then forced through the space to the other end under pressure by the remaining portion of the fluid which exhausts with the yarn. The confined space required for this process is defined by a metal spring having gaps between the convolutions thereof. In this apparatus the yarn is propelled by the action of the fluid from a nozzle through a tubular passage and then into the interior of the spring. The spring is curved to a desired extent to obtain optimum packing of the yarn therein.
U.S. Pat. No. 3,380,242 describes yet another process for providing a crimp to synthetic yarns wherein the yarn is subjected to the action of a turbulent stream by passing it through a jet to which a hot gas is supplied. The yarn and hot gas leaving the jet enter a venturi tube wherein the individual filaments of the yarn while in a plastic state and under substantially zero tension are separated from each other and crimped individually while whipping about in the turbulent plasticizing stream. The crimp produced by this process has a random three-dimensional curvilinear extensible configuration.
There are still a number of drawbacks, such as uneven or irregular dyeing characteristics, non-uniform crimping and the occurrence of snarls or tangles in the yarn which need to be overcome. For example, in the manufacture of tufted carpets it has been found that tufting machines require particularly uniform yarns and that snarled yarns will cause stoppage, broken filaments and even end breakage. Also, the snarled or tangled yarn will provide faults in the carpet product. Therefore, manufacturers of texturized carpet yarns are continuously looking for apparatus and processes to provide bulky yarns which will dye uniformly and which are free from snarls and tangles.
SUMMARY OF THE INVENTION
Advantageously, the present invention provides a continuous pneumatic process that produces bulky yarns having a high degree of random crimp and that can be carried out at high speeds by an apparatus which is simple to manufacture and which can be operated without elaborate controls. Furthermore, the dense yarn mass produced during the process of this invention is characterized by a symmetrical compact arrangement of the filaments which enables the yarn to be easily removed from the apparatus. This yarn mass provides a bulky yarn product that has a highly uniform and even random crimp in each of the filaments and that is substantially free of snarls and tangles.
This invention contemplates a process for texturizing or bulking a multifilament synthetic polymeric yarn wherein the yarn is passed in a gas stream to a diffuser zone to cause the gas to expand and the yarn filaments to splay open; the yarn filaments are directed away from the expanding gas stream towards a continuous smooth side wall surface defining one end of a bulking chamber; the filaments are impacted with each other and the smooth side wall surface to form a compact yarn mass at the one end of the bulking chamber; and the yarn mass is pushed into and through a slotted side wall or otherwise gas permeable portion of the bulking chamber; while the gas simultaneously passes through the yarn mass initially formed at one end of the bulking chamber and then discharges laterally from the yarn mass pushed into the slotted portion of the bulking chamber.
In this process, the yarn is initially delivered at a constant speed by a feeding device such as feed rollers, godet or the like to a bulking jet. Delivery yarn speeds of from 500 to 2,000 meters per minute may be used; preferably the speeds are from 1,000 to 1,500 meters per minute. Prior to entering the bulking jet, the yarn is preheated to 100° C. to 200° C. by a plate heater, godet or like heating device or in some cases, the yarn is heated by being drawn immediately before entering the bulking jet.
The yarn is then aspirated into the bulking or aspirator jet by the venturi effect of a heated gas, such as superheated steam or compressed air. The yarn carried in the gas stream then enters a preheat tube where the yarn temperature is raised by the heated gas to plasticize the yarn prior to crimping and/or folding in the bulking chamber. In the preheat tube, the yarn is heated to temperatures between the second order transition point and the melting point of the yarn; the temperature of the yarn is maintained below the sticking point to avoid the formation of separate coherent filament groups within the yarn.
The yarn and gas stream exit from the preheat tube into a diffuser zone having a diverging conical wall surface. In this zone, the gas is expanded very rapidly to create great turbulence, thereby causing the yarn filaments to splay open, to flutter violently, and to move towards the conical wall surface. Folding-over of the yarn filaments occurs as the filaments impinge against each other and a smooth side wall surface of a plug forming zone of the bulking chamber immediately adjacent to and downstream from the diffuser zone. Consequently, the yarn accumulates at the front end of the bulking chamber to form a compacted mass in the form of an elongated, cylindrical plug which seals off the downstream end of the bulking chamber. Further accumulation of yarn and the force of the entering gas cause the accumulated yarn plug to be pushed forward into a slotted wall portion of the bulking chamber while the yarn newly entering the chamber impinges at random on the upstream end of the dynamically forming plug in the plug forming zone. All of the gas from the diffuser zone now flows through the compacted yarn mass at the front end of the bulking chamber and after reaching the slotted portion of the bulking chamber, the gas exhausts laterally from the yarn plug. In this manner, the yarn in the smooth wall portion is uniformly treated with the gas to cause crimping and bulk-setting of the yarn.
The yarn filaments, which fold upon each other and themselves and on the smooth side wall surface, are, generally, arranged at an angle to the longitudinal axis of the bulking chamber (as well as the coinciding longitudinal axis of the plug) with intermediate portions forming successive inwardly and outwardly curved folds, or pleats much like those of an accordion. The filaments appear to splay open and then close together in a pulsating manner during formation of the plug. The filaments converge initially form a concave surface towards the downstream end of the chamber upon which subsequent filaments are compacted. This arrangement causes the filaments to be built-up in a conical-like stacked arrangement within the bulking chamber. Generally, the major portions of the filaments form an angle with a plane perpendicular to the longitudinal axis of the chamber that may vary from about 10° to 30°. Also, the smooth side wall surface provides an ironing-effect on the outer surface of the plug. Consequently, when the plug moves forward in the bulking chamber and when the steam exhausts through the slots or perforations in the bulking chamber, yarn is not carried out with the gas which would cause large loops, snarls and other variations in the yarn crimp.
The continuous multifilament yarns to be texturized by this invention are made from various thermoplastic synthetic polymeric materials such as nylon; polyester, e.g. polyethylene terephthalate; polyolefins, e.g. polypropylene; acrylic polymers, e.g. polyacrylonitrile and copolymers of acrylonitrile; polyvinyl chloride, polyphenylene oxides and other fiber-forming materials. Preferably, the yarns used for the purposes of this invention are those made entirely of nylon or polyester. However, yarns made of composite filaments such as nylon and polyester may also be employed.
The denier of the feeder yarns utilized in the practice of this invention may vary from about 50 to 4,000 and the denier used for producing carpet yarns usually varies from about 1,000 to 3,000. These yarns, which are drawn prior to bulking, include twisted or untwisted flat yarn as well as spin-drawn yarn, spun yarn which is subsequently drawn, and the like yarns. Also, the yarn may be drawn immediately before being introduced into the bulking jet. In general, the yarn is drawn at conventional draw ratios employed for orientation of synthetic polymeric filaments prior to crimping, e.g. 2.5:1 to 4:1; with a draw ratio of 3.6:1 being particularly effective for nylon carpet yarns. Partially drawn feed yarns produced from high speed filament spinning may also be utilized, in which case draw ratios before the bulking jet will be proportionately lower during the additional drawing.
The feeder yarn usually will have selected oil and/or emulsion finishes applied thereto to achieve a proper moisture and finish content.
It has been found that the gas used to aspirate the yarn in accordance with this invention advantageously is a dry gas such as superheated steam or compressed air. Preferably, superheated steam is used. This steam has a pressure of from about 50-100 psig. and a temperature from about 200° C. to about 275° C. The preferred pressure for nylon 6 carpet yarns is from 60 to 80 psig. and preferred temperature is from 220° C. to 240° C. Usually the temperature of the steam is above the melting point of the yarn since heat losses in the system and the short residence time of the yarn with the steam prevent the yarn from being raised to this melting temperature.
Air suitable for purposes of this invention can be taken from the atmosphere at ambient conditions and compressed to 50-100 psig. and heated to 200° to 275° C.
After the yarn plug has been pushed from the bulking chamber, the yarn plug, while still intact, is guided through a tubular conduit to a plug guide where the yarn is removed from the plug by a take-up device at a rate that is about 15-25% slower than the feed rate. Sufficient tension is applied to the yarn to cause it to stretch out to a length less than the original length, and to pull the filaments back into a yarn bundle.
Optionally, the yarn may be passed through a tangle jet for additional bulk control to establish desired yarn properties and then through a steam annealing jet before winding into a take-up package. U.S. Pat. No. 3,461,521 discloses specific annealing and air tangling means that can be utilized.
This invention is also directed to an apparatus for effecting the heretofore described bulking process, which apparatus comprises: (1) a pneumatic aspirator jet having an inlet means for supplying a heated gas to a jet orifice for producing a gas stream within the aspirator, and a yarn inlet means for introducing a yarn into the gas stream; (2) a preheat tube secured to the aspirator jet defining a narrow passage for receiving the yarn carried by the gas stream and for allowing the yarn to be preheated by the gas; (3) a diffuser having a conical diverging surface at the end of said preheat tube; and (4) a bulking chamber adapted to contain a compacted yarn mass therein, said chamber having a smooth side wall portion adjacent to the conical surface of the diffuser for forming the compacted yarn mass and a slotted wall portion for receiving the compacted yarn mass and for discharging gas laterally from said yarn mass.
Advantageously, the position of the front of the plug within the bulking apparatus of this invention remains substantially constant. However, the invention also contemplates control means for regulating the position of the compacted yarn mass, i.e. the yarn plug in the bulking chamber. More specifically, it has been found that the position of the plug is dependent on the temperature and/or pressure of the entering heated gas as well as the temperature of the preheated feeder yarn. Yarn sensing means can be placed in the bulking chamber to determine the position of the initially formed plug. When this portion of the plug is displaced from the smooth wall portion of the bulking chamber onto the slotted portion, the temperature and/or pressure of the gas is decreased sufficiently to cause the yarn plug to return to its proper position on the front smooth wall portion. Likewise, displacement of the plug into the diffuser can be corrected by increasing the temperature and/or pressure.
In another system of the invention, the plug within the bulking apparatus can be controlled by regulating the position of the end of the plug pushed out of the apparatus. The plug is moving at a rate on the order of 1/200th of the yarn input rate in the conduit or like means for guiding the yarn. The plug is directed into a plug guide wherein an accumulator device or yarn sensing means, e.g. feeler elements, contact the yarn. When the plug moves past a predetermined set point, the yarn feeler element closes a switch and thereby causes the apparatus to shutdown. If the yarn recedes toward the inlet of the plug guide and accumulator device, another feeler element and associated switch are actuated to cause shutdown. Between these positions, additional sensing means can be used to regulate the speed of the take-up device. A control device of this type is further described in the application of Roger H. Fink et al. executed on even date herewith (Ser. No. 517,786 filed Oct. 24, 1974 and now U.S. Pat. No. 3,958,734).
The process and apparatus of the invention will be further understood from the following detailed description and the accompanying drawings wherein:
FIG. 1 is a sectional view of a preferred embodiment of the apparatus for texturizing a yarn according to this invention;
FIG. 2 is a cross-sectional view of the apparatus taken along line 2--2 in FIG. 1;
FIG. 3 is a perspective side view of a yarn plug produced by the process of the invention; and
FIG. 4 is a sectional view of the yarn plug taken along line 4--4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, nylon feeder yarn 1 is drawn from a pair of feed rollers or like feeding device into an aspirator jet unit, generally designated by reference numeral 2, through yarn inlet tube 3. Superheated steam is supplied to the aspirator jet unit by steam inlet pipe 4 and discharges into a temperature sensing zone 5 before passing through a narrow passage 6 of the jet nozzle 7 to the orifice 8.
The longitudinal axis of the yarn inlet tube is arranged at an angle of about 45° with the longitudinal axis of the jet and is positioned with an exit opening upstream of and closely adjacent to the jet orifice. Also, as shown in FIG. 2, the axis of the yarn inlet tube 3 and the axis of the passage 6 leading to the orifice 8 are in the same vertical plane.
Advantageously, it has been found that when the discharge end, i.e. the tip, of the jet nozzle is bent at an angle of from 2° to 8° from the longitudinal axis of the nozzle, the symmetry of the yarn plug, i.e. with respect to the arrangement of the filaments therein and uniformity of its outer surface, is greatly improved. Furthermore, the tip preferably should be bent towards the lower right-hand quadrant of the cross-section shown in FIG. 2, although advantageous effects are also obtained when the tip is bent towards the surrounding sectors that are circumscribed by an arc angle of 45° (the area to the right of line "a--a" in FIG. 2 defines the sectors wherein these results are obtained). It will be understood that the "tip" of the jet nozzle refers to about the last 3/8 inch of the nozzle.
It will be appreciated that it is generally preferred also to employ an external preheater means (not shown) such as a plate heater, heated godet, etc. that will heat the yarn to a temperature of from 150° C.-200° C. before it enters the yarn inlet tube.
The feeder yarn is propelled or carried by the steam through the conically-shaped entrance 9 (having a convergent angle of about 60°) of the preheat tube 10 into passage 11 where the yarn is preheated by the superheated steam to a temperature between the second order transition point and the melting point of the yarn.
The yarn and steam then enter a diffuser 12 at the other end of tube 10 which is also provided with a conical wall 13. The angle of divergence of wall 13 may vary from about 20° to 60° and preferably is about 30°.
In the diffuser, the steam rapidly expands and causes the yarn to splay outwardly towards the surface of wall 13. The flat shoulder 14 at the end of the diffuser creates an eddy-effect to allow the yarn filaments to go onto a smooth wall portion 15 which defines the front end of the bulking chamber 16 and then to fold inwardly against themselves thereby forming a compacted yarn mass. The yarn mass soon accumulates and forms an elongated plug that is pushed into an air permeable, e.g. slotted, wall portion 17 of the bulking chamber by the back pressure developed in the smooth side wall portion due to resistance of the steam flowing through the plug. A plurality of slots 17' are arranged uniformly around the periphery of the chamber. In the embodiment shown, 18 slots are provided in the tubular member defining the bulking chamber. Reference numeral 18 generally designates the plug; whereas 18' refers to the initially formed yarn mass or plug; and reference numberal 18" designates the portion of the plug extending out of the slotted portion. It will be appreciated that the tubular member forming the air permeable portion of the bulking chamber may be provided with perforations having different configurations, e.g. circular, which are arranged in various patterns to provide uniform escape of gas therefrom. Also, this portion of the chamber could be formed by convolutions of a coil or like wall construction having opening therein. Preferably a slotted tubular member, as shown, is employed since it provides guide strips between the slots that promote displacement of the plug with uniform escape of the steam.
In the smooth side wall portion 15, all of the steam passes axially through the formed plug before discharging laterally through slots 17'. The steam exiting from the slots then collects in an exhaust chamber 19 surrounding the slotted portion of the bulking chamber. The steam is then discharged to the atmosphere or a collecting tank via exhaust pipe 20. A heat insulated shroud 21 surrounds the entire yarn bulking apparatus. Plug 18 is further pushed through a tubular conduit 22 to a take-up unit 23 in a manner similar to that described in the above-referenced Fink application. This unit includes a plug guide for positioning the end of the plug as a yarn bundle is pulled from the plug by a take-up device for winding the yarn into a package.
In order to determine the temperature of the steam just prior to entering the jet nozzle a temperature sensing control 24 with a temperature probe 25 is provided. The temperature probe extends into zone 5 at substantially right angles to the steam entering through inlet pipe 4. A housing 26 is provided for the temperature probe. As heretofore described, the take-up device withdraws the yarn at a rate which is about 15-25% less than the rate the yarn is introduced by the feed means. Both the take-up device and the feed means operate at substantially constant rates. Also, appropriate control means may be provided to allow for variations in the plug formation during operation of the apparatus. These controls have been described heretofore.
From the foregoing detailed description of the apparatus and process, it will be recognized that the present invention provides several advantages in texturizing the yarn. In particular, the smooth wall portion of the diffuser enables the yarn to fold upon itself to form a more uniform plug in that the filaments pack more uniformly to provide greater density and the smooth outer periphery of the plug allows it to pass more uniformly through the bulking chamber. Also, since the yarn filaments which fold upon themselves on the smooth side wall portion of the bulking chamber; are generally arranged radially inward from the smooth side wall portion and at an angle to its longitudinal axis, when the plug moves forward due to the pressure exerted on it by the steam, the steam is allowed to exhaust through the slots in the slotted portion of the bulking chamber without causing the filaments of the yarn to pass into the slots.
Moreover, it is of considerable importance that all of the steam must pass through the initially formed portion of the plug. This results in a more uniform and effective steam heating and conditioning of the filaments in the folded and compacted state. Also, the steam and filaments carried by the steam more uniformly impinge on the initially formed yarn plug since the steam does not escape directly to the atmosphere but is controlled by being blown through at least the initially formed portion of the plug. Consequently, the crimps obtained in the filaments are more uniform and evenly distributed throughout.
Because the plug forms on a solid side wall portion of the bulking chamber and all steam passes forward through the plug at this stage of the process, a substantially greater pushing force (i.e. plug compacting force) is exerted on the front of the yarn plug. Consequently, the plug is less sensitive to stack-height variation and thereby permits longer plugs to be utilized without causing variations in the bulkiness and crimps of the yarn. Also, the aspirator jet is less subject to variations due to a change in back pressure since the plug can move forward and backward in the smooth side wall portion of the bulking chamber without changing the exhaust pattern of the steam through the slotted wall portion of the chamber.
It will also be appreciated that since there is a substantially large pushing force available for causing the plug to move forward, since the apparatus is less sensitive to moderate variations in the positioning of the initial plug portion and since all the steam is exhausted from the plug before the plug exits from the top of the slotted portion of the bulking chamber, the end or top of the plug is made available for contact with sensing devices such as microswitches, pneumatic sensors, photoelectric sensors and the like for end-out detection and/or windup speed control. Also, the configuration of the yarn plug is more geometrically defined and has a firm outer periphery thereby enabling the plug to be sensed more easily by feeler type devices.
The process of the invention will be further understood from the following examples:
EXAMPLE 1
A nylon carpet yarn of 136 filaments with trilobal cross-section and a denier of 2,080 after being drawn to an approximate 4.0 draw ratio is taken from a creel and passed over a plate-type heater operated at 188° C. This yarn then enters the nip of two feed rollers and is nipped with sufficient force to pull the yarn across the preheater plate. From the feed rolls, the yarn is introduced into the yarn inlet tube of an apparatus of the type illustrated in FIGS. 1 and 2 of the drawings. This yarn is initially strung up by passing the feeder yarn through the apparatus to be received by an operator who secures the yarn to a take-up device, particularly a flat package take-up device. This take-up device operates at a take-up speed of approximately 835 meters per minute; whereas the feed rate is 980 meters per minute.
Simultaneously, with actuation of the take-up device superheated steam at 235° C. and 75 psig. is introduced into the steam inlet pipe. The yarn is continuously drawn into the bulking apparatus to provide a yarn plug which is continuously forced out of the apparatus and then passed through a plug guide operatively associated with the take-up device wherein a yarn bundle is continuously separated from the plug at a tension of up to about 5 grams by the take-up device.
The resulting yarn product was evaluated over a week's time and found to exhibit the following average properties;
Bulked denier: 2759
Strength (G/Den): 2.22
Elongation (%): 58.3
Bulk(%): 15
Tangle Factor (100 in): 217
Crimp Count (1 in.): 13.0
Shrinkage (%) 2.9
Finish (%): 0.8
Also, evaluation of the plug revealed that the density of the plug varied from a minimum of about 3.6 g/cu.in. to a maximum of about 3.75 g/cu. in.
EXAMPLE 2
Additional runs were conducted in which the same feeder yarn as used in Example 1 was employed in the same apparatus to produce carpet yarns. Upon evaluation over a period of several weeks, it was found that the denier of the yarn varied from a low of 2722 to a high of 2803 and the average crimp count per inch varied from about 12 to about 14. Also, the other above-noted properties were found to be substantially uniform over this period and comparable to those obtained in Example 1. It will be apparent that these results establish that the process of the present invention provides an exceptionally uniform yarn product having excellent crimp. In all cases, the yarn was found to be substantially free of snarls and tangles.
EXAMPLE 3
Microscopic examination of the yarns produced in the foregoing Examples revealed that each of the filaments has a uniform degree of eveness and crimp and that the crimp count throughout substantially all of the filaments of the yarn varied from 12 to 14, with occasional minute crunodal loops appearing in the filaments. These loops are removed from the yarn upon applying a tension of about 80 grams.
The configuration of the yarn plug or mass of compacted yarn produced by the process exemplified in the foregoing Examples is shown in FIGS. 3 and 4. It will be seen that the plug has a body with an elongated rod-like shape in which the filaments of the yarn are compacted in a dense arrangement. A major portion of the filaments have portions which extend at an angle to the axis of the plug as heretofore described with intermediate portions or sections of the filaments forming alternate inwardly and outwardly curved folds or pleats. The appearance of this arrangement of the filaments is somewhat like that of an accordion. It will be noted that in FIG. 3, an end portion of the semi-rigid body of the plug has been broken away from the remaining portion of the plug to show the arrangement of the filaments.
As further shown in FIG. 3, the filaments when pulled from the plug in the form of a yarn bundle appear to converge together from points evenly distributed alternately at the center and then at the periphery of the plug. These filaments are elongated into the form of a yarn bundle without the occurrence of any snarls or tangles.
EXAMPLE 4
In order to further evaluate the voluminousity of texturized yarn obtained by the process of this invention, additional experiments were conducted. In these experiments, sample lengths of yarn were passed through a sensing head of a G.E. "Qualigard" yarn monitoring device. In general use, the yarn sensing head of this device operates as a backpressure air gaging sensor which detects variations in yarn denier and converts the variations to a minute proportional air pressure.
In the following experiments, the sensing head was employed to provide a backpressure reading that is proportional to the voluminousity of the texturized yarn. Air was supplied to a SHPAV with a constant pressure, i.e. 25 psig. This air enters the sensor slot at its midpoint and escapes through the slot at either end. A yarn passing through the sensor slot impedes the air flow and creates a backpressure proportional to the total effective cross-sectional area of the yarn. The backpressure is converted into a "Qualigard" reading in inches of water, a larger number for equivalent flat denier indicating a more voluminous yarn.
The test apparatus used was a "Qualigard" Model CR 280 YM31A with sensing head No. CR280 GP11A060. This test apparatus was calibrated by inserting a wire having a diameter of 0.0404 into the slot of the sensing head. The air supply to the sensing head pressure adjustment valve was adjusted to 25 psig. and the sensing head pressure adjustment valve was adjusted to read 14 inches of water. Then the yarn sample was passed through the sensor slot at a present speed of 1 inch per sec. and a tension of 70 grams.
Samples of nylon yarn produced in accordance with the procedure outlined in Example 1 having actual denier of 2700 (Sample A) and samples of nylon yarns (Samples B and C) having deniers comparable to Sample B, which are commercially available, were evaluated. The results of these tests are tabulated below:
______________________________________Yarn Qualigard Reading Actual Denier______________________________________A 35 2700B.sup.1 22 2750C.sup.2 23 2600______________________________________ .sup.1 Product of Allied MERGE 90026 (2750) .sup.2 Product of DuPont MERGE 13 828M (2600)
From the above data, it will be apparent that the texturized yarns of the invention are more voluminous than the comparable commercially available yarns.
The smooth tightly packed yarn plug produced by the process of this invention has a density from about three to four grams per cubic inch. The density and size of the plug are sufficient to permit the plug to be physically handled or manipulated by a machine without any significant distortion. This permits numerous treatments to be made while the yarn is in this compact and slow moving geometry within the apparatus of the invention.
Advantageously, the surface of the yarn plug may also be cut to a shallow depth at spaced intervals around the periphery of the plug. In this manner, some but not all of the filaments in the resulting yarn bundle would be cut resulting in a fuzzy or staple-like yarn product.
It will be further appreciated that various anti-static and/or anti-soiling materials may be added to the yarn while it is retained in the bulk form by directly applying these materials to the plug. Also, additional heat-setting of the yarn can be effected while the yarn is in the plug form.
It will be appreciated that the dimensions of the various elements of the apparatus of the present invention may vary considerably while still providing the necessary passages for bulking of the yarn. Generally, the nozzle jet has a diameter that is equal to or approximately one-half the diameter of the preheat tube. Also, the bulking chamber usually has a diameter of at least about seven times the diameter of the nozzle jet with a smooth side wall portion of at least about one-half inch to insure the formation of a suitably sized plug. Moreover, the length of the entire bulking chamber usually varies from about three to ten times its diameter with the slots provided in the slotted wall portion each having a width from a few to several one hundreds of an inch.
It will be appreciated that at the higher operating pressures, e.g. at 70 psig. or above, the aspirating effect that occurs at the yarn inlet of the jet means is no longer apparent, i.e. the pressure goes from negative to positive during the bulking operation.
While the novel embodiments of the invention have been described, it will be understood that various omissions, modifications and changes in these embodiments may be made by one skilled in the art without departing from the spirit and scope of the invention. | Multifilament synthetic polymer yarn is texturized by passing the yarn in a gas stream to a diffuser zone to cause the gas to expand and the yarn filaments to splay open. The yarn filaments are then separated from the expanding gas stream towards a continuous smooth side wall surface defining one end of a bulking chamber. At this end of the chamber the filaments are impacted with each other and the smooth wall surface to form a compact yarn mass. This yarn mass is pushed into and through a slotted portion of the bulking chamber. Simultaneously the gas passes through the yarn mass initially formed in the chamber and then discharges laterally from this mass as it is pushed into the slotted portion. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to semiconductor devices and more particularly to an improved conductor structure.
2. Description of Related Art
A buried bit line ROM cell is by far the most competitive ROM structure of high density ROM memories because it is contactless and hence the cell size is smaller. The dimension of a cell is determined mainly by the pitches of the word line polysilicon structures employed to connect to the cells and the buried N+ bit lines. When the cell dimension shrinks, the buried bit line N+ doping needs to be reduced to avoid the problem of short channel punch through.
A device made with the low N+ concentration produced by the reduced level of doping is sensitive to the counter doping from P- type (boron) doping for programming in the channel region.
The boron implantation with a dose >1×10 14 /cm 2 in the channel area for programming also goes into the source/drain buried N+ area with an As+ implantation dose of about 1×10 15 /cm 2 , which increases source/drain capacitance. Low buried bit line resistance is important because every cell will have a different bit line resistance to metal pick up contact (low resistance metallic line in contact with the contact opening.) For example, there will be one contact for every 32 cells.
FIG. 1 shows a plan view of a semiconductor device and FIG. 2 shows a sectional view of that device taken along line 2--2 in FIG. 1. For a certain design rule, the minimal opening for ROM code implantation is the same as channel area 10 in a semiconductor substrate 9 shown in FIGS. 1 and 2 where 10 is the channel area and the word line 11 is formed of polysilicon or polycide, in accordance with the state of the art and buried bitlines 14 and 14' are at right angles to word line 11.
The cross section along the direction of word line 11 taken along line 2--2 in FIG. 1 is shown in FIG. 2. The word line 11 crosses over the SDOX (Source/Drain Oxide) layer 12. The SDOX layer 12 is grown over an N+ implant area during gate oxide oxidation. SDOX layer 12 is thicker (between about 600 Å about 1500 Å) than the gate oxide (about 200 Å) and the channel area 10 composed of a gate oxide over P- well (P- sub) area. The bit lines 14, 14' (source/drain) doped with N+ ions lie beneath the SDOX layer 12. The source and the drain regions can be interchangeable. The source and the drain are bit lines also.
Photoresist layer 15 has been added to the structure and patterned in the usual photolithographic fashion. The openings 16 are above the channel areas 10 and the boron B+ ions are implanted in subchannel area 18 beneath the channel area 10.
The implanted boron plus lateral diffusion from both the N+ area and the channel boron area results in lower N+ concentration near the source/drain edge 99 as shown in FIG. 2, which in turn, results in higher N+ resistance. Also, the formation of N+/P+ junctions (P+ represents boron doping in channel area) results in high source/drain junction capacitance (C j .) All the factors of high sheet resistance (high Rs of N+) and high junction capacitance,( high C j of N+/P+) are the challenges for high speed design of buried bit line ROM products. Note that R s (sheet resistance) as employed herein refers the value of diffused resistance per unit square of a buried bit line. The unit of R s is ohms per square. As employed herein, junction capacitance (C j ) refers to source/drain to substrate junction capacitance.)
FIG. 3 is a plan view showing a region of the P+ layer 30 within a ROM opening 31 framed by the bitlines 14 and 14' and within the upper word line 11.
FIG. 4 shows a section taken along line 4--4 in FIG. 3 with the P+ layer illustrated beneath the channel area 13.
An object of this invention is to make the ROM code implantation (boron for this case) into the center part of the channel area, which can achieve the goals of enhancing programming (turning the transistor off) and preventing the P+ layer from encroaching upon or contacting with the N+ source/drain junction.
SUMMARY OF THE INVENTION
A semiconductor device and a method of manufacturing a semiconductor device includes the steps of forming a first conductivity type layer on one surface of a work piece comprising a semiconductor substrate. A gate oxide is formed on the surface of the substrate. A first conductive structure is formed on the gate oxide, preferably consisting essentially of polysilicon. An insulating structure is formed in contact with the first conductive structure. Material is removed from the surface of the first conductive structure to expose at least a portion of the surface of the first layer, and to form on the remaining structure on the workpiece a second conductive structure consisting essentially of polysilicon. The second conductive structure is in electrical contact with the first conductive structure. Thus a compound conductive structure is provided on the work piece.
Preferably, the first conductive structure consists essentially of polysilicon, and the second conductive structure consists essentially of polysilicon.
Preferably, the first conductive structure is patterned into segments, the insulating structure is formed between the segments, and the second structure is deposited over the top of the first conductive structure and the insulating structure.
Preferably, a sidewall structure is formed adjacent to the insulating structure prior to deposition of the second conductive structure, and preferably, the sidewall comprises a nitride spacer.
It is preferred that the process of this invention includes the additional steps as follows:
a) patterning the conductive structure into segments,
b) forming a sacrificial structure on the first conductive structure,
c) forming the insulating structure over the work piece,
d) removing the sacrificial structure,
e) exposure of at least a portion of the surface of the first conductive structure between the segments, and
f) deposition of the second structure over the top of the first conductive and the insulating structures.
Preferably the sacrificial structure is composed of a sandwich of oxide and polysilicon and the insulating structure comprises a CVD oxide layer deposited over the work piece.
Preferably the first conductive structure is patterned into segments, the insulating structure is formed on the surface of the first conductive structure, and the second structure is deposited over the top of the first conductive structure and the insulating structure into contact with at least the edges of the first conductive structure.
Preferably, a sidewall structure is formed adjacent to the insulating structure prior to deposition of the second conductive structure.
Preferably, a nitride deposition is patterned on the first structure and then a sidewall structure is formed adjacent to the insulating structure prior to deposition of the second conductive structure.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other aspects and advantages of this invention are explained and described below with reference to the accompanying drawings, in which:
FIG. 1 is a plan of a semiconductor device illustrating a certain design rule, with a minimal opening for ROM code implantation in a semiconductor substrate.
FIG. 2 shows a section taken along line 2--2 in FIG. 1.
FIG. 3 shows a plan view of a region of a P+ layer within a ROM opening framed by the bitlines and within an upper word line.
FIG. 4 shows a section taken along line 4--4 in FIG. 3.
FIG. 5 shows a perspective, fragmentary, partially sectional view of a semiconductor substrate in accordance with this invention.
FIG. 6 shows the device of FIG. 5 after additional processing steps have been performed.
FIG. 7 shows the device of FIG. 6 after resist has been removed in the conventional way lifting off excess oxide and leaving the oxide which was deposited into openings.
FIG. 8 is a top plan view of FIG. 7.
FIG. 9 shows the product of FIGS. 7 and 8 after photoresist has been applied and patterned.
FIGS. 10A-10E show a second embodiment of the process of this invention.
FIGS. 11A-11D show a third embodiment of the process of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
Referring to FIG. 5 which is a perspective, fragmentary, partially sectional view, a semiconductor substrate 20 has a p sub (p well) formed by the conventional process of diffusion and drive-in at a dose level of about 5×10 12 /cm 2 . A gate oxide layer 24 having a thickness of about 200 Å, which was formed by the process dry oxidation at 900° C. or a well-known conventional method, has in turn been coated with a poly 1 layer 22 formed to a thickness of about 500 Å using a conventional method such as LPCVD. The device with poly 1 layer 22 is then coated with photoresist 23 which has been patterned as shown in FIG. 5 with parallel stripes of photoresist 23. The photoresist 23 is patterned in accordance with the well known state of the photolithography art.
The mask formed in the resist 23 is employed for removing poly 1 layer 22 in the areas which were exposed by the development of the mask 23. The unwanted portions of poly 1 layer 22 are etched away by an anisotropic dry etching method. Mask 23 serves as the poly 1 etch mask and also serves as a mask for the buried N+ implant in buried bit line regions 27.
A "VT adjustment implant" is made as shown in FIG. 5. A VT adjustment implant refers to a regular ion-implant step made to adjust the VT (threshold voltage) value of a transistor which can be done either before or after gate oxidation. A wet chemical etch can be employed as an alternative.
Next, FIG. 6 shows the device of FIG. 5 after additional processing steps have been performed. An ion implant of buried arsenic (As) N+ ions is deposited into the regions 27 (using the same mask as poly 1 layer 22) shown in FIG. 6. The chemical species of the arsenic dopant is implanted with a dose of between about 1×10 15 /cm 2 to about 3×10 15 /cm 2 , preferably less than or equal to 3×10 18 /cm 2 . It is implanted at an energy of between about 50 keV and about 100 keV in a high current implanter type of tool.
Subsequently, referring to FIG. 6, a thick layer of about 5000 Å of oxide 26 (SiO 2 ) is deposited by a low temperature CVD process (at a temperature of about 300° C.) for the purpose of lift off. The SiO 2 is deposited by a low temperature CVD process at a temperature of between about 250° C. and about 350° C. to a thickness of about 5000 Å by CVD (chemical vapor deposition) from gases selected from the group consisting of silane (SiH 4 ) and oxygen (O 2 .)
In FIG. 7 the resist 23 in FIG. 6 has been removed in the conventional way lifting off the excess oxide 26 and leaving the oxide 26 which was deposited in the openings down onto the poly 1 layer 22. Then an optional silicon nitride Si 3 N 4 spacer 28 has been deposited adjacent to the oxide 26 using the process of nitride deposition following an etch back employing a conventional anisotropic dry etching process.
This process with the nitride spacer 28 narrows the code implant opening further. However, the poly 2 deposit narrows the code implant to a degree approximating a sufficient amount. Accordingly, in that case, the nitride spacer 28 is optional. Above the spacer 28 and oxide 26, another polysilicon, poly 2, layer 29 is deposited upon the top of the oxide 26, the spacers 28 and the exposed poly 1 layer 22. Note that the poly 1 and poly 2 layers are connected mechanically and electrically or "shorted together", i.e. in electrical contact, in the channel area 33 between the bit lines 27. The poly 2 layer is deposited by the conventional method with a poly 2 thickness of between about 2000 Å and about 4000 Å.
Referring to FIG. 8, the pattern of poly 1 layer 22 is parallel long lines. Poly 2/poly 1 etch (layers 32 and 22) is a stacked layer etch.
Note that the thickness of the poly 2 layer 29 determines the width of the code implant because the layer deposits on the side walls as it deposits onto the poly 1 layer.
The thicker dimension of the oxide 26 reduces the capacitance between the word lines 32 and the bit lines 27, since they are spaced farther apart. The poly 2 layer is doped with phosphorous.
After the doping of poly 2 layer 29, an optional silicide deposition (not shown) can be made. The use of silicide or poly 2 is optional. Silicide on poly 2 is a well known polycide gate process, which is helpful to reduce the word line resistance.
Referring to FIG. 9, the poly 2 layer 29 is next covered with photoresist layer 35 and exposed to word line photolithography and a mask is developed. Next the poly 2 layer 29 and poly 1 layer 22 are etched using the mask formed by the resist layer 35.
There is an N+/P+ source/drain of peripheral transistors formed (not shown.) The strips of poly 2 word lines 32 are shown in FIG. 8 which is a top plan view of FIG. 7. The buried bit lines 27 are also shown to facilitate explanation. FIG. 9 shows the product of FIG. 7 after photoresist 35 has been applied above the poly 2 layer 29, etc.
The photoresist 35 is formed into a mask with an opening 37 above the channel 33. An ion implant 36 of boron B+ ions is implanted into the opening 37. The chemical species of the dopant implanted is boron with a dose of between about 7×10 13 /cm 2 to about 2×10 14 /cm 2 , at an energy of about 100 keV. At the end of the ion implantation, the resist is removed.
By combining the nitride spacer 28 and the poly 2 structure 29, a self aligned smaller ROM code opening is provided for implanting of boron.
Second Preferred Embodiment
Referring to FIG. 10A, a semiconductor substrate 20 is coated with a gate oxide layer 40, which is coated in turn with a poly 1 layer 38 with a thickness of about 500 Å. Next, an oxide layer 39 is applied to a thickness of about 200 Å above poly 1 layer 38. Oxide layer 39 in turn is coated with a layer 60 of poly 2 deposited to a thickness of about 3,000 Å. A mask is applied and openings 62 are opened in the layers 38, 39 and 60 down to the gate oxide 40. Then the substrate 20 is ion implanted with N+ ions according to the process described above in connection with FIG. 5 producing the buried bit lines, source/drain of memory cells as shown by regions 57. The process of employing poly 2 raises the height of the structure giving a resulting thicker oxide layer than the poly 1 gate electrode 38.
Referring to FIG. 10B a layer 64 of CVD oxide, photoresist or SOG (Spin On Glass) is deposited over the structure of FIG. 10A.
Referring to FIG. 10C the device is shown with a planarized surface provided by a planarization etch back process where layer 64 has been planarized by a dry etch back exposing the upper surface of the poly 2 layer 60.
Referring to FIG. 10D, the poly 2 layer 60 and the layers of oxide 39 have been removed. The result is that the upper surface of poly 1 layer 38 is exposed through openings 68.
Referring to FIG. 10E a layer 70 of poly 3 is deposited upon the product of FIG. 10D in contact with poly 1 layer 38 partially filling the openings 68. Layer 38 of poly 1 and layer 70 of poly 3 are electrically connected. The result is that, the word lines are formed in layer 70 (after it has been etched by a lithography process as described above.)
Third Preferred Embodiment
Referring to FIG. 11A, a semiconductor substrate 20 is coated with a gate oxide layer 40. Layer 40 is coated in turn with a poly 1 layer 41 with a thickness of about 500 Å, which in turn is coated with a layer 42 of silicon nitride (Si 3 N 4 ) deposited to a thickness of about 3000 Å.
Above the nitride layer 42, a photoresist mask 43 has been formed by depositing photoresist, exposing and developing the mask 43 in the photoresist with openings 44 for the N+ bit line to be formed in FIG. 11C.
Referring to FIG. 11B, the nitride layer 42 has been etched using the process of nitride etching employed above leaving the openings 44.
Next, in a blanket deposition, oxide layer 45 is deposited by chemical vapor deposition to a thickness of about 3000 Å, using the process described with respect to oxide 26 in FIG. 6 above.
Then the oxide layer 45 is etched using a conventional dry etch process to form oxide spacers 45 adjacent to the nitride structure 42 remaining leaving the openings 44 narrower by the width of the spacers 45.
Referring to FIG. 11C, the poly 1 is etched using the process employed above for etching poly 1 in FIG. 5. A conventional poly etch process can be employed.
Next, an N+ implant is performed in bit lines 47. The process implants ions of arsenic (As), as N+ ions, deposited into the implant regions (bit lines 47 shown in FIG. 11C.) The chemical species of the N+ dopant is implanted with a dose of between about 1×10 15 /cm 2 , and preferably less than or equal to about 5×10 15 /cm 2 . It is implanted at an energy of between about 50 keV and about 100 keV in a conventional high current type of tool.
After the N+ bit line implantation, it is optional that an oxidation of the surface of the gate oxide is performed by a conventional thermal oxidation, e.g. steam oxidation at a temperature of about 900° C. for about 10 minutes.
In FIG. 11D, the following steps occur.
1) There is a poly 2 dep/doping (silicide formation (optional.)
2) An optional poly 2 (word line) masking and etching is performed, as before.
3) A ROM code masking is applied as before.
4) A boron implant is performed as before.
While this invention has been described in terms of the above specific embodiment(s), those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims, i.e. that changes can be made in form and detail, without departing from the spirit and scope of the invention. Accordingly all such changes come within the purview of the present invention and the invention encompasses the subject matter of the claims which follow. | A semiconductor device and a method of manufacturing a semiconductor device includes the steps of forming a first conductivity type layer on one surface of a work piece comprising a semiconductor substrate. A gate oxide is formed on the surface of the substrate. A first conductive structure is formed on the gate oxide consisting essentially of polysilicon. An insulating structure is formed in contact with the first conductive structure. Material is removed from the surface of the first conductive structure to expose at least a portion of the surface of the first layer, and to form on the remaining structure on the workpiece a second conductive structure consisting essentially of polysilicon. The polysilicon is in electrical contact with the first conductive structure. Thus, a compound conductive structure is provided on the work piece. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority under 35 USC §119 from Korean Patent Application No. 10-2013-0027636 filed on Mar. 15, 2013 in the Korean Intellectual Property Office (KIPO), and all the benefits accruing therefrom, the contents of which are herein incorporated by reference in their entirety.
BACKGROUND
1. Technical Field
Exemplary embodiments of the present disclosure are directed to methods and apparatuses for soft-decision detection in 2×2 MIMO systems, and more particularly to methods and apparatuses for detecting the soft-decision of a signal modulated through an MDCM (Modified Dual-Carrier modulation), one of precoding modulation schemes in a UWB (ultra-wideband) system based on a 2×2 MIMO (multi-input multi-output) MB-OFDM (multi-band orthogonal frequency division multiplexing) scheme.
2. Discussion of the Related Art
An MB-OFDMA UWB communication system employs an MDCM technology, which is a precoding modulation scheme that can improve PER performance and the receive distance. MDCM technology is a modification of a DCM technology that provides higher speed transmission. MDCM technology combines and converts two independent 16-QAM (quadrature amplitude modulation) symbols into two 256-QAM symbols that are carried on two subcarriers which are spaced apart from each other by the maximum distance of an OFDM symbol. MDCM technology allows diversity gains for different subcarriers to be acquired in one frequency band.
To detect an MDCM signal while acquiring the diversity gains in a receiving stage, an ML (Maximum-Likelihood) scheme may be used. Since a SISO system can detect imaginary and real parts, a SISO system can be implemented without greatly increasing complexity even if a complex ML scheme is used. However, when MDCM technology is applied to a 2×2 MIMO system, the 2×2 MIMO system might not separately detect real and imaginary parts, and the 2×2 MIMO system performs detection similar to a 4×4 MIMO system. Therefore, a 2×2 MIMO system performs detection through an ML scheme or an SD (sphere decoding) scheme used in an existing MIMO system.
Since an ML scheme is complex, an ML scheme might not be implemented in a real system. Although an SD scheme is less complex than an ML scheme, an SD scheme is sequential due to a depth-first scheme. Accordingly, an SD scheme is not suitable for an MDCM-applied 2×2 MIMO system that must process data at a high data rate.
In addition, the MB-OFDM UWB physical layer standard recommends the use of MDCM modulation technology together with LDPC (low-density parity check) channel coding technology. Accordingly, LDPC channel decoding must be performed at the receiver of an MB-OFDM system. Since LDPC channel decoding is performed based on a log-likelihood ratio (LLR) for each encoded bit, a detector for the 2×2 MIMO system employing MDCM transmits a correct LLR value to an LDPC decoder.
A detection scheme that generates an LLR value and transmits the LLR value to a channel decoder is referred to as a soft-decision detection scheme. Although an ML scheme is applicable to a soft-decision detection scheme, and optimal performance can be achieved, the complexity of an ML scheme inhibits implementation. In addition, since an LLR value for soft-decision might not be generated through an SD detection scheme, SD detection impossible may not be possible.
SUMMARY
Some exemplary embodiments provide methods and apparatuses for soft-decision detection in 2×2 MIMO systems capable of generating LLR values, which are not generated through an SD scheme, and which have significantly lower computational complexity than that of the ML scheme.
Some exemplary embodiments provide methods and apparatuses for soft-decision detection in 2×2 MIMO systems capable of facilitating implementation of a decoder in a high-speed 1280+ Mbps transmission mode.
According to exemplary embodiments, a method for detecting soft-decisions in a 2×2 MIMO system, includes detecting all candidate symbol vector sets S for which there exists all values of a real part and an imaginary part; and calculating a log-likelihood ratio (LLR) with respect to the candidate symbol vector sets S from
LLR
(
b
k
i
)
=
min
s
∈
S
⋂
β
i
,
k
-
ED
(
s
)
2
σ
n
2
-
min
s
∈
S
⋂
β
i
,
k
+
ED
(
s
)
2
σ
n
2
,
in which β i,k − represents a set having as elements those candidate symbol vectors in set S for which a kth bit of a symbol transmitted through an ith transmitter antenna is 0, β i,k + represents a set having as elements those candidate symbol vectors in set S for which the kth bit of the symbol transmitted through the ith transmitter antenna is 1, σ n represents a standard deviation of additive white Gaussian noise (AWGN), and ED(s) represents a Euclidean distance for an element s of the candidate symbol vector set S.
Each candidate symbol vector set S may be a union S=S P ∪S B of a forward candidate symbol vector set S F and a backward candidate symbol vector set S B .
The method may further comprise forward detecting symbols in an order of [Ŝ 2 n+50 , Ŝ 2 n ] and [Ŝ 1 n+50 , Ŝ 1 n ], and backward detecting symbols in an order of [Ŝ 1 n+50 , Ŝ 1 n ] and [Ŝ 2 n+50 , Ŝ 2 n ].
Forward detecting and backward detecting may be performed on a 2×2 matrix based on candidate symbol vector pairs [Ŝ 2 n+50 , Ŝ 2 n ] and [Ŝ 1 n+50 , Ŝ 1 n ], respectively.
Forward detecting may include selecting p symbols for Ŝ 2 n+50 ; selecting q Ŝ 2 n symbols for each of the p Ŝ 2 n+50 symbols to select a total of p×q Ŝ 2 n symbols; selecting r additional Ŝ 2 n symbols; selecting one Ŝ 1 n+50 symbol for each of the p×q+r Ŝ 2 n symbols to select a total of p×q+r Ŝ 1 n+50 symbols; and selecting one Ŝ 1 n symbol for each of the p×q+r Ŝ 1 n+50 symbols to select a total of p×q+r Ŝ 1 n symbols.
Forward detecting the candidate symbol vector pair [Ŝ 2 n+50 , Ŝ 2 n ] may include converting a received signal comprising the candidate symbol vector pair [Ŝ 2 n+50 , Ŝ 2 n ] into an upper triangular matrix by applying a conjugate transpose of a matrix obtained through QR decomposition to the received signal; calculating a Euclidean distance for all cases of the candidate symbol vector pair [Ŝ 2 n+50 , Ŝ 2 n ]; selecting L Ŝ 2 n symbols for the Ŝ 2 n+50 from symbol vector pairs [Ŝ 2 n+50 , Ŝ 2 n ]; determining if values of the real part and the imaginary part exist in the selected Ŝ 2 n symbols; and selecting an additional Ŝ 2 n symbol that minimizes the calculated Euclidean distance with respect to a Ŝ 2 n symbol for which the values of the real part and the imaginary part are absent.
The method may further include performing channel ordering for the received signal before forward detecting the candidate symbol vector pair, and applying the conjugate transpose of the matrix obtained through the QR decomposition of a channel matrix to the received signal to convert the received signal to the upper triangular matrix.
Forward detecting the candidate symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ] may include applying the conjugate transpose of the matrix obtained through the QR decomposition to the received signal comprising the symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ] to convert the received signal into the upper triangular matrix; selecting Ŝ 1 n+50 symbols from symbol vector pairs [Ŝ 1 n+50 , Ŝ 1 n ]; and selecting a Ŝ 1 n symbol with respect to each of the selected Ŝ 1 n+50 symbols.
The method may further include removing channel interference caused by the selected candidate symbol vector pairs [Ŝ 2 n+50 , Ŝ 2 n ] before forward detecting the candidate symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ], and performing channel ordering for the symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ].
Backward detecting may include selecting s symbols for Ŝ 1 n of the symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ]; selecting one Ŝ 2 n+50 symbol for each of the s Ŝ 1 n symbols to select a total of s Ŝ 2 n+50 symbols; and selecting one Ŝ 2 n symbol for each of the Ŝ 2 n+50 symbols to select a total of s Ŝ 2 n symbols.
Backward detecting the candidate symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ] may include converting a received signal comprising the candidate symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ] to an upper triangular matrix by applying a conjugate transpose of a matrix obtained through QR decomposition to the received signal; calculating a Euclidean distance for all cases of the candidate symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ]; and selecting an Ŝ 1 n symbol that minimizes the calculated Euclidean distance with respect to each of Ŝ 1 n symbols for which there exits values of the real part and the imaginary part.
The method may further include performing channel ordering for the received signal before backward detecting the candidate symbol vector pair, and applying the conjugate transpose of the matrix obtained through the QR decomposition of a channel matrix to the received signal to convert the received signal to the upper triangular matrix.
Backward detecting the candidate symbol vector pair [Ŝ 2 n+50 , Ŝ 2 n ] may include applying the conjugate transpose of the matrix obtained through the QR decomposition to the received signal including the symbol vector pair [Ŝ 2 n+50 , Ŝ 2 n ] to convert the received signal to the upper triangular matrix; selecting Ŝ 2 n+50 symbols from symbol vector pairs [Ŝ 2 n+50 , Ŝ 2 n ]; and selecting a Ŝ 2 n symbol with respect to each of the selected Ŝ 2 n+50 symbols.
The method may further include removing channel interference caused by the selected candidate symbol vector pairs [Ŝ 1 n+50 , Ŝ 1 n ] before backward detecting the candidate symbol vector pair [Ŝ 2 n+50 , Ŝ 2 n ], and performing channel ordering for the symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ].
According to exemplary embodiments, an apparatus for soft-decision detection in a 2×2 MIMO system, includes, a preprocessor configured to perform channel ordering, remove interference, and perform a QR decomposition operation with respect to a channel matrix of a received signal; a forward symbol vector detector configured to detect a symbol vector set S F comprising candidate symbols for which values of a real part and an imaginary part exist with respect to a first symbol pair according to a forward order based on a result of a forward QR decomposition of the preprocessor; a backward symbol vector detector configured to detect a symbol vector set S B comprising candidate symbols for which values of a real part and an imaginary part exist with respect to a second symbol pair according to a backward order based on a result of a backward QR decomposition of the preprocessor; and a log-likelihood ratio calculator configured to calculate a log-likelihood ratio with respect to all candidate symbol vector sets S=S F ∪S B from
LLR
(
b
k
i
)
=
min
s
∈
S
⋂
β
i
,
k
-
ED
(
s
)
2
σ
n
2
-
min
s
∈
S
⋂
β
i
,
k
+
ED
(
s
)
2
σ
n
2
,
in which β i,k − represents a set having as elements those candidate symbol vectors in set S for which a kth bit of a symbol transmitted through an ith transmitter antenna is 0, β i,k + represents a set having as elements those candidate symbol vectors in set S for which the kth bit of the symbol transmitted through the ith transmitter antenna is 1, σ n represents a standard deviation of additive white Gaussian noise (AWGN), and ED(s) represents a Euclidean distance for an element s of the candidate symbol vector set S.
According to exemplary embodiments, a method for detecting soft-decisions in a 2×2 MIMO system includes detecting all candidate symbol vector sets S for which there exist all values of a real part and an imaginary part, wherein each candidate symbol vector set S is a union S=S F ∪S B , of a forward candidate symbol vector set S F and a backward candidate symbol vector set S B ; forward detecting symbols in an order of [Ŝ 2 n+50 , Ŝ 2 n ] and [Ŝ 1 n+50 , Ŝ 1 n ], and backward detecting symbols in an order of [Ŝ 1 n+50 , Ŝ 1 n ] and [Ŝ 2 n+50 , Ŝ 2 n ], wherein forward detecting and backward detecting are performed on a 2×2 matrix based on candidate symbol vector pairs [Ŝ 2 n+50 , Ŝ 2 n ] and [Ŝ 1 n+50 , Ŝ 1 n ], respectively.
The method may further include calculating a log-likelihood ratio (LLR) with respect to the candidate symbol vector sets S from
LLR ( b k i ) = min s ∈ S ⋂ β i , k - ED ( s ) 2 σ n 2 - min s ∈ S ⋂ β i , k + ED ( s ) 2 σ n 2 ,
wherein β i,k − represents a set having as elements those candidate symbol vectors in set S for which a kth bit of a symbol transmitted through an ith transmitter antenna is 0, β i,k + represents a set having as elements those candidate symbol vectors in set S for which the kth bit of the symbol transmitted through the ith transmitter antenna is 1, σ n represents a standard deviation of additive white Gaussian noise (AWGN), and ED(s) represents a Euclidean distance for an element s of the candidate symbol vector set S.
Forward detecting the candidate symbol vector pair [Ŝ 2 n+50 , Ŝ 2 n ] may include converting a received signal comprising the candidate symbol vector pair [Ŝ 2 n+50 , Ŝ 2 n ] into an upper triangular matrix by applying a conjugate transpose of a matrix obtained through QR decomposition to the received signal, calculating a Euclidean distance for all cases of the candidate symbol vector pair [Ŝ 2 n+50 , Ŝ 2 n ], selecting L Ŝ 2 n symbols for the Ŝ 2 n+50 from symbol vector pairs [Ŝ 2 n+50 , Ŝ 2 n ], determining if values of the real part and the imaginary part exist in the selected Ŝ 2 n symbols, and selecting an additional Ŝ 2 n symbol that minimizes the calculated Euclidean distance with respect to a Ŝ 2 n symbol for which the values of the real part and the imaginary part are absent. Forward detecting the candidate symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ] may include applying the conjugate transpose of the matrix obtained through the QR decomposition to the received signal comprising the symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ] to convert the received signal into the upper triangular matrix, selecting Ŝ 1 n+50 symbols from symbol vector pairs [Ŝ 1 n+50 , Ŝ 1 n ], and selecting a Ŝ 1 n symbol with respect to each of the selected Ŝ 1 n+50 symbols.
Backward detecting the candidate symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ] may include converting a received signal comprising the candidate symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ] to an upper triangular matrix by applying a conjugate transpose of a matrix obtained through QR decomposition to the received signal, calculating a Euclidean distance for all cases of the candidate symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ], and selecting an Ŝ 1 n symbol that minimizes the calculated Euclidean distance with respect to each of Ŝ 1 n symbols for which there exists values of the real part and the imaginary part. Backward detecting the candidate symbol vector pair [Ŝ 2 n+50 , Ŝ 2 n ] may include applying the conjugate transpose of the matrix obtained through the QR decomposition to the received signal including the symbol vector pair [Ŝ 2 n+50 , Ŝ 2 n ] to convert the received signal to the upper triangular matrix, selecting Ŝ 2 n+50 symbols from symbol vector pairs [Ŝ 2 n+50 , Ŝ 2 n ], and selecting an Ŝ 2 n symbol with respect to each of the selected Ŝ 2 n+50 symbols.
As described above, according to an MDCM detection method in a 2×2 MIMO system of exemplary embodiments, the 2×2 MIMO system can perform the soft-decision demodulation of all received MDCM symbols. Accordingly, the demodulator for high-speed 1280+ Mbps transmission mode of can be easily implemented in an MB-OFDM UWB system. In addition, when compared with an ML scheme, soft-decision demodulation requires significantly fewer operations. Accordingly, when an exemplary embodiment is implemented in hardware, system integration can be enhanced, and power consumption can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram that schematically illustrates a 2×2 MIMO-OFDM transmission device.
FIG. 2( a ) illustrates a 16-QAM constellation to generate the S n symbol according to one exemplary embodiment, and FIG. 2( b ) illustrates a 16-QAM constellation to generate the S n+50 symbol according to an exemplary embodiment.
FIG. 3 is a block diagram that schematically shows a 2×2 MIMO-OFDM reception device.
FIG. 4 is a block diagram that illustrates the internal structure of an MIMO receive block according to exemplary embodiments.
FIG. 5 is a schematic view that illustrates a process of detecting forward and backward symbol vectors.
FIG. 6 is a graph that illustrates a bit error rate for a simulation result in a 2048 Mbps transmission mode in a 2×2 MIMO MB-OFDM system in which an MDCM soft-decision detector is applied to a 2×2 MIMO system according to an exemplary embodiment.
FIG. 7 is a graph that illustrates a packet error rate for the same simulation performance result as that of FIG. 6 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
Various exemplary embodiments will be described more fully hereinafter with reference to the accompanying drawings, in which some exemplary embodiments are shown. The present inventive concept may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. Like numerals may refer to like elements throughout.
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. FIG. 1 is a block diagram that schematically illustrates a 2×2 MIMO-OFDM transmission device.
Referring to FIG. 1 , the transmission device 100 includes an LDPC (Low Density Parity Code) encoder 110 , a constellation mapper 120 , an MDCM precoder 130 , and an OFD modulator 140 . OFDM-modulated signals are transmitted through transmitter antennas 150
A series of bits, which are LDPC-encoded by the LDPC encoder 110 , are grouped such that each group contains 8 bits b 0 , b 1 , b 2 , b 3 , b 4 , b 5 , b 6 , and b 7 for MDCM modulation. The 8 bits are provided to the constellation mapper 120 , so that the upper 4 bits b 0 , b 1 , b 2 , and b 3 are mapped to a 16-QAM symbol and the lower bits b 4 , b 5 , b 6 , and b 7 are mapped to a 16-QAM symbol S n+50 . FIG. 2 illustrates 16-QAM constellation diagrams. FIG. 2( a ) is a 16-QAM constellation to generate the symbol S n according to one exemplary embodiment, and FIG. 2( b ) is a 16-QAM constellation to generate the symbol S n+50 according to an exemplary embodiment.
The generated symbols S n and S n+50 are provided to the MDCM precoder 130 and two 256-QAM symbols as represented by Equation 1:
X
=
Φ
S
[
X
n
X
n
+
50
]
=
[
4
1
1
-
4
]
[
S
n
S
n
+
50
]
.
Equation
1
In Equation 1, X, Φ, and S respectively represent an MDCM symbol matrix, a linear precoding matrix, and a 16-QAM symbol matrix. The linear precoding matrix Φ includes a real number linear dispersion code and a unitary matrix over the integers. The linear precoding matrix Φ can ensure a simple precoding process implementation due to the integers while maintaining the power spectrum density (PSD) characteristics of the transmitted signal
X n and X n+50 are MDCM symbols that have the same constellation as a 256-QAM constellation. X n and X n+50 are provided to the OFDM modulator 140 and are transmitted by subcarriers spaced apart by 50 OFDM symbols. In this case, n represents a subcarrier index. In a 2×2 MIMO system, MDCM modulation is performed with respect to each stream as shown in the above procedure, and an MDCM symbol is OFDM-modulated with respect to each symbol and transmitted.
FIG. 3 is a block diagram that schematically shows a 2×2 MIMO-OFDM reception device 200 .
Referring to FIG. 3 , a 2×2 MIMO-OFDM reception device 200 includes a plurality of receiver antennas 210 , a MIMO receiver 220 , a channel estimator 230 , a de-interleaver 240 , and a channel decoder 250 . Signals received through the receiver antennas 210 are transmitted to the MIMO receiver 220 and the channel estimator 230 . The channel estimator 230 estimates a channel matrix between the transmitter antennas 150 of the transmission device 100 and the receiver antennas of the reception device 200 and outputs the channel matrix to the MIMO receiver 220 . The MIMO receiver 220 detects a received signal vector corresponding to a signal detection scheme suggested in an exemplary embodiment and a transmitted symbol using the estimated channel matrix output from the channel estimator 230 , calculates an LLR value for each transmitted bit included in the transmitted symbol vector, and outputs the LLR value to the de-interleaver 240 . After de-interleaving LLR values received from the MIMO receiver 220 that correspond to a preset de-interleaving scheme, the de-interleaver 240 outputs the de-interleaved LLR value to the channel decoder 250 . The channel decoder 250 soft-decision decodes the LLR values received from the de-interleaver 240 to recover the LLR value from an information bit string of the transmitted signal.
FIG. 4 is a block diagram that illustrates the internal structure of the MIMO receiver 220 according to exemplary embodiments.
Referring to FIG. 4 , the MIMO receiver 220 includes a preprocessor 222 , a forward symbol vector detector 224 , a backward symbol vector detector 226 , and an LLR calculator 228 .
The preprocessor 222 includes a norm calculator 222 a , a first channel ordering unit 222 b , a first QR decomposition unit 222 c , a second channel ordering unit 222 d , and a second QR decomposition unit 222 e . The preprocessor 222 receives a channel matrix H estimated by the channel estimator 230 to calculate a norm, and performs a channel ordering process and a QR decomposition process to generate matrixes Q H , Q 1 , and Q 2 .
The forward symbol vector detector 224 includes a receiving vector transformer 224 a , a Euclidean distance calculator 224 b , a first candidate symbol vector detector 224 c , and a second candidate symbol vector detector 224 d.
The backward symbol vector detector 226 includes a receiving vector transformer 226 a , a Euclidean distance calculator 226 b , a first candidate symbol vector detector 226 c , and a second candidate symbol vector detector 226 d.
1. Selection of a Forward Candidate Symbol Vector
The term “forward” refers to a direction for detecting symbols of a candidate symbol vector in order of Ŝ 2 n+50 , Ŝ 2 n , Ŝ 1 n+50 , and Ŝ 1 n . A process of forward detection may be summarized as follows. First, select p symbols for Ŝ 2 n+50 , and then select q Ŝ 2 n symbols for each of the p Ŝ 2 n+50 symbols to select total p×q Ŝ 2 n symbols. Next, select r additional Ŝ 2 n symbols, select one Ŝ 1 n+50 symbol for each of the p×q+r Ŝ 2 n symbols to select a total of p×q+r Ŝ 1 n+50 symbols, and then select one Ŝ 1 n symbol for each of the p×q+r Ŝ 1 n+50 symbols to select a total of p×q+r Ŝ 1 n symbols. Details of these steps are provided as follows.
In a 2×2 MIMO system, the received MDCM symbols may be represented by Equation 2:
Y
=
HX
+
N
[
Y
1
n
Y
2
n
Y
1
n
+
50
Y
2
n
+
50
]
=
[
H
11
n
H
12
n
0
0
H
21
n
H
22
n
0
0
0
0
H
11
n
+
50
H
12
n
+
50
0
0
H
21
n
+
50
H
22
n
+
50
]
[
X
1
n
X
2
n
X
1
n
+
50
X
2
n
+
50
]
+
[
N
1
n
N
2
n
N
1
n
+
50
N
2
n
+
50
]
.
Equation
2
In equation 2, X i n represents an MDCM symbol modulated to an n th subcarrier in an i th transmit antenna, and Y i n represents a received signal demodulated from the n th subcarrier at an i th receive antenna.
The norm calculator 222 a calculates norm values of a column vector H through Equation 2.
The first channel ordering unit 222 b changes the element order of the column vector of a channel so that the minimum value of the calculated norm values is placed in the second row or the fourth row. If there exists a column vector that has the minimum norm value in the second or fourth rows, there is no change to the element order of the column vector. If there exists a column vector that has the minimum norm value in the first or third rows, the element order of the column vector is changed to exchange the element of the first row with the element of the second row, and exchange the element of the third row with the element of the fourth row.
This is expressed as a following equation:
H
=
[
h
1
,
h
2
,
h
3
,
h
4
]
,
if
min
i
h
i
2
∈
[
1
,
3
]
{
H
ordered
F
=
[
h
2
,
h
1
,
h
4
,
h
3
]
H
ordered
I
=
[
h
1
,
h
2
,
h
3
,
h
4
]
,
and
if
min
i
h
i
2
∈
[
2
,
4
]
{
H
ordered
F
=
[
h
1
,
h
2
,
h
3
,
h
4
]
H
ordered
I
=
[
h
2
,
h
1
,
h
4
,
h
3
]
.
Channel ordering first detects a transmitted symbol from a signal received from a receiver antenna estimated as having the most deteriorated channel state, and then detects the transmitted symbols in the order of signals received through antennas estimated as having superior channel states. The following description assumes that the signals of Equation 2 have undergone channel ordering.
The first QR decomposition unit 222 c divides the ordered channels into first and second rows and third and fourth rows to perform QR decomposition. In other words, the first QR decomposition unit 222 c performs QR decomposition based on an MGS (Modified Gramm-Schmidt) orthogonalization scheme. This is summarized in the form of a matrix and expressed as Equation 3:
[
Q
n
,
R
n
]
=
QR
[
H
11
n
H
12
n
H
21
n
H
22
n
]
[
Q
n
+
50
,
R
n
+
50
]
=
QR
[
H
11
n
+
50
H
12
n
+
50
H
21
n
+
50
H
22
n
+
50
]
.
Equation
3
The matrix Q is a unitary matrix, in that Q H ×Q=I, where I is an identity matrix and Q H is a conjugate transpose of matrix Q.
Q n H and Q n+50 H obtained from the first QR decomposition unit 222 c are provided to the receiving vector transformer 224 a of the forward symbol vector detector 224 . The receiving vector transformer 224 a multiplies the conjugate transposes Q n H and Q n+50 H of Q n and Q n+50 by the received signal through a QR decomposition to obtain a converted received vector Z shown in Equation 4:
[
Z
1
n
Z
2
n
Z
1
n
+
50
Z
2
n
+
50
]
=
[
Q
n
H
O
2
×
2
O
2
×
2
Q
n
+
50
H
]
[
Y
1
n
Y
2
n
Y
1
n
+
50
Y
2
n
+
50
]
=
[
R
11
n
R
12
n
0
0
0
R
22
n
0
0
0
0
R
11
n
+
50
R
12
n
+
50
0
0
0
R
22
n
+
50
]
[
X
1
n
X
2
n
X
1
n
+
50
X
2
n
+
50
]
+
[
N
1
n
N
2
n
N
1
n
+
50
N
2
n
+
50
]
.
Equation
4
In this case, the matrix R is an upper triangular matrix that facilitates the removal of interference from an antenna.
Since the second and fourth rows in Equation 4 are independent from the first and third rows, the second and fourth rows may be separated from the first and third rows as expressed in Equation 5:
[
Z
2
n
Z
2
n
+
50
]
=
[
R
22
n
0
0
R
22
n
+
50
]
[
X
2
n
X
2
n
+
50
]
+
[
N
2
n
N
2
n
+
50
]
.
Equation
5
Since the X 2 n , and X 2 n+50 have an MDCM relation in Equation 5, Equation 5 may be expressed as Equation 6:
[
Z
2
n
Z
2
n
+
50
]
=
[
R
22
n
0
0
R
22
n
+
50
]
[
4
1
1
-
4
]
[
S
2
n
S
2
n
+
50
]
+
[
N
2
n
N
2
n
+
50
]
.
Equation
6
The second channel ordering unit 222 d of the preprocessor 222 performs an ordering that places the greater of R 22 n and R 22 n+50 in Equation 6 in the first row. Accordingly, performance degradation resulting from error transfer is minimized. The following description assumes that channel ordering is achieved as expressed by Equation 6.
As expressed by Equations 6 and 7, the second QR decomposition unit 222 e of the preprocessor 222 performs another QR decomposition.
[
Q
1
,
R
1
]
=
QR
{
[
R
22
n
0
0
R
22
n
+
50
]
[
4
1
1
-
4
]
}
Equation
7
Since the diagonal elements R 22 n and R 22 n+50 of matrix R that result from the QR decomposition in Equation 3 have real values, and all elements of a linear precoding matrix have real values, all elements resulting from the QR decomposition in FIG. 7 have real values.
The conjugate transpose Q 1 H of matrix Q 1 is provided to the first candidate symbol vector detector 224 c of the forward symbol vector detector 224 . Accordingly, Equation 6 may be re-expressed as Equation 8 in the first candidate symbol vector detector 224 c .
[
Z
2
n
Z
2
n
+
50
]
=
Q
1
H
[
Z
2
n
Z
2
n
+
50
]
=
[
R
11
′
R
12
′
0
R
22
′
]
[
S
2
n
S
2
n
+
50
]
+
[
N
2
n
N
2
n
+
50
]
.
Equation
8
The matrix R′ is an upper triangular matrix that facilitates the removal of interference from the antenna.
The Euclidean distance calculator 224 b of the forward symbol vector detector 224 finds Euclidean distances for all symbol vectors s 1 =[S 2 n ,S 2 n+50 ] expressed in Equation 8. The equation for finding the Euclidean distances may be expressed as Equation 9:
ED s 2 n ,s 2 n+50 =∥Z 2 n+50 −R′ 22 S 2 n+50 ∥ 2 +∥Z 2 n −R′ 11 S 2 n+50 −R′ 12 S 2 n+50 ∥ 2 . Equation 9
Since all elements of the matrices Q and R that result from the QR decomposition of Equation 7 are real numbers, all elements R′ 11 , R′ 12 , and R′ 22 of the matrix R are real numbers. Accordingly, Equation 9 may be divided into a real part and an imaginary part as expressed in Equation 10:
ED
S
2
n
,
S
2
n
+
50
=
Re
[
Z
2
n
+
50
]
-
R
22
′
Re
[
S
2
n
+
50
]
2
+
Re
[
Z
2
n
]
-
R
11
′
Re
[
S
2
n
+
50
]
-
R
12
′
Re
[
S
2
n
+
50
]
2
+
Im
[
Z
2
n
+
50
]
-
R
22
′
Im
[
S
2
n
+
50
]
2
+
Im
[
Z
2
n
]
-
R
22
′
Im
[
S
2
n
]
-
R
12
′
Im
[
S
2
n
+
50
]
2
.
Equation
10
Since all elements of the symbol vector s 1 =[S 2 n ,S 2 n+50 ] have 16-QAM symbols, the number of cases of the real and imaginary parts of each symbol corresponds to Re[S]ε[−3,−1,1,3], and Im[S]ε[−3,−1,1,3]. Accordingly, the first and third norms of Equation 10 have four cases, and the second and fourth norms of Equation 10 have 16 cases.
Accordingly, the number of multiplications required to calculate the Euclidean distances for all cases of the symbol vector s 1 =[S 2 n ,S 2 n+50 ] in Equation 10 is 4×2+16×2=40 in total.
The first candidate symbol vector detector 224 c of the forward symbol vector detector 224 detects Ŝ 2 n using a scheme shown in Equation. 11 with respect to all cases of S 2 n+50 , that is, all 16-QAM symbols:
S
^
2
n
=
Q
1
(
Z
2
n
-
R
12
′
S
^
2
n
+
50
R
11
′
)
.
Equation
11
Q 1 ( ) is a slicing function that selects L 16-QAM symbols that best approximate parameters in brackets using Equation 11.
The following description of an exemplary embodiment assumes that L=4.
In other words, four symbols Ŝ 2 n are selected with respect to one symbol Ŝ 2 n+50 . Accordingly, the total number of cases for a candidate symbol vector s 1 =[S 2 n ,S 2 n+50 ] is 64.
In addition, an LLR value may be calculated using another equation. Letting the Euclidean distance for elements s=[Ŝ 2 n+50 , Ŝ 2 n , Ŝ 1 n+50 , Ŝ 1 n ] of a set S be ED(s), the LLR value may be expressed by Equation 12:
LLR
(
b
k
i
)
=
min
s
∈
S
⋂
β
i
,
k
-
ED
(
s
)
2
σ
n
2
-
min
s
∈
S
⋂
β
i
,
k
+
ED
(
s
)
2
σ
n
2
.
Equation
12
In Equation 12, k represents a bit index of a symbol, and has a value in the range of 0 to 7. σ n represents a standard deviation of additive white Gaussian noise (AWGN).
β i,k − is a set of cases of a symbol vector [Ŝ 2 n+50 , Ŝ 2 n , Ŝ 1 n+50 , Ŝ 1 n ] in which a k th bit of an i th transmitted symbol is 0. β i,k + is a set of cases of a symbol vector [Ŝ 2 n+50 , Ŝ 2 n , Ŝ 1 n+50 , Ŝ 1 n ] in which a k th bit of an transmitted symbol is 1.
If the intersection of the candidate symbol vector set S with either the set β i,k − or the set β i,k + is an empty set, the LLR value may not be calculated. Therefore, a symbol vector is added such that the intersection is not an empty set.
To prevent the value of an opposite bit from being absent when calculating the LLR value, it is determined whether all values of the real and imaginary parts of the candidate symbol Ŝ 2 n of the 16-QAM candidate symbol vector are in {−3, −1, 1, 3}, and with respect to the absent value, a symbol vector having the minimum Euclidean distance calculated from Equation 10 is additionally selected as a candidate symbol vector.
According to an experimental result, the number of elements of the candicate symbol vector Ŝ 2 n is 67.
Through the above scheme, 16 candidate symbol vectors for the symbol Ŝ 2 n+50 , and 67 candidate symbol vectors for the symbol Ŝ 2 n are primarily selected.
If the second candidate symbol vector detector 224 d of the forward symbol vector detector 224 terminates detection of the primary candidate symbol vector, the second candidate symbol vector detector 224 d removes interference with respect to the candidate symbol vector s 1 =[S 2 n ,S 2 n+50 ] as expressed by Equation 13 using Equation 4:
[
Z
1
n
Z
1
n
+
50
]
=
[
Z
1
n
Z
1
n
+
50
]
-
[
R
12
n
0
0
R
12
n
+
50
]
[
4
1
1
-
4
]
[
S
^
2
n
S
^
2
n
+
50
]
=
[
R
11
0
0
R
11
n
+
50
]
[
4
1
1
-
4
]
[
S
1
n
S
1
n
+
50
]
+
[
N
1
n
N
1
n
+
50
]
.
Equation
13
The second QR decomposition unit 222 e performs QR decomposition with respect to a portion of Equation 13 corresponding to a channel as expressed by Equation 14:
[
Q
2
,
R
2
]
=
QR
{
[
R
11
n
0
0
R
11
n
+
50
]
[
4
1
1
-
4
]
}
.
Equation
14
The ordering process places the greater of R 11 n , and R 11 n+50 of Equation 14 in the second row. The following description assumes that channel ordering is achieved as expressed by Equation 13.
The second candidate symbol vector detector 224 d of the forward symbol vector detector 224 receives the conjugate transpose Q 2 H of the matrix Q 2 , and Equation 13 may be re-expressed as Equation 15:
[
Z
1
n
Z
1
n
+
50
]
=
Q
2
H
[
Z
1
n
Z
1
n
+
50
]
=
[
R
11
″
R
12
″
0
R
22
″
]
[
S
1
n
S
1
n
+
50
]
+
[
N
1
n
N
1
n
+
50
]
.
Equation
15
In this case, the matrix R n is an upper triangular matrix that facilitates the removal of interference from an antenna.
The second row of Equation 15 may be expressed as Equation 16, to detect the symbol Ŝ 1 n+50 :
S
^
1
n
+
50
=
Q
2
(
Z
1
n
+
50
R
22
″
)
Equation
16
In Equation 16, Q 2 ( ) is a slicing function that selects one 16-QAM symbol that best approximates parameters in brackets. A symbol vector s 2 =[Ŝ 2 n+50 , Ŝ 2 n , Ŝ 1 n+50 ] that includes the detected symbol Ŝ 1 n+50 is generated. Equation 17 is performed with respect to the symbol Ŝ 1 n+50 detected as the candidate.
S
^
1
n
=
Q
1
(
Z
2
n
-
R
12
″
S
^
1
n
+
50
R
11
″
)
Equation
17
In Equation 17, Q 2 ( ) is a slicing function that selects one 16-QAM symbol that best approximates parameters in brackets. Accordingly, one symbol Ŝ 1 n is detected with respect to symbol Ŝ 1 n+50 .
Accordingly, if the detected Ŝ 1 n is included in the candidate symbol vectors s 2 =[Ŝ 2 n+50 , Ŝ 2 n , Ŝ 1 n+50 ], four symbol vectors [Ŝ 2 n+50 , Ŝ 2 n , Ŝ 1 n+50 , Ŝ 1 n ] comprise one forward vector. A candidate symbol vector set S F having the above vectors as elements may be expressed by Equation 18:
[ Ŝ 2 n+50 ,Ŝ 2 n ,Ŝ 1 n+50 ,Ŝ 1 n ]εS F Equation 18
2. Selection of a Backward Candidate Symbol Vector
The term “backward” refers to a direction for detecting symbols of a candidate symbol vectors in order of Ŝ 1 n+50 , Ŝ 1 n , Ŝ 2 n+50 , and Ŝ 2 n . A process of backward detection may be summarized as follows. First, select s symbols for Ŝ 1 n of the symbol vector pair [Ŝ 1 n+50 , Ŝ 1 n ], next select one Ŝ 2 n+50 symbol for each of the s Ŝ 1 n symbols to select a total of s Ŝ 2 n+50 symbols, and then select one Ŝ 2 n symbol for each of the s Ŝ 2 n+50 symbols to select a total of s Ŝ 2 n symbols. Details of these steps are provided as follows.
The symbol vector set S F includes all symbol vectors in which the values of real and imaginary parts of Ŝ 2 n+50 are in {−3, −1, 1, and 3} without omission. In addition, the symbol vector set S F includes all symbol vectors in which the values of real and imaginary parts of Ŝ 2 n are in {−3, −1, 1, and 3} without omission. In other words, the symbol vector set S F includes all cases of Ŝ 2 n+50 . In the case of the Ŝ 2 n , values that do not exist in an intermediate process are included in the candidate symbol vector.
However, it cannot be determined whether the symbol vector set S F includes all symbol vectors in which the values of real and imaginary parts of the Ŝ 2 n+50 are in {−3, −1, 1, and 3} without omission. Similarly, it cannot be determined whether the symbol vector set S F includes all symbol vectors in which the values of real and imaginary parts of the Ŝ 2 n are in {−3, −1, 1, and 3} without omission.
Accordingly, since there is no opposite bit value when a soft-decision process is performed, an LLR value may not be found.
To address this issue, the above process is inversly performed, so that symbol vectors exist for which the values of the real and imaginary parts of Ŝ 1 n+50 , and Ŝ 1 n are in {−3, −1, 1, and 3} without omission.
Since the inverse process is performed with respect to the symbol vectors in which the values of the real and imaginary parts of the Ŝ 1 n+50 , and the Ŝ 1 n are in {−3, −1, 1, and 3} without omission, the inverse process is similar to the forward process. However, a smaller number of symbol vectors are present in the inverse process.
As described above, the first channel ordering unit 222 b of the preprocessor 222 exchanges the position of the first row with the position of the second row in Equation 2 according to the inverse channel ordering, and exchanges the position of the third row with the position of the fourth row as expressed in Equation 19:
[
Y
1
n
Y
2
n
Y
1
n
+
50
Y
2
n
+
50
]
=
[
H
12
n
H
11
n
0
0
H
22
n
H
21
n
0
0
0
0
H
12
n
+
50
H
11
n
+
50
0
0
H
22
n
+
50
H
21
n
+
50
]
[
X
2
n
X
1
n
X
2
n
+
50
X
1
n
+
50
]
+
[
N
1
n
N
2
n
N
1
n
+
50
N
2
n
+
50
]
.
Equation
19
The first QR decomposition unit 222 c performs QR decomposition with respect to the channel matrix of Equation. 19, and the channel matrix may be expressed as in Equation. 20:
[
Q
I
n
,
R
I
n
]
=
QR
[
H
12
n
H
11
n
H
22
n
H
21
n
]
[
Q
I
n
+
50
,
R
I
n
+
50
]
=
QR
[
H
12
n
+
50
H
11
n
+
50
H
22
n
+
50
H
21
n
+
50
]
.
Equation
20
The receiving vector transformer 226 a of the backward symbol vector detector 226 multiplies the channel matrix of Equation 19 by the conjugate transposes of Q 1 n , and Q 1 n+50 , and the multiplication result may be expressed as Equation 21:
[
Z
I
,
1
n
Z
I
,
2
n
Z
I
,
1
n
+
50
Z
I
,
2
n
+
50
]
=
[
Q
I
n
H
0
2
×
2
0
2
×
2
Q
I
n
+
50
H
]
[
Y
1
n
Y
2
n
Y
1
n
+
50
Y
2
n
+
50
]
=
[
R
I
,
11
n
R
I
,
12
n
0
0
0
R
I
,
22
n
0
0
0
0
R
I
,
11
n
+
50
R
I
,
12
n
+
50
0
0
0
R
I
,
22
n
+
50
]
[
X
2
n
X
1
n
X
2
n
+
50
X
1
n
+
50
]
+
[
N
I
,
1
n
N
I
,
2
n
N
I
,
1
n
+
50
N
I
,
2
n
+
50
]
.
Equation
21
Since the second and fourth rows in Equation 21 are independent from the first and third rows, the second and fourth rows in Equation 21 may be expressed as Equation 22:
[
Z
I
,
2
n
Z
I
,
2
n
+
50
]
=
[
R
I
,
22
n
0
0
R
I
,
22
n
+
50
]
[
X
1
n
X
1
n
+
50
]
+
[
N
I
,
2
n
N
I
,
2
n
+
50
]
.
Equation
22
Since the X 1 n and the X 1 n+50 in Equation 22 have an MDCM relation, the X 1 n and the X 1 n+50 may be expressed as Equation 23:
[
Z
I
,
2
n
Z
I
,
2
n
+
50
]
=
[
R
I
,
22
n
0
0
R
I
,
22
n
+
50
]
[
4
1
1
-
4
]
[
S
1
n
S
1
n
+
50
]
+
[
N
I
,
2
n
N
I
,
2
n
+
50
]
.
Equation
23
The second QR decomposition unit 222 e of the preprocessor 222 performs the QR decomposition as expressed in Equations 23 and 24.
[
Q
1
I
,
R
1
I
]
=
QR
{
[
R
I
,
22
n
0
0
R
I
,
22
n
]
[
4
1
1
-
4
]
}
.
Equation
24
If Equation 23 is multiplied by the conjugate transpose of Q 1 1 obtained from Equation 24, Equation 23 may be expressed as Equation 25:
[
Z
I
,
2
n
Z
I
,
2
n
+
50
]
=
[
R
I
,
11
′
R
I
,
12
′
0
R
I
,
22
′
]
[
S
1
n
S
1
n
+
50
]
+
[
N
I
,
2
n
N
I
,
2
n
+
50
]
.
Equation
25
The Euclidean distance calculator 226 b finds the Euclidean distances for all S 1 n and S 1 n+50 in Equation 25. This may be expressed as Equation 26:
ED s 1 n ,s 1 n+50 =∥Z I,2 n+50 −R′ I,22 S 1 n+50 ∥ 2 +∥Z I,2 n −R′ I,11 S 1 n+50 −R′ I,12 S 1 n+50 ∥ 2 . Equation 26
Through Equation 26, the Euclidean distances for all symbol vectors of s I 1 =[S 1 n ,S 1 n+50 ] can be found using 40 multiplication operations based on Equation 10 and the above-described scheme.
The first candidate symbol vector detector 226 c of the backward symbol vector detector 226 selects a symbol vector s I 1 =[S 1 n ,S 1 n+50 ] having a minimum Euclidean distance calculated by Equation 25 as a candidate symbol vector when the values of the real and imaginary parts of the S 1 n are in {−3, −1, 1, and 3}.
Similarly, the first candidate symbol vector detector 226 c of the backward symbol vector detector 226 selects a symbol vector s I 1 =[S 1 n ,S 1 n+50 ] having a minimum Euclidean distance as a candidate symbol vector when the values of the real and imaginary parts of the S 1 n+50 are in {−3, −1, 1, and 3}. In other words, the candidate symbol vector set s I 1 =[S 1 n ,S 1 n+50 ] includes at least one symbol vector when the values of the real and imaginary parts of S 1 n and S 1 n+50 are in {−3, −1, 1, and 3}. To select the backward candidate symbol vector, since the candidate symbol vectors are selected such that symbol vectors exist for which the values of the real and imaginary parts of S 1 n and S 1 n+50 are in {−3, −1, 1, and 3} without omission, the number of candidate symbol vectors is small as compared with the case of selecting the forward candidate symbol vector. According to an experimental result, an average of 13 candidate symbol vectors are selected.
If the second candidate symbol vector detector 226 d of the backward symbol vector detector 226 terminates the detection of the primary backward candidate symbol vector, the second candidate symbol vector detector 226 d removes interference by applying Equation 27 to all symbol vectors of the selected candidate symbol vector set.
[
Z
I
,
1
n
Z
I
,
1
n
+
50
]
=
[
Z
I
,
1
n
Z
I
,
1
n
+
50
]
-
[
R
I
,
12
n
0
0
R
I
,
12
n
+
50
]
[
4
1
1
-
4
]
[
S
^
1
n
S
^
1
n
+
50
]
Equation
27
Equation 27 may be summarized as Equation 28:
[
Z
I
,
1
n
Z
I
,
1
n
+
50
]
=
[
R
I
,
11
0
0
R
I
,
11
n
+
50
]
[
4
1
1
-
4
]
[
S
2
n
S
2
n
+
50
]
+
[
N
1
n
N
1
n
+
50
]
.
Equation
28
The second QR decomposition unit 222 e of the preprocessor 222 performs QR decomposition with respect to a portion of Equation 28 corresponding to a channel as expressed by Equation 29:
[
Q
2
I
,
R
2
I
]
=
QR
{
[
R
I
,
11
n
0
0
R
I
,
11
n
+
50
]
[
4
1
1
-
4
]
}
.
Equation
29
The second candidate symbol vector detector 226 d multiplies Equation 28 by a conjugate transpose of Q 2 I obtained from Equation 29, that is, a Hermitian matrix, and Equation 28 may be expressed as Equation 30:
[
Z
I
,
1
n
Z
I
,
1
n
+
50
]
=
Q
2
I
H
[
Z
I
,
1
n
Z
I
,
1
n
+
50
]
=
[
R
I
,
11
″
R
I
,
12
″
0
R
I
,
22
″
]
[
S
2
n
S
2
n
+
50
]
+
[
N
1
n
N
1
n
+
50
]
.
Equation
30
The Ŝ 2 n+50 of the second column in Equation 30 is detected through a scheme expressed by Equation 31:
S
^
2
n
+
50
=
Q
(
Z
I
,
1
n
+
50
R
I
,
22
″
)
.
Equation
31
The Ŝ 2 n is detected by using the detected Ŝ 2 n+50 through a scheme expressed by Equation 32:
S
^
2
n
=
Q
(
Z
I
,
1
n
-
R
I
,
12
″
S
^
2
n
+
50
R
I
,
22
″
)
.
Equation
32
The symbol vectors Ŝ 2 n+50 , Ŝ 2 n , Ŝ 1 n+50 , and Ŝ 1 n are formed by detecting Ŝ 2 n in a final stage. The symbol vector set detected through the inverse process may be expressed as S I and as Equation 33:
[ Ŝ 2 n+50 ,Ŝ 2 n ,Ŝ 1 n+50 ,Ŝ 1 n ]εS I . Equation 33
The symbol vector set S I has all symbol vectors, in which the values of real and imaginary parts of the S 1 n and S 1 n+50 are in {−3, −1, 1, and 3}, without omission. Therefore, in the union S=S F ∪S I of the symbol vector set S F detected in the selection of the forward candidate symbol vector and the symbol vector set S I detected in the selection of the backward candidate symbol vector, symbol vectors exist for which the values of the real and imaginary parts of Ŝ 2 n+50 , Ŝ 2 n , Ŝ 1 n+50 , and Ŝ 1 n are in {−3, −1, 1, and 3}, without omission.
Accordingly, since an opposite bit value always exists when a soft-decision process is performed, an LLR value may be found.
FIG. 5 is a schematic view that illustrates procedures for detecting the above forward and backward candidate symbol vectors.
3. LLR Calculation
The LLR calculator 228 calculates LLR values for the forward and backward candidate symbol vectors. The calculation of the LLR values may be expressed in Equation 34:
LLR
(
b
k
1
)
=
min
s
∈
S
⋂
β
1
,
k
-
ED
(
s
)
2
σ
n
2
-
min
s
∈
S
⋂
β
1
,
k
+
ED
(
s
)
2
σ
n
2
LLR
(
b
k
2
)
=
min
s
∈
S
⋂
β
2
,
k
-
ED
(
s
)
2
σ
n
2
-
min
s
∈
S
⋂
β
2
,
k
+
ED
(
s
)
2
σ
n
2
Equation
34
As expressed by Equation 34, the LLR value is found as a difference between a value that minimizes ED(s) in the intersection of the candidate symbol vector set S and β 1,k − , and a value that minimizes ED(s) in the intersection of the candidate symbol vector set S and β 1,k + . According to a method of an exemplary embodiment, since the intersection of the candidate symbol vector set S with either β 1,k − or β 1,k + is not the empty set, the LLR value can be calculated exactly. The LLR calculator 228 calculates the LLR value using Equation 34 and the union produced in the above procedure and transmits the LLR value to the channel decoder.
The following Table 1 compares the number of required real number multiplication operations in an MDCM detection scheme in a 2×2 MIMO system according to an exemplary embodiment and a MDCM detection scheme based on an ML scheme. Only the real number multiplications are represented in Table 1 since a multiplication has a much greater computational complexity than an addition.
TABLE 1
Real number
Demodulation
multiplication
scheme
Operation
operations #
ML
Calculation of Euclidean
16 4 × 8 = 524,288
Distance
Exemplary
preprocess
calculation of
16
Embodiment
channel norm
Calculation of QR
complex: 64 × 2 = 128
decomposition
real: 3 × 2 × 2 = 12
Calculation of QR
complex: 24 × 2 = 48
update
real: 6 × 2 + 16 × 2 =
48
Forward
Calculation of
40 + 67 × 2 + 67 ×
process
Euclidean distance
2 = 308
Backward
Calculation of
40 + 13 × 2 + 13 ×
process
Euclidean distance
2 = 92
652
According to a detection method of an exemplary embodiment, the multiplication complexity is reduced by 99% as compared with the multiplication complexity of an ML scheme.
FIG. 6 is a graph that illustrates a bit error rate for a simulation result in a 2048 Mbps transmission mode in a 2×2 MIMO MB-OFDM system in which an MDCM soft-decision detector is applied to a 2×2 MIMO system according to an exemplary embodiment. FIG. 7 is a graph that illustrates a packet error rate for the same simulation result as that of FIG. 6 . In FIG. 6 , the horizontal axis represents the ratio of bit energy to noise power, and the vertical axis represents a coded BER (coded bit error rate). In FIG. 7 , the horizontal axis represents the ratio of bit energy to noise power, and the vertical axis represents a coded PER (coded packet error rate).
As illustrated in FIG. 6 , an MDCM soft-decision detector in a 2×2 MIMO system according to an exemplary embodiment represents a performance degradation of about 0.5 dB at a bit error rate of about 10 −5 as compared with a ML soft-decision detector. In addition, as illustrated in FIG. 7 , an MDCM soft-decision detector in a 2×2 MIMO system represents a performance degradation of about 0.4 dB at a packet error rate of about 10 −2 .
Therefore, according to an exemplary embodiment, although the performance of an ML soft-decision detector is slightly degraded, the complexity is reduced by 99% or more.
An exemplary embodiment may be applied to a UWB technology to achieve Gbps performance in a MIMO OFDM system employing an MDCM precoding scheme, and may be extended to a MIMO OFDM system employing real number linear dispersion codes.
The foregoing is illustrative of exemplary embodiments and is not to be construed as limiting thereof. Although a few exemplary embodiments have been described, those skilled in the art will readily appreciate that many modifications are possible in exemplary embodiments without materially departing from the novel teachings of the present inventive concept. Accordingly, all such modifications are intended to be included within the scope of the present inventive concept as defined in the claims. Therefore, it is to be understood that the foregoing is illustrative of various exemplary embodiments and is not to be construed as limited to the specific exemplary embodiments disclosed, and that modifications to the disclosed exemplary embodiments, as well as other exemplary embodiments, are intended to be included within the scope of the appended claims. | A method for detecting soft-decisions in a 2×2 MIMO system includes detecting all candidate symbol vector sets S in which there exist all values of a real part and an imaginary part, and calculating a log-likelihood ratio (LLR) with respect to the candidate symbol vector sets S from
LLR
(
b
k
i
)
=
min
s
∈
S
⋂
β
i
,
k
-
ED
(
s
)
2
σ
n
2
-
min
s
∈
S
⋂
β
i
,
k
+
ED
(
s
)
2
σ
n
2
. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 07/563,048, filed Aug. 6, 1990, now U.S. Pat. No. 5,040,823 which is a continuation-in-part of application Ser. No. 07/397,723, filed Aug. 23, 1989, now U.S. Pat. No. 4,966,390.
BACKGROUND OF THE INVENTION
The present invention relates to a vehicle anti-roll system, and more particularly, to a hydraulically-operated anti-roll system which limits the amount of tilt induced in a vehicle to counteract turn-induced roll.
For the purpose of establishing the general environment in which the invention operates, it is asserted that a vehicle such as an automobile consists of a body, four tires, two front and two rear, a frame with axles for mounting the front and rear wheels, and a suspension for connecting the vehicle body to the axles.
When a vehicle turns, the suspension permits the vehicle body to rotate slightly about its longitudinal axis in response to the rolling force exerted on the body during the turn. Typically, vehicle passengers experience this effect as a tilt of the vehicle body, with the side of the body on the outside of the curve being relatively lower than the side of the body on the inside. Further, the vehicle body tends to pitch forward so that the front of the body is relatively lower than the rear. The pitch and roll combine to incline the vehicle body toward the front corner on the outside of the turn.
Anti-roll systems are known in the art which counteract vehicle roll by providing a lifting force acting between the vehicle body and suspension on the outside of the curve or a vehicle lowering force acting between the body and suspension on the inside turn side of the vehicle. Some anti-roll systems in the art provide complementary lifting and lowering forces simultaneously.
U.S. Pat. No. 3,752,497 of Enke et al illustrates an anti-roll system in which complementary lifting and lowering forces are applied. In the Enke et al patent, two sets of complementary lifting and lowering forces are provided, one set to the front wheels, and one set to the rear.
In U.S. Pat. No. 3,820,812 of Stubbs, an anti-roll system includes two separate assemblies, each working on the front and rear axles on a respective side of a vehicle. Each assembly provides a lifting or lowering force to its respective side, without reference to the action of the other assembly.
U.S. Pat. No. 3,885,809 of Pitcher illustrates an anti-roll system in which two separate correction units on opposite sides of the vehicle provide lifting and lowering forces to counteract roll. The Pitcher anti-roll system also includes a lift limitation assembly interconnected with the anti-roll system components and serving the rear of the vehicle.
U.S. Pat. No. 4,345,661 of Nishikawa provides a correcting force to one side of a vehicle to counteract turn-induced roll.
My U.S. Pat. No. No. 4,589,678 operates on the front wheels to counteract roll. It also provides limitation of front wheel correction by means of a piston controlled hydraulic line operating between a hydraulic reservoir and a cylinder and piston assembly.
All of these existing anti-roll systems utilize hydraulic circuitry and components for generating lifting and lowering forces. In each case, an element corresponding to a cylinder and piston assembly is positioned at a vehicle wheel and acts between the wheel and the vehicle body by moving a piston within a cylinder. Movement of the piston toward the top of the cylinder compresses the assembly's longitudinal profile and exerts a lowering force by drawing together the vehicle body and the wheel. Movement of the piston downwardly in the cylinder spreads the assembly longitudinally and exerts an erecting force which separates the body and the wheel. The operations of a plurality of such assemblies are coordinated by hydraulic circuitry. The circuitry reacts to roll forces by developing hydraulic signals in the form of pressurized hydraulic fluid, and delivering those signals in appropriate configurations to the cylinder and piston assemblies. None of the instances cited above provides a closed hydraulic circuit which connects all four front and rear cylinder and piston assemblies into an integrated anti-roll system in which all of the parts act cooperatively and in response to a single hydraulic signal. Beyond not teaching this combination, these references further do not suggest the joinder of such an anti-roll system with a tilt limitation feature which limits the degree of correcting tilt developed at all four wheels to counteract vehicle rolling. Neither do these references illustrate shock absorbency internal to the hydraulic components of an anti-roll system.
SUMMARY OF THE INVENTION
The inventor has observed that the counteracting response of a hydraulically-actuated anti-roll system to vehicle roll forces is measureably enhanced by provision of the capability, on each side of the vehicle, to limit the amount of tilt correction induced by the system.
The invention is a system for roll compensation in a vehicle having front and rear wheels, means for rotatably supporting these wheels, a vehicle body, and a suspension connecting the body and the wheels. The anti-roll system of the invention includes a valved hydraulic signal generator for providing a differential hydraulic signal indicative of vehicle roll. The differential hydraulic signal is defined by a pressurizing hydraulic potential corresponding to a first turn direction and a return hydraulic potential corresponding to a second turn direction. A first pair of cylinder and piston assemblies are provided for roll correction at the rear wheels, and a second pair of cylinder and piston assemblies are provided for roll correction at the front wheels. The system includes a hydraulic circuit connected to the valved hydraulic signal generator and to the rear and front wheel cylinder and piston assemblies for conducting the differential hydraulic signal to all of the cylinder and piston assemblies. In conducting the hydraulic signal, the circuit provides the pressurizing potential of the hydraulic signal to move the pistons in a first front wheel assembly and a first rear wheel assembly in a first correcting direction, while providing the return potential to move the pistons in the second front wheel assembly and the second rear wheel assembly in a second correcting direction. A hydraulic conductor directly connects corresponding ends of the rear wheel cylinder and piston assemblies to support hydraulic conduction between these assemblies in response to conduction of the differential hydraulic signal to all of the cylinder and piston assemblies. The system includes a tilt-limitation means connected to the hydraulic circuit for limiting the maximum displacement of the pistons in the front wheel cylinder and piston assemblies which limits the amount of roll correction afforded by the system.
A principal object of this invention is to provide an improved anti-roll system for a vehicle.
A distinct advantage of the described anti-roll system is found in the limitation of the amount of corrective tilt introduced.
Other features of this invention, described below, also permit standard shock-absorbing suspension functions to be performed in response to vertical disturbances, such as jounce and rebound, without disturbing, or requiring operation of, the anti-roll function of this invention.
Other objects and distinct advantages of this invention will become evident when following description is read with reference to the below-described drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a hydraulic circuit representation demonstrative of a first embodiment of the invention.
FIG. 2 is a schematic diagram illustrating control of the solenoid valve of FIG. 1.
FIG. 3 is a side cutaway view illustrating a rear wheel cylinder and piston assembly used in the embodiment of FIG. 1 with an internal, hydraulically-operated shock absorption provision.
FIG. 4 is a side cutaway view showing a front wheel cylinder and piston assembly used in the embodiment of FIG. 1 with an internal, hydraulically-actuated shock absorption provision.
FIG. 5 illustrates a damper assembly interposed between the two rear wheel cylinder and piston assemblies of FIG. 1.
FIG. 6 illustrates a second embodiment of the
FIG. 7A is a side cutaway view illustrating a front wheel cylinder and piston assembly used in the embodiment of FIG. 6.
FIG. 7B is a perspective view of a floating piston in the assembly illustrated in FIG. 7A.
FIG. 8 is a side cutaway view illustrating a rear wheel cylinder and piston assembly used in the embodiment of FIG. 6.
FIG. 9 is a side cutaway view of a back pressure valve used in the embodiment of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the schematic representation of an automobile includes a pair of front wheels 10 and 12, a pair of rear wheels 14 and 16, and a frame with front axles for rotatably mounting the front wheels 10 and 12. The front axles include attachment points 17 and 18. The frame also includes rear axles for rotatably mounting the rear wheels 14 and 16, the rear axles having real axle mounting points 20 and 22. The frame, the vehicle body which is attached to the frame, and the suspension system which is attached to the body and to the frame, are not illustrated explicitly in FIG. 1. However, the mechanical interconnection of these parts with those illustrated in FIG. 1 and already described above is well known to the skilled artisan.
A hydraulic signal generator includes a conventional hydraulic pump 30 that continuously pumps hydraulic fluid under pressure. In the description which follows, the pumped, pressurized hydraulic fluid is referred to as a "differential signal" and includes complementary pressurizing (P) and return (R) potentials provided, respectively, through hydraulic lines 31 and 32. The hydraulic pump 30 is connected through the lines 31 and 32 to a conventional solenoid-operated, hydraulic spool valve 35, which includes a spool (not shown) and solenoid coils 36a and 36b for positioning the spool. The valve is anchored to the frame. The valve 35 can comprise, for example, a standard, electrically actuated, double acting, four-way free flow device which receives and forwards the R and P potentials produced by the hydraulic pump 30 with a polarity determined by the position of the spool 36. As is known, the spool can be moved within the valve 35 from a rest position in either of the directions indicated by the arrow A. At the rest position, the spool blocks the hydraulic signal from being transmitted by the valve. Movement in one direction provides the potentials P and R in one polarity. Movement of the spool in the opposite direction reverses the polarity of the potentials.
The valve 35 provides the differential hydraulic signal through ports 40 and 42. Hydraulic lines 50, 51, and 52 are connected in common to port 40 at node connector 53. Hydraulic lines 60, 61, and 62 are connected in common to valve port 42 through the node connector 63. A first front wheel cylinder and piston assembly 70 includes a cylinder 71 a piston assembly 72 and a piston shaft 73. The piston shaft 73 is connected at one end to the right front portion of the vehicle body at 26a. The cylinder 71 is connected to the right front axle at 17. The cylinder 71 includes an upper port 74, and lower port 75, and a position-sensing port 76 located between the ports 74 and 75. In the left front of the vehicle is provided a cylinder and piston assembly 80 having a cylinder 78, a piston assembly 79, and a piston shaft 81. The cylinder 78 is connected to the left front axle at 18, while the piston shaft 81 is anchored to the left front of the vehicle body at 26b. The cylinder 78 has upper port 83, lower port 85 and position-sensing port 86.
The right front cylinder and piston assembly 70 is connected at its upper port 74 to the hydraulic line 50, at its lower port 75 to the hydraulic line 62, and at its position-sensing port 76 to a hydraulic line 55, which is connected to the return R line of the hydraulic pump 30. Similarly, the cylinder 78 is connected at its upper port 83 to the hydraulic line 60, at its lower port 85 to the hydraulic line 52 and its position-sensing port 86 to the hydraulic line 65, the hydraulic line 65 being connected at 66 in common with the line 55 to the return line 32 port of the hydraulic pump 30.
A pair of rear wheel cylinder and piston assemblies 90 and 100 are disposed at, respectively, the right rear and left rear of the vehicle. The assembly 90 includes a cylinder 91 in which is disposed a piston 93 connected to a piston shaft 92. The piston shaft 92 is anchored at 20 to the right rear axle of the vehicle. The cylinder 91 is connected to the body of the vehicle at 94. The left rear cylinder and piston assembly 100 includes a cylinder 101, a piston 103, and a piston shaft 102. The piston shaft 102 is anchored to the left rear axle at 22, while the cylinder 101 is anchored to the left rear of the vehicle body at 104.
The cylinder and piston assembly 90 has a lower hydraulic port 97 connected to the hydraulic line 51, and a lower hydraulic port 97. The left cylinder and piston assembly 100 has a lower hydraulic port 107 connected to the hydraulic line 61, and an upper hydraulic port 105 connected through hydraulic circuit 109 to the upper port 95 of the assembly 90.
Reference to FIG. 2 will provide an understanding of how the solenoid-driven valve 35 operates. The solenoid valve 35 is anchored to the vehicle body and generates a hydraulic signal for tilt correction in response to operation of the steering mechanism of the automobile in which the system of FIG. 1 is mounted. In this regard, the steering mechanism is conventional and includes a steering rack 121 which is stationarily attached to the vehicle. Steering is provided by the tie rods 122 and 124, each connected to a respective front wheel. For a right turn, the tie rod 122 is extended, while the rod 124 is retracted, causing the wheels 10, 12 to pivot toward the right. Correspondingly, for a left turn, the tie rod 124 extends, the tie rod 122 retracts, causing the wheels 10, 12 to pivot to the left. A control plate 129 is attached to the tie rod 122 to move with it and to provide an indication of turn direction. A preferred alternative is to locate the control plate on the steering column, which provides immediate indication of turn direction. A pair of proximity sensors are stationarily mounted to the vehicle body, adjacent the plate 129, to sense its position and to provide sense signals to a pair of relays 133 and 135, respectively. The relays 133 and 135 are connected to the solenoid coils 36a and 36b, respectively, of the solenoid valve 35.
When the vehicle is traveling in a straight line, the proximity sensor 129 will be adjacent both of the sensors 30 and 132, deactivating both of the relays 133 and 135. In this case, the solenoid coils are inactive and the valve spool is in a neutral position which blocks provision of the P and R potentials to the ports 40 and 42. A right-hand turn will move the plate 129 away from the sensor 130, activating the relay 133, and through it, the solenoid coil 36a. This will configure the solenoid valve 35 to provide the pressurizing signal potential through the port 42 and the return potential of the hydraulic signal through the port 40. Conversely, during a left-hand turn, the plate 129 moves away from the sensor 132, activating the relay 135, and through it, the coil 36b. This provides the pressurizing potential of the hydraulic signal through the port 40 and the return potential through the port 42.
Returning to FIG. 1, it is asserted that, as the vehicle executes a left-hand turn, the centrifugal forces generated tend to roll the vehicle body clockwise on its longitudinal axis, raising the inside (left) edge, and lowering the outside (right) edge of the body. As a result, the right-hand cylinder and piston assemblies 70 and 90 are compressed, while the left-hand assemblies are expanded. This means that, on the right-hand side, the pistons 72 and 93 move downwardly and upwardly, respectively, in their cylinders. Correction requires reversing these directions On the left-hand side of the vehicle, the pistons 79 and 103 move up and down, respectively, in their cylinders; correction requires reversal of these movements. The anti-roll correction provided by this invention will configure the hydraulic signal discussed above in such a manner as to provide hydraulic signal components to the assemblies 70 and 90 to counteract their compression, while providing hydraulic components to the assemblies 80 and 100 to counteract their expansion.
When the turn direction sensors 130 and 132 indicate that vehicle in which the system of FIG. 1 is mounted makes a left-hand turn, the relays 133 and 135 configure the value 35 such that the pressurizing potential is provided at the port 42 and the return potential at the port 40 of the valve 35. With the left-hand turn, the right-hand side of the vehicle rotates toward the ground, compressing the assemblies 70 and 90. The pressurizing potential of the hydraulic signal is provided, in the right-hand side of the vehicle, to the bottom port 75 of the assembly 70. At the same time, the return potential of the hydraulic signal is provided to the upper port 74 and lower port 97 of the right-hand cylinder and piston assemblies 70 and 90, respectively. Considering the right front assembly 70, the return potential at the upper port 74 permits the piston 72 to move upwardly in the cylinder 71. This potential is complemented by the pressurizing potential provided through the port 75, which pushes the piston 72 upwardly. Similarly, in the right rear cylinder and piston assembly, the return potential is conducted through the signal line 51 to the assembly 90 through the port 97, which permits the piston 93 to be pushed downwardly in the cylinder 91.
Continuing with the description of the right-hand turn correction, on the left-hand side of the vehicle, the pressurizing potential is conducted to the top of the piston 79 in the assembly 80, and to the bottom of the piston 103 in the assembly 100. The return potential is conducted to the bottom of the cylinder 79 in the assembly 80. With the piston 79 receiving the pressurizing potential on its top surface and the return potential on its bottom face, the piston will be moved downwardly in the cylinder 78, thereby compressing the assembly 80. Similarly, the pressurizing potential delivered to the bottom of the piston 103 through the port 107 will move the piston 103 upwardly in the cylinder 101, thereby compressing the assembly 100.
Completing the description of the circuit of FIG. 1, during the left-hand turn, upward movement of the piston 103 will displace hydraulic fluid from the upper portion of the cylinder 101 into the upper portion of the cylinder 91 by the path 105, 109, 95. This will transfer the pressurizing potential to the upper surface of piston 93, thereby complementing the downward motion of the piston resulting from introduction of the return potential through the port 97.
For an understanding of the tilt limitation feature, recall that the return potential is provided to the position-sensing ports 76 and 86. The return potential will be introduced only when the respective piston has undergone a sufficient downward displacement. Upward displacement of the piston of a front wheel cylinder and piston assembly will not uncover the assembly's position sensor port.
Therefore, continuing with the left-hand turn explanation, the left-hand turn will tend to compress the right-hand cylinder and piston assemblies, resulting in a relative downward movement of the piston 72 within the cylinder 71 and an upward movement of piston 79 in cylinder 78. However, at the time that the left-hand turn is initiated, the corrective action of the anti-roll system described heretofore exerts a compressing correction on the left-hand assemblies 80 and 100. The compressing correction moves the piston 79 downwardly in the cylinder 78. When the piston 79 has undergone a sufficient downward displacement, the return potential is introduced into the upper portion of the cylinder 78 through the position sensing port 86. This "short-circuits" the return and pressurizing potentials of the hydraulic signal in the cylinders 78, 91, and 101 thereby preventing any further roll correction in either the left- or right-hand cylinder and piston assemblies. This effectively limits the amount of tilt which the system introduces to correct the roll experienced in the left-hand turn.
In operation, correction is introduced into the system any time the valve 35 is actuated in response to a change of steering angle from a neutral position. Thus, correction "leads" or "anticipates" slightly the roll of the vehicle. As the turn begins in response to steering, the roll force comes into effect. The roll and correction forces are kept in balance by the position sensing ports whose actions tend to keep the vehicle body level in a turn.
The skilled artisan will appreciate that the just-given explanation for left-hand turn correction, when reversed, will counteract the roll introduced by a right-hand turn.
After a turn has been completed, the steering assembly is returned to its neutral or straight-ahead configuration, thereby closing the solenoid valve 35, removing the return and pressurizing potentials of the hydraulic signal from the ports 40 and 42. This results in a return of the cylinder and piston assemblies 70, 80, 90 and 100, to their neutral positions. In the neutral positions, the pistons 72 and 79 are positioned in their respective cylinders at locations which cover the position-sensing ports of the cylinders.
FIG. 3 illustrates construction details of the rear wheel cylinder piston assemblies which will provide an understanding of how they operate to provide shock absorption, while also providing anti-roll correction. The rear wheel cylinder and piston assembly 100 is illustrated with the understanding that the illustration and the following explanation apply also to the assembly 90. The assembly 100 includes the cylinder 101 in which the piston 103 moves longitudinally. The piston 103 includes a piston body 200 with two through ports 201 and 202 which open completely through the body 200 between its upper and lower faces. Two valve springs 207 and 210 are provided on the lower and upper faces, respectively, of the piston body 200. The spring 207 covers and closes the lower end of the port 201, while the spring 210 covers and closes the upper end of the port 202. The spring 207 has an orifice 208 which communicates with the port 202, while the spring 210 has an orifice 211 which communicates with the port 201. Shock absorption is provided when the piston shaft 102 is displaced either up or down as the rear wheel to whose axle it is attached encounters a bump or a pothole. Assuming a bump, the shaft 102 transfers an upwardly-directed shock displacement to the piston 103. If the piston were solid, the incompressibility of the hydraulic fluid with which the cylinder 101 is filled would prevent the piston moving, assuming no complementary displacement of the piston in the opposite rear wheel cylinder and piston assembly. However, the upward force exerted on the piston 103 causes a relative displacement of hydraulic fluid downward through the through port 201 against the valve spring 207. Although the spring 207 closes the lower opening of the port 201, the spring will give way from the opening in response to the relatively downwardly-moving column of hydraulic fluid, thereby permitting the fluid to flow through the port 201. This permits the piston 103 to move upwardly in the cylinder 101. Similarly, downward motion of the piston in response to a sharp movement of the piston shaft 102 is permitted by movement of hydraulic fluid upwardly through the through port 202 against the spring 210. The inventor, recognizing the need to damp piston movement resulting from jounce (bumps) differently than piston movement resulting from rebound (potholes), has provided a spring constant for the spring 210 which is higher than the spring constant for the spring 207. Relatedly, the spring 210 may be thicker than the spring 207. During cornering, when the fluid is circulated through the ports 107 and 105, the spring 210 provides a compressing force that is greater than the extending force of the assembly 90. This pulls the inside rear corner of the vehicle down, counteracting the natural tendency of the vehicle to pitch diagonally, down at the outside front end and upwardly at the inside rear.
FIG. 4 illustrates construction details of the front wheel cylinder and piston assemblies, which will provide an understanding of how they operate to provide shock absorption, while also providing an anti-roll correction. FIG. 4 illustrates in greater detail the assembly 80, with the understanding that the details of FIG. 4 are also found in the other front wheel cylinder and piston assembly 70. In the cylinder and piston assembly 80, the piston 79 comprises an assembly including a lower piston 300 fixed to the shaft 81 by a nut 302. The lower piston 300 has an disc configuration through which fluid access is provided by ports 300a and 300b. A non-metallic piston ring 303 positions the fixed piston 300 against the inner wall of the cylinder 78. A foam accumulator 305 is concentrically positioned on the shaft 81 above the fixed piston 300. A rubber washer 307 is placed at the bottom of the fixed piston. Disposed above the fixed piston 300 is a "floating" piston 309, which has an upside-down, open cup-like configuration. A metallic piston ring 311 seals the outer surface of the floating piston 309 against the inner surface of the cylinder 78. An upper rubber washer 312 provides a fluid-resistant seal between the shaft 81 and the central bore of the floating piston 309 through which the shaft 81 extends. A lower rubber washer 313 also provides a fluid-resistant seal between the shaft 81, and the central bore of the floating piston. A rigid annular retainer in the form of a metal disc 318 is attached to the shaft 81 to provide an upper stop for a rubber spring 315. The disc has a radius which is less than the radius of the cylinder 78. A flexible annular washer in the form of a rubber disc 319 is held concentrically on the shaft 81 above the disc 318. The washer 319 has a radius which is less than the radius of the cylinder 78, but greater than that of disc 318. The washer is preferably held against the disc by a retaining ring (not shown). An annular foam accumulator 321 is positioned concentrically on the piston shaft in the cylinder 78 between the upper end of the cylinder and the washer 319.
The rubber washer 312 extends radially to contact the interior surface of the cylinder 78; the washer 313 extends radially to contact the inner surface of the floating piston 309; therefore, the hydraulic fluid 325 can flow between the inner surface of the cylinder 78 and the perimeters of these washers. The inner bore 310 of the floating piston 309 has a larger diameter than the shaft 81. This allows the inside edges of the washers 312 and 313 to curl and permit fluid to pass momentarily. The piston 309 will follow, due to the curling resistance of the washers, and reseat.
The neutral position of the piston shaft 81 with respect to the cylinder 78 positions fixed and floating pistons 300 and 309 as illustrated in FIG. 4. In this regard, the floating piston 309 is positioned so that its upper edge is just above the position-sensing port 86. This seals the port, preventing the introduction of the return potential into the cylinder 78. Assume now that a left-hand turn is begun, in which case, the cylinder and piston assembly 80 will expand, moving the piston assembly 79 upwardly in the cylinder 78. Immediately, the solenoid valve 35 is configured to provide the pressurizing potential through the upper port 83 and the return component through the lower port 85, to counteract the upward displacement of the piston assembly 79. Now, the pressurizing potential presses downwardly on the floating piston 309. The net effect is to produce a downward correcting motion on the floating piston 309. This moves the entire piston assembly 79 downwardly until the combination of compression of the washer 307 and downward movement of the fixed piston 300 displaces floating piston 309 downwardly by an amount sufficient to uncover the position sensing port 86. At this point, the pressurizing potential component will be "short circuited" through the port 86, preventing any further downward movement of the piston assembly 79. When these correcting forces are removed, the mechanical suspension of the automobile will move the piston assembly 79 back to the unactivated, neutral position illustrated in FIG. 4.
Next, when the correction potentials are reversed so that the port 85 is pressurized and the return potential is provided in the port 83, the net pressure acting on the fixed piston 300 will move it upwardly, and with it the floating piston 309. As inspection of FIG. 4 will confirm, the floating piston 309 must be displaced upwardly a significant distance before the port 86 is uncovered. However, before the floating piston can be displaced by this distance, the floating piston in the right front cylinder and piston assembly will have been displaced downwardly, thereby shorting the return to the pressurizing potential through the upper portion of the cylinder 71.
Assume now that the left front wheel encounters a bump, resulting in a sudden displacement of hydraulic fluid upwardly through the port 300a and 300b of the fixed piston 300. The amount of flow is determined by the ratio of the total area of the ports 300a and 300b to the total surface area of the upper face of the fixed piston 300 and ports 83, 85 and flow into the upper portion of the cylinder. Displacement of hydraulic fluid upwardly is transferred against the lower face of the floating piston 309, resulting in a upward displacement of the floating piston against the force of the spring 315. Upward displacement of the floating piston 309 causes the outward edge of the washer 319 to curl upwardly, which permits hydraulic fluid 325 to be displaced upwardly into the top of the cylinder 78. Displacement in this direction is absorbed by compression of the foam 321. After upward displacement by the bump, the cylinder and piston assembly 80 is returned to its neutral configuration of FIG. 4 by the mechanical suspension components, including the external springs 39a and b illustrated in FIG. 1, which act between the body of the vehicle and the cylinder 78.
Next assume that the left front wheel 12 encounters a pothole. In this case, the cylinder 78 is pulled downwardly with respect to the piston assembly 79. Now, the hydraulic fluid in the lower portion of the cylinder 78 is increased by flow through port 85 and moves downwardly, from the interior of the piston 300 as aided by expansion of the foam 305. Simultaneously, hydraulic fluid is forced downwardly from the top of the cylinder 78; the downward displacement being accompanied by compression of the foam 321. However, the displacement of fluid downwardly past the washer 319 is relatively slower than upward displacement past the washer 319 because downward curvature of the washer is limited by the disc 318. The downward displacement of the hydraulic fluid acts against the floating piston 309 to keep it forced against the rubber washer 307. Again, when the pothole is passed, the external mechanical suspension components of the vehicle return the cylinder and piston assembly of FIG. 4 to their neutral positions.
Sudden surges of hydraulic fluid in the system of FIG. 1 are dampened by the damping mechanism of FIG. 5. The damping mechanism of FIG. 5 consists of a cylinder 400 with a stationary annular disk 405 with through ports 407 and 409. A pair of valve springs 410 and 412 are disposed on respective opposing faces of the annular disk 405. Spring 140 has an opening 411 which communicates with the port 407; the spring 412 has an opening 413 which communicates with the through port 409. The spring constant of the springs 410 and 412 are substantially equal. The damping mechanism of 400 operates in much the same manner as the shock absorbing element of the pistons in the front and rear wheel assemblies 90 and 100 with the exception that the annular disk 405 does not move. In this regard, a sudden surge of hydraulic fluid into the port 420 will be communicated through the port 407 against the spring 412. If the surge is of sufficient magnitude, the spring 412 will be slightly displaced to permit displacement of fluid from the left to the right-hand side of the cylinder 400. Similarly, a surge of hydraulic fluid entering the cylinder 400 through the port 422 will be dampened by the spring 410.
Refer now to FIGS. 6-9 for an understanding of the second embodiment of the invention in which numerals which are identical with the numerals in FIG. 1 indicate like parts. Thus, the schematically-represented system of FIG. 6 is understood to be used in conjunction with a vehicle including a body, a frame, wheels, a suspension which connects the body to the wheels, and means for rotatably connecting the wheels 10, 12, 14, and 16 to the frame. The suspension is represented in part by springs 39a-39b. In FIG. 6, there are a plurality of hydraulicly-actuated cylinder and piston assemblies which include the assemblies 570, 580, 590, and 600. The assemblies 570 and 580 are front wheel assemblies which are connected to the vehicle between the vehicle body and the front wheels 10 and 12, respectively. The assemblies 590 and 600 are rear wheel assemblies which are connected between the vehicle body and the rear wheels, 14 and 16, respectively. The cylinder and piston assemblies are hydraulicly actuated to be alternately compressed or expanded in response to the flow of hydraulic fluid.
The front wheel assembly 570 includes a cylinder in which is slidably disposed a piston 572. The cylinder has upper and lower ports 574 and 575 and a position-sensing port 576 which is normally closed to the upper and lower ports by the rest position of the piston 572. Identically, the cylinder and piston assembly 580 includes a cylinder with a piston 579, upper and lower ports 583 and 585, respectively, and a position-sensing port 586 normally closed by the piston 579.
The rear cylinder and piston assembly 590 includes a cylinder with a slidable piston 593 and upper and lower ports 595 and 597, respectively. Identically, the rear wheel assembly 600 has a cylinder with a slidable piston 603, an upper port 605, and a lower port 607.
A differential hydraulic signal is provided from a pumped source (not shown) by way of a valve 535 which is identical in structure and operation with the valve 35 of FIG. 1. Further, the valve 535 is operated by a control means (not shown) identical in all respects with that illustrated in FIG. 2. Thus, the valve operates in response to a vehicle turn by outputting a differential hydraulic signal including pressure (P) and return (R) potentials which indicate the direction of the vehicle turn as discussed above with reference to the valve 35 of FIG. 1. One output of the valve 535 is connected to the lower port 575 of the assembly 570 by a hydraulic connection 700. Hydraulic connection 702 connects the other output of the valve 535 to the lower port 585 of the assembly 580. The position-sensing ports 576 and 586 are connected by hydraulic lines 704 and 705 to a common point 708 which is connected through a back pressure valve 710 to the return potential R of the hydraulic pump (not shown).
On a first (right) side of the vehicle, the cylinder and piston assembly pairs 570 and 590 are interconnected through upper port 574 and lower port 597 by a hydraulic line 720, accumulator 710, identical in construction to accumulator 723. The upper ports 595 and 605 of the rear wheel cylinder and piston assemblies are interconnected by hydraulic line 722, accumulator 723, and hydraulic line 724. The circuit is completed by hydraulic line 726, and accumulator 711, which connects the ports 607 and 583 of the pair of cylinder and piston assemblies 600 and 580, respectively, on the second (left) side of the vehicle.
Assume now that the vehicle with the anti-roll system illustrated in FIG. 6 makes a left-hand turn, in which case the right-hand side of the vehicle will incline downwardly with respect to the left-hand side of the vehicle. This is referred to as "roll". Additionally, the front end of the vehicle will incline downwardly with respect to the rear, which is referred to as "pitch". In this case, the rolling force on the vehicle is counteracted by expansion of the cylinder and piston assemblies 570 and 590 and by compression of the cylinder and piston assemblies 580 and 600. The valve 535 will be configured to deliver the pressurizing potential of the hydraulic signal through the hydraulic line 700 to the lower port 575 of the assembly 570, while the return potential is provided to the lower port 585 of the assembly 580 through the hydraulic line 702.
Considering now the components on the right-hand side of the automobile, the pressurizing potential introduced through the port 575 will move the piston 572 upwardly, forcing fluid out of the upper port 574 through the conductor 720 and into the bottom port 597 of the rear assembly 590. This will move the piston 593 upwardly. Upward movement of the pistons 572 and 593 will provide an erecting force on the right-hand side of the vehicle to counteract the downward inclination induced by the rolling force of the left-hand turn.
To complement the expansion of the assemblies 570 and 590, the assemblies 580 and 600 on the left-hand side of the vehicle will be compressed by the return potential delivered to the lower port 585. Under the influence of the return potential, the piston 579 will move downwardly drawing hydraulic fluid into the assembly via 583, 726, 607. Extraction of the fluid from the bottom of the assembly 600 will cause the piston 603 to move downwardly. The downward movement of the pistons 579 and 603 will compress the assemblies 580 and 600, thereby counteracting the upward inclination of the left-hand side of the vehicle during a left-hand turn. The connection 722, 723, 724 between the upper ports 595 and 605 of the rear assemblies 590 and 600 permits the exchange of fluid between those assemblies. During the left-hand turn just described, the hydraulic fluid will flow from the assembly 590 to the assembly 600.
In response to a right-hand turn, the valve 535 will be configured to provide the pressurizing potential of the hydraulic fluid signal to the lower port 585 and the return potential to the lower port 575. In this case, the actions of the cylinder and piston assemblies will be the reverse of that just described.
Refer now to FIGS. 7A and 7B for an understanding of the structure and operation of the front wheel cylinder and piston assemblies 570 and 580. FIG. 7A illustrates only the assembly 570, with the understanding that the assembly 580 is identical in all respects.
As the cross-section drawing of FIG. 7A illustrates, the front wheel cylinder and piston assembly 570 includes a piston 572 which is slidable within the cylinder. The piston 570 is connected by a piston rod 730 to the body of the automobile by conventional means. The piston includes a piston body 732 with radially-spaced, axially-extending bores 733a, 733b. Although only two bores are shown in the Figure, it is understood that more may be provided in cross-sectional planes not shown. One end of each bore is flared radially to provide a fluid passage around the end of a disk. The bore 733a is flared at the top of the piston so that fluid can flow from the upper portion of the cylinder, around the edge of the disk 749, into the bore. The bore 733b is similarly flared at the bottom of the piston to provide a fluid passage around the edge of the disk 749. An annular teflon piston ring 735 encircles an indented outer surface of the piston 572. The piston 572 is attached to the rod 730 by an arrangement which includes a threaded nut 737, a washer 738, and two O-rings 739a and 739b, and the disk 740. The top of the piston is retained on the rod by an arrangement including a retaining ring 743, a washer 745, an O-ring 747 and a disk 749. The disks 740 and 749 can comprise conventional valve springs which operate as described above with regard to the valve springs 207 and 210 illustrated in FIG. 3. The O-rings 739a and b and 747 act essentially as springs and compress in response to movement of the plates 740 and 749, respectively.
A lower floating piston 753 seals the bottom of the cylinder 570. The lower floating piston is generally cylindrical with an upper portion 755 in which is cut an annular slot 756. An O-ring 758 in the slot 756 provide a fluid seal which retains the hydraulic fluid in the cylinder 570. The bottom portion of the floating piston 753 has a rectangular slot which is completely occupied by three rubber cylinders made of O-ring material (759a, 759b, and 759c). Two of the rubber cylinders are beneath the bolt, while one is positioned above it. Holes are cut diametrically at the bottom of the cylinder 570 so that the floating piston 753 can be retained at the bottom of the cylinder by the elongate bolt 760 and nut 761.
Positioned above the piston 572 is an upper floating piston assembly including a rubber spring 762 having a through bore through which the piston rod 730 extends. Above the rubber spring 762 an annular cup-shaped floating piston 763 having a cylindrical cut-out center portion with a bottom surface 764 which contacts the upper end of the rubber spring 762. A pair of 90-degree through-ports 765a and 765b are cut through the surface 764 from which they extend upwardly until making 90-degree turns. The upper ends of the through ports 765a and 765b are sealed by an O-ring 767 seated in an annular groove in the upper portion of the floating piston 763. The cup-shaped floating piston 763 has an axial bore through which the piston rod 730 extends and the piston is free to move on the rod. A stopping O-ring 768 is placed on the rod 730 between the upper inner surface of the cylinder 570 and the upper surface of the floating piston 763. The largest diameter of the floating piston 763 is less than the inner diameter of the cylinder 570, affording a fluid path between the inner surface of the cylinder 570 and the piston's extreme outer surface. Fluid is able to travel in either direction on this path. Uni-directional fluid paths are afforded upwardly through the through-bore 765a and 765b. When fluid pressure is transferred in this direction, the O-ring 767 will give outwardly slightly to open these passages. However, fluid flowing against the O-ring 767 from within the upper portion of the cylinder will only seat the ring more tightly against the bores 765a and 765b, preventing fluid flow downwardly through these passages.
When an automobile to which the cylinder and piston assembly 570 has been mounted is normally loaded and at rest, the lower end of the piston 572 occupies a position between the position sensing port 576 and the lower port 575. When a pressurizing potential is introduced through the bottom port 575 to expand the cylinder and piston assembly 570, the piston 572 moves upwardly in response to the pressurizing potential until the position-sensing port 576 is uncovered. When this occurs, the pressurizing potential is returned through the port 576, thereby preventing any further roll correction. When the pressurizing signal is removed, the cylinder 572 returns to its rest position where its lower end is positioned between the ports 575 and 576.
Tilt limitation as practiced in the second embodiment of the anti-roll system, which is illustrated in FIG. 7, is enabled in response to expansion of the front wheel cylinder and piston assemblies. This contrasts with the operation of the front wheel cylinder and piston assemblies in the first embodiment. As explained above and as reference to FIG. 4 shows, tilt limitation in the first embodiment is activated in response to compression of the front wheel cylinder and piston assemblies. In practice, the requirements and circumstances of an application will determine which of these embodiments is the best mode of practicing the invention. The inventor has found that, all things being equal, the cylinder and piston assembly used in the second embodiment provides a certain advantage. In many applications, when a vehicle is loaded with passengers or freight, a portion of the added load is applied to the cylinder and piston assemblies of the anti-roll system. In the first embodiment, this results in compression of the front wheel cylinder and piston assemblies which moves the top surface of the piston toward the position sensing port. This reduces the amount of roll correction that the first embodiment can introduce until tilt limitation occurs. In contrast, compression of the cylinder and piston assembly illustrated in FIG. 7 will move the lower surface of the piston 272 downwardly, thereby increasing the amount of roll compensation which the second embodiment will provide before tilt limitation occurs.
The combination of the disks 740 and 749 with the through-bores in the piston 572 provides shock absorption substantially as described above with reference to FIG. 3. The difference is that shock displacement of the piston causes fluid to flow around the edge of a disk, through the flared end of a through bore and against the disk at the other end of the through bore. Use of the O-rings 739 and 747 to transfer retaining force to the disks 740 and 749 affords a low-cost, reliable spring action which opposes movement of the disks in response to fluid displacement in the cylinder and piston assembly 570. Thus, for example, assuming that the front wheel where the assembly 570 is mounted hits a bump, the assembly 570 will undergo a short, sharp compression which is accommodated by movement of hydraulic fluid around the disk edge through the bore in the cylinder 733b against the disk 749. The disk 749 will transfer the shock force in response to which the O-ring 747 will compress. When the O-ring compresses, the disk moves away from the hole, permitting fluid to flow through it. As the shock impulse dies, the compression of the O-ring will assist in returning this disk 749 to a position covering the bore 733b. The two O-rings 739a and b provide stiffer resistance against rebound than does the single O-ring 747 against jounce.
The upper floating piston assembly also affects shock absorption in the front wheel cylinder and piston assemblies. In this regard, if the front wheel to which the assembly in FIG. 7A is attached encounters a pot-hole, the assembly of FIG. 7A is expanded sharply. The sharp expansion is accommodated by hydraulic fluid flow downwardly through the through bore 733a of the piston 572. Upward movement of the piston 572 also moves the upper floating piston assembly upwardly until the O-ring 768 encounters the upper interior surface of the cylinder 570. When this occurs, the upward movement of the piston 572 is damped and reduced by the compression of the rubber spring 762 against the surface 764 of the upper floating piston 763.
The lower floating piston 753 confers an unexpected result in operation of the anti-roll system. Refer now to FIGS. 7A and 7B. When the upper end of the rod 730 is attached to the vehicle body with a solid bushing and low profile tires are mounted to the vehicle frame, the surface of the road on which the vehicle travels is "transferred" to the cylinder and piston assemblies of the anti-roll system. Relatedly, as bumps and holes are encountered, sudden upward and downward displacement of the wheels tends to cause related compression and expansion of the cylinder and piston assemblies. The road envelope is absorbed to some extent in conventional shock absorbing pistons by using a rubber bushing in mounting the piston to the vehicle body. In this case, the bushing absorbs some of the impulse displacement transferred to the cylinder and piston assembly from the road surface. A solid bushing will not provide this absorption. However, in the assembly of FIG. 7A, the impulse response to bumps and potholes in the road surface is partially absorbed by the lower floating piston. As the piston 572 responds to the random impulses in the surface of the road by the shock absorbing action described above, the surges which this action produces in the hydraulic fluid are absorbed by upward and downward translation of the lower floating piston 755 on the rubber cylinders 759 about the center line of the stationary bolt 760. The inventor has found that this floating piston configuration significantly suppresses the audible response of the cylinder and piston assemblies of an anti-roll system to road surface effects. Further, with two rubber cylinders beneath the bolt, and one above it, the floating piston yields more in response to rebound than to jounce.
The rear wheel cylinder and piston assemblies are equivalent and the assembly 590 is illustrated in, and explained with reference to, FIG. 8. The assembly 590 includes a moveable piston 593 which slides reciprocally within the cylinder in response to movement of hydraulic fluid through the ports 595 and 597. Sustained, low frequency fluid transfer through these ports results from provision of the differential fluid signal provided through the valve 535. This response has already been explained. The rear wheel cylinder and piston assemblies also provide shock absorption in these fixed pistons with an arrangement virtually identical with that employed in the front wheel cylinder and piston assemblies. Such shock absorption is provided through the piston 593 which is mounted to the piston rod 770 between a threaded nut 771 and a retaining ring 776. Nut 771 thrusts against a washer 773 and an O-ring 775 which holds an annular disk. Similarly, at the top of the piston, retaining washer 777 transfers retaining force through an O-ring 778 to a valve spring with holes which match selected bores through the piston 593. This arrangement provides shock absorption response for the assembly 590 as explained above for the front wheel assemblies.
The assembly 590 also includes an upper floating piston assembly 780 which operates identically to the upper floating pistons of the front wheel assemblies. The upper floating piston assembly includes a rubber spring 781, a cup-shaped floating piston 782 with a sealing O-ring 783 and a stopping O-ring 784.
The rear assembly 590 also includes a lower cylindrical portion 800 which is in perpendicular fluid communication with the cylinder 590. A lower, cup-shaped floating piston 801 is slidably disposed in the extension 800 and is retained therein by an O-ring 802 and a retaining piston 803 having an annular O-ring 804 which hydraulically seals the extension 800. The piston 803 is retained in the extension 800 by a retaining ring 805. The lower floating piston 801 is filled with a foam accumulator material 806. A rubber spring 807 is disposed between the interior surface of the cylinder 590 and the back of the lower floating piston 801. The diameter of the lower floating piston 801 is slightly less than the interior diameter of the extension 800, and radial through bores 808 complete a fluid path along the side of the lower floating piston 801 into its interior.
In operation, the lower floating piston assembly assists in shock absorption. In this regard, when a pot-hole is encountered by a rear wheel, the real wheel cylinder and piston assembly of FIG. 8 expands, with the piston 593 moving upwardly with respect to the cylinder. This pulls a vacuum in the lower portion of the cylinder beneath the piston 593 which causes the lower floating piston 801, the O-ring 802, and the sealing piston 803 to move inwardly against the rubber spring 807. When the riding surface again levels, the compression in the rubber spring 807 returns the floating piston, O-ring, and sealing piston against the retaining ring 805. When a bump is encountered, and the piston 593 moves downwardly in the cylinder, hydraulic fluid is displaced downwardly in the cylinder toward the floating piston assembly. This downward movement is dampened when the fluid flows between the outer surface of the floating piston 801 and the extension 800, through the radial through bores 808 against the foam accumulator 806. The accumulator 806 compresses in response to the downward movement of the hydraulic fluid and expands when the bump is passed and the riding surface is once again level.
With this description of the construction and operation of the front and rear cylinder and piston assemblies, consider again the operation of the second embodiment of FIG. 6 in response to a left-hand turn. In left-hand turn, the combined roll and pitch makes the outside front of the automobile tend to dip, while the outside rear of the automobile tends to rise. This tends to compress the right front assembly 570 and expand the rear left assembly 600. In response to the turn, the pressurizing potential is introduced through port 575 of the front assembly 570 while the return potential is connected to the port 585 of the front assembly 580. Refer now to FIGS. 7A and 8. Introduction of the pressurizing potential at port 575 causes a shock-like impulse which increases the pressure at the bottom of the piston 572. The pressure pushes the piston upward in the cylinder, thereby expanding the assembly in reaction to the compression exerted by the turn forces. Some of the shock-like impulse caused by the introduction of the return potential through the port 575 is transferred upwardly through the through port 733b of the piston 572 around the sides and through the through ports of the upper floating piston assembly and out the upper port 524 of the front wheel assembly 570. The pressurizing potential is maintained through the upper port 524 until the position-sensing port 576 is uncovered.
For so long as the pressurizing potential is provided through the upper port 524, the right rear assembly 590 is activated by introduction of the pressurizing potential through the lower port 597. The initial impulse of the pressurizing potential is transferred through the fixed piston 593 and the floating piston out the upper port 595 of the rear assembly. Pressurizing potential is introduced through the upper port 605 of the left rear assembly 600 where it exerts a downward force on the upper floating piston assembly and fixed piston of the left rear assembly. As FIG. 8 shows, the full pressurizing potential introduced through the port 595 is brought against the top of the fixed piston 593 by flow of fluid around the sides of the floating piston and by compression of the rubber spring 781 by downward movement of the floating piston 782. This exerts an immediate compressing action on the left rear assembly which tends to lower the inside rear corner of the automobile during a left-hand turn.
In FIG. 9, the back pressure valve 710 is illustrated. The valve consists of a bored, substantially cylindrical member having hydraulic ports 485 and 487 which connect conventionally to hydraulic conductors. A spring-loaded valve 791 is disposed in an inner chamber 790 of the valve. The valve 791 is loaded by a spring 792 which seats the valve 791 to close the opening 793 when the differential hydraulic signal is absent. When the signal is applied to the system, the pressure keeps the valve opened. Surges of the hydraulic fluid in the anti-roll system of FIG. 7 are damped by displacement of the internal valve 791 against the spring 792. When the surge expires, the spring 792 returns the valve to its partially-open position.
Returning to FIG. 6, hydraulic fluid surges in the anti-roll system of FIG. 6 are also damped by an accumulator 723 (which is shown in cross-section in FIG. 6) connected between the rear cylinder and piston assemblies. The accumulator 723 is a hollow elongate cylinder with hydraulic coupling ports 795 and 796. The ports 795 and 796 are conventionally coupled to the hydraulic line 722 and 724. Disposed in the cylinder is an air-filled bladder 799 made of a flexible material. The hydraulic fluid used in the system is incompressible when compared to the air which fills the bladder 799. Thus, when a surge occurs in the hydraulic fluid in the upper portions of the rear wheel cylinder and piston assemblies, some of the force of the surge is transferred against the outer surface of the bladder 799. Since the air which fills the bladder 799 is relatively compressible, some of the force of the surge will be absorbed by compression of the bladder. When the surge dissipates, the bladder expands to an equilibrium volume forcing fluid back up through the piston. Fluid resistance in the lines connecting the accumulator 723, 710, and 711 are turned to serve in the damping process of medium frequency bumps.
In the first and second embodiments of the anti-roll system illustrated and disclosed above, tilt limitation is provided through the position sensing ports of the front wheel cylinder and piston assemblies. In either embodiment, provision of tilt limitation on each side of a vehicle permits a smooth and fast response to vehicle turns. While both embodiments show provision of tilt limitation in the front wheel cylinder and piston assemblies, this is not intended to limit provision of tilt limitation in other cylinder and piston assemblies of an anti-roll system. Further, while, in each embodiment, tilt limitation is activated in response to compression but not expansion, or to expansion but not compression, a need may arise where tilt limitation would be activated in response to compression of one set of assemblies and to expansion of another set of assemblies.
Another feature which produces an unexpected result in this invention can be appreciated with reference to FIGS. 7A and 8. Assuming equal diameters for the cylinders of the assemblies 570 and 590, the inventor has found that providing a piston rod 730 having a larger diameter (d 1 ) than the diameter (d 2 ) of the piston rod 770 will accelerate the response of the front wheel cylinder and piston assemblies to a differential hydraulic signal, compared with the response of the rear wheel assemblies. The larger diameter of the front wheel assembly receiving the pressurizing signal means that a larger surface area will be presented to the portion of the signal which is transferred by the shock absorbing design of the piston. The larger surface area will integrate more of the pressurizing force, thereby "boosting" the expansion of the outside front assembly. This "boost" will counteract the tendency of the inside rear wheel to lift off of the road surface, and suppress any tendency which the vehicle may have to oversteer during a turn.
Finally, all of the hydraulic lines which interconnect the elements of the anti-roll system of this invention can be made of a flexible material, which will increase the damping of the system to surges in the hydraulic fluid.
With this description, it should be evident to those skilled in the art that my invention can be practiced other than as described above, without departing from the spirit of these teachings. | An anti-roll system for turn compensation in a vehicle generates a differential hydraulic signal in which a pressurizing potential corresponds to a first curve direction and a complementary return hydraulic potential. The system includes a pair of rear wheel cylinder and piston assemblies and a pair of front wheel cylinder and piston assemblies. A hydraulic circuit is connected to conduct the pressurizing potential to move the pistons in a first rear wheel cylinder and piston assembly and a first front wheel cylinder and piston assembly, while conducting the return signal to move the pistons in second front wheel cylinder and piston assembly and a second rear wheel cylinder and piston assembly. A hydraulic conductor directly connects corresponding ends of the rear wheel cylinder and piston assemblies to provide a hydraulic conduction between those assemblies in response to conduction of the differential hydraulic signal. A tilt limitation feature is provided in the front wheel cylinder and piston assemblies and is connected to the hydraulic circuit for limiting the maximum displacemnt of the pistons in the rear and front wheel cyilnder and piston assemblies. In a vehicle, the system reacts to a turn by causing the front and rear wheel cylinder and piston assemblies to tilt the vehicle in a direction to counteract the vehicle rolling force caused by the turn. The tilt-limitation element operates to limit the amount of tilt produced by the system of the invention to counteract vehicle roll force. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to furnaces constructed of hearth and sidewall refractories, and more particularly relates to systems for the compressive binding of these refractories.
BACKGROUND OF THE INVENTION
[0002] Furnaces are used extensively in the smelting and converting of ferrous and non-ferrous ores and concentrates. Furnaces of this type are generally circular or rectangular, having a bottom wall (hearth) and vertical walls comprised of refractory bricks and a roof or off gas hood. These furnaces are also characterized by a binding and support structure, the purpose of which is to maintain the refractory bricks of the hearth and walls in compression.
[0003] Adequate compression of the furnace walls, and particularly the hearth, is critical to maximize furnace campaign life and to prevent costly and potentially catastrophic furnace failure. During heating of the furnace to operating temperature, the individual bricks comprising the hearth and the walls expand, resulting in outward expansion of the hearth. Conversely, cooling of the furnace results in contraction of the individual bricks and overall shrinking of the furnace. If the compressive forces on the hearth or the walls are insufficient, gaps will be formed between the bricks during cooling phases of the furnace operation. These gaps can be infiltrated with molten metal or other material, resulting in permanent growth of the furnace. Repetition of heating and cooling cycles results in further incremental expansion of the furnace (known as “ratcheting”), which usually results in a reduction of the furnace campaign life, by the potential for molten infiltration into the hearth refractory or excessive expansive forces exerted on the binding system.
[0004] In rectangular furnaces, the binding system usually consists of regularly spaced vertical beams known as “buckstays”, which are held together at the top and bottom by horizontal tie members extending across the furnace, the bottom tie members passing beneath the hearth and the upper tie members passing above the furnace roof. The structure of electric furnaces is discussed in more detail in Francki et al., Design of refractories and bindings for modem high-productivity pyrometallurgical furnaces, Non-Ferrous Metallurgy, Vol. 86, No. 971, pp. 112 to 118. Frequent adjustment of the tie members, as by loosening or tightening retaining nuts at the tie member ends, is necessary to maintain relatively constant compression on the refractories during thermal cycling of the furnace. The binding systems of most large rectangular furnaces in operation today are equipped with compression spring sets sized to maintain the desired compression on the brick work, thereby permitting some expansion and contraction of the furnace while maintaining the hearth under compression.
[0005] While spring sets permit some furnace movement, they do not eliminate the need for periodic adjustment of the spring loads to ensure that the forces on the tie members and the furnace hearth remain relatively constant during use of the furnace. Adjustment of the spring loads is performed with hydraulic jacking equipment, and is a difficult and unpleasant operation due the fact that the vicinity of the furnace is usually hot, dirty and ill-lit and because the adjustment screws on the spring sets usually become more difficult to turn with time. Therefore, the frequency of adjustment tends to be low and spring binding systems are often not used to their full advantage.
[0006] The problems with prior art adjustment systems are exemplified by U.S. Pat. No. 3,197,385 (Wethly), issued on Jul. 27, 1965. This patent relates to the use of hydraulic jacking equipment for adjustment of tie rod tension in a coke oven battery. According to Wethly, the tension in each tie rod is adjusted by a hydraulic tensioning jack which is mounted on the ends of the rods. However, the tensioning jack must be sequentially mounted on each tension rod to adjust the tension in the rods one by one, in sequence. In the sequential adjustment system taught by Wethly, it would be difficult to control the tension in the rods with any degree of precision since adjusting the tension in one rod will have an effect on the tension in neighboring rods. Furthermore, the sequential mounting and use of a hydraulic jack in close proximity to the furnace is an unpleasant task which is likely to be performed only when absolutely necessary, and therefore the frequency of adjustment is likely to be low.
[0007] Therefore, a need exists for improved furnace binding systems for both rectangular and circular furnaces. Preferably, such systems would permit the compressive forces on the refractory hearth and furnace walls to be accurately adjusted, and would permit adjustment of the compressive forces to be carried out remotely and continuously, thereby maximizing furnace life and improving safety.
SUMMARY OF THE INVENTION
[0008] The present invention overcomes the above-described problems of the prior art by providing a furnace binding and adjustment system in which the compressive forces on the furnace hearth can be accurately controlled and monitored on a continuous basis. The system of the invention includes fluid-pressurized tensioning or compression means for maintaining compressive forces on the hearth and/or furnace walls. The compressive forces applied to the furnace by the binding system are regulated by one or more pressure regulation means adapted to simultaneously or individually adjust the fluid pressure in one or more of the tensioning or compression means, thereby overcoming the problems in the prior art.
[0009] The control of the tensioning or compression means by one or more pressure regulation means is particularly well suited to remote operation, whereby a furnace operator situated in a control room can regulate the pressure in the pressure regulation means, thereby eliminating the need to carry out manual adjustments in the vicinity of the furnace. Furthermore, since the fluid pressure in the pressure regulation means and in the tensioning or compression means is proportional to the compressive forces exerted on the furnace, the binding system of the present invention permits accurate measurement and control of the compressive forces exerted on the furnace.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0011] [0011]FIG. 1 is an end view, partly in cross-section, of an electric furnace incorporating a furnace binding and adjustment system according to a first preferred embodiment of the present invention;
[0012] [0012]FIG. 2 is a side view, partly in cross-section, of the furnace shown in FIG. 1;
[0013] [0013]FIG. 3 is a plan view, showing in isolation the buckstays, tie members and fluid-pressurized tensioning means in the lower portion of the furnace shown in FIG. 1;
[0014] [0014]FIG. 4 is a side view showing in isolation a pair of opposed buckstays with a tie member and a fluid-pressurized tensioning means as shown in FIG. 3;
[0015] [0015]FIG. 5 is a front view of the left buckstay in FIG. 4, showing the fluid-pressurized tensioning means;
[0016] [0016]FIG. 6 is a front view of the right buckstay of FIG. 4, showing the retaining nut on the tie member end;
[0017] [0017]FIG. 7 is an enlarged plan view showing one of the fluid-pressurized tensioning means of FIG. 3 in the lower portion of the furnace, together with its associated buckstay and tie member ends;
[0018] [0018]FIG. 8 is a partial cross-section through the tensioning means of FIG. 4;
[0019] [0019]FIG. 9 is a side view of a second preferred fluid-pressurized tensioning means for use in the binding and adjustment system of the invention, the tensioning means being shown with its associated buckstay and tie member end;
[0020] [0020]FIG. 10 is a front view of the fluid-pressurized tensioning means of FIG. 9;
[0021] [0021]FIG. 11 is a simplified, schematic plan view of a furnace binding system according to a third preferred embodiment of the present invention;
[0022] [0022]FIG. 12 is a simplified, schematic side view showing one variation of the furnace binding system of FIG. 11; and
[0023] [0023]FIG. 13 is a simplified, schematic side view showing a fourth preferred embodiment of the invention in which a fluid-pressurized cylinder directly applies compressive forces to a furnace.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] A first preferred furnace binding and adjustment system, adapted for maintaining compression on a refractory furnace hearth of a rectangular furnace, is now described below with reference to FIGS. 1 to 10 .
[0025] [0025]FIG. 1 illustrates the basic structure of a typical rectangular electric furnace 10 to which the system of the present invention is applied. The cross-section of FIG. 1 is taken transverse to the longitudinal axis of the furnace. Furnace 10 comprises a pair of opposed sidewalls 12 and 14 , a pair of opposed end walls 16 and 18 (FIG. 2), a hearth 20 , an arched roof 22 , and a plurality of electrodes 24 spaced along the longitudinal axis of the furnace 10 .
[0026] The hearth 20 , as well as the sidewalls 12 , 14 and end walls 16 , 18 are constructed of refractory brick in a known manner. The refractory bricks of the hearth and the side and end walls are maintained in compression by vertical metal shell plates 19 which are contained by flexible bindings comprised of regularly-spaced vertical buckstays 30 held together at the top and bottom by horizontal tie members 32 , 33 .
[0027] As best shown in FIG. 3, the buckstays 30 are arranged in regular, spaced relation around the side and end walls of the furnace 10 . Each buckstay comprises a vertical steel beam having a lower end 34 extending below the hearth 20 and the furnace bottom and an upper end 36 extending above the tops of the furnace walls 12 , 14 , 16 , 18 and the furnace roof 22 .
[0028] The buckstays 30 are arranged in pairs, with the buckstays of each pair being positioned on opposite sides of the furnace. In FIG. 3, the buckstays of each pair are in opposed relation to one another directly across the furnace from one another.
[0029] The buckstays 30 of each pair are connected at their upper ends 36 by at least one upper tie member 32 and at their lower ends 34 by at least one lower tie member 33 . In the preferred embodiment shown in the drawings, the upper ends 36 of each pair of buckstays 30 are connected by a single upper tie member 32 , and the lower ends 34 of each pair of buckstays 30 are connected by a single lower tie member 33 . It will be appreciated that the expansive forces are greatest at the lower ends 34 of buckstays 30 due to expansion of the hearth 20 , and therefore it may be preferred to connect the lower ends 34 of each pair of buckstays 30 with two or more lower tie members 33 .
[0030] As shown throughout the drawings, the upper ends 36 and lower ends 34 of buckstays 30 are apertured to permit the ends of the tie members 32 , 33 to extend therethrough. The furnace binding and adjustment system further comprises a plurality of fluid-pressurized tensioning means 40 provided at the ends of tie members 32 , 33 , the tensioning means 40 being adjustable so as to permit lateral expansion and contraction of the furnace 10 while applying compressive forces to the hearth, sidewall and end wall refractories through the buckstays 30 .
[0031] At the lower ends of buckstays 30 , shown in FIG. 3, a tensioning means 40 is preferably provided at a first end of each lower tie member 33 .
[0032] Similarly, a plurality of tensioning means 40 are provided at the ends of the upper tie members 32 . However, the tie members 32 extending across the central portions of the side walls 12 , 14 are preferably not provided with tensioning means 40 as there is relatively little lateral expansion of the furnace 10 at these points. Since the end walls 16 , 18 are shorter than side walls 12 , 14 , each upper tie member 32 extending between the end walls 16 , 18 may preferably be provided with a tensioning means at one of its ends.
[0033] Several different types of tensioning means can be employed in the system of the invention, of which two types are described herein. The tensioning means 40 preferably comprises a fluid-pressurized device for applying tension to the tie members. In the first preferred embodiment illustrated in FIGS. 1 to 8 , each tensioning device includes a hydraulic cylinder 42 having a bore through which the first end of a tie member 32 or 33 extends.
[0034] Specifically referring to FIG. 8, hydraulic cylinder 42 comprises a cylindrical housing 44 enclosing a piston 46 , the housing 44 having a cylindrical side wall 48 , a rear wall 50 with a central aperture 52 sized to receive the tie member 33 , and a front wall 54 having an aperture 56 sized to receive the piston 46 . The aperture 52 is surrounded by a sleeve 58 extending through the housing 44 from rear wall 50 to front wall 54 , the sleeve 58 forming a bore 60 through which the tie member 33 extends.
[0035] The piston 46 has a rear portion comprising a flange 62 which forms a seal with the side wall 48 of housing 44 , thereby dividing housing 44 into a pair of chambers 64 , 66 , which communicate with a manifold 68 (FIGS. 4 and 5) through respective hydraulic fluid lines 70 and 72 .
[0036] The first end of tie member 33 is retained by a retaining nut 74 which is threaded onto the end of tie member 33 (threads omitted for clarity), the nut 74 engaging the end face 76 of piston 46 , and preferably spaced therefrom by a washer 78 .
[0037] As shown in the drawings, the tie members 32 , 33 extend through pipes 90 which are welded through the buckstays. The second end of tie member 33 passing through the buckstay 30 on the opposite side of the furnace is retained by a retaining nut 74 (FIGS. 4 and 6).
[0038] As mentioned above, the fluid pressure in the tensioning means 40 is regulated by pressure regulation means, generally identified by reference numeral 67 in the drawings. In the preferred embodiment of the invention, pressure regulation means 67 are provided at each of the tensioning means 40 , thereby permitting the fluid pressure of the tensioning means 40 to be regulated simultaneously or individually. The pressure regulation means comprises manifold 68 , already mentioned above, which communicates with the two chambers 64 , 66 of hydraulic cylinder 42 through hydraulic fluid lines 70 , 72 . The manifold 68 controls the fluid pressure inside hydraulic cylinder 42 , and therefore controls the amount of tension in the tie members 32 , 33 . Preferably, each pressure regulation means 67 further comprises a gas over fluid accumulator 98 (FIGS. 4 and 5) which acts to minimize changes in pressure due to changes in the forces exerted on the buckstays by the refractories.
[0039] The pressure regulation means 67 further comprises a supply of fluid and pumping means for pumping the fluid to the tensioning means 40 . In the preferred embodiments of the invention, the fluid supply comprises a hydraulic fluid reservoir 97 and a pump 99 for pumping hydraulic fluid between the reservoir 97 and the manifold 68 . Reservoir 97 , pump 99 and the lines through which they are connected to the tensioning means are schematically shown in FIG. 1.
[0040] The system according to the invention further comprises control means for controlling operation of the pressure regulation means. Control means are generally indicated by reference numeral 101 and schematically shown in FIG. 1 as the means by which operation of the pump 99 and the manifold 68 are controlled. As shown, control means 101 are operated from a control room 103 , schematically shown in FIG. 1, which is preferably remotely located relative to the furnace 10 .
[0041] A second preferred tensioning means 100 for use in the first embodiment of the invention is illustrated in FIGS. 9 and 10, and comprises a bell crank-type hydraulic tensioning device incorporating a conventional hydraulic cylinder 102 having a piston (not shown) which reciprocates in a direction substantially perpendicular to the tie members 32 , 33 . The cylinder 102 is mounted in a bracket 104 having a bottom plate 106 secured to an outer surface of a buckstay 30 and a pair of spaced sidewalls 108 extending from the edges of plate 106 . An aperture 110 through the top of cylinder 102 aligns with a first pair of apertures 112 in the sidewalls 108 of bracket 104 and is secured thereto by retaining pin 114 .
[0042] The piston of cylinder 102 is actuated by connecting rod 116 , the distal end of which is pivotably connected to an end of a tie member 33 through a lever arm 118 having a first end 120 and a second end 122 . The first end 120 of lever arm 118 is pivotably connected to the distal end of connecting rod 116 , and the second end 122 of lever arm 118 is provided with a collar 124 through which the end of tie member 33 extends and is secured against relative movement by a retaining nut 74 . The second end 122 of lever arm 118 is pivotably connected to the side walls 108 of bracket 104 by a pin 126 extending through lever arm 118 and extending into a second pair of apertures 128 in sidewalls 108 of bracket 104 . Thus, reciprocal movement of cylinder 42 is translated to inward and outward movement of tie member 33 relative to buckstay 30 .
[0043] The fluid pressure in tensioning means 40 is regulated by pressure regulation means 67 and control means 101 , as described above. Furthermore, it will be appreciated that tensioning means 100 may also include a saddle and a safety nut, similar to that described above.
[0044] Further preferred aspects of the present invention are now described in connection with FIGS. 11 to 13 . FIGS. 11 to 13 are simplified drawings of some of the components of a furnace binding system. In each of these drawings, an arrangement of components is shown for applying compressive forces at one location of a furnace. However, it will be appreciated that a number of such arrangements are preferably provided to form a furnace binding system, and that the binding system is preferably controlled as described above, thereby permitting remote operation and simultaneous application of compressive forces at several points on the furnace.
[0045] [0045]FIG. 11 illustrates a third preferred embodiment of a furnace binding system in which a fluid-pressurized cylinder 200 , which is similar to fluid-pressurized cylinder 42 described above, is used to apply a tensioning force to a tie member 202 extending between cylinder 200 and a retaining member 204 . Retaining nuts 206 are received on the opposite ends of tie member 202 to retain the tie member 202 relative to the cylinder 200 and retaining member 204 . The cylinder 200 is supported on a support member 208 which applies force on a furnace wall 210 in the direction of the arrows shown in FIG. 11.
[0046] The arrangement of components shown in FIG. 11 is similar to that described above with reference to FIGS. 1 to 8 , except that the tie member 202 does not extend across the furnace. In one preferred embodiment, the support member 208 may comprise a buckstay and the retaining member 204 comprises a beam or other stationary member located inwardly of the furnace wall 210 , and situated either above or below the furnace wall 210 . It will be appreciated that the arrangement shown in FIG. 11 could be used to apply horizontal compressive forces to a furnace, thereby compressing the hearth as in the first preferred embodiment. The arrangement shown in FIG. 11 is applicable to furnaces of any shape, including circular and rectangular furnaces.
[0047] In the arrangement shown in FIG. 11, it will be appreciated that a fluid-pressurized cylinder having a bell crank mechanism similar to that shown in FIGS. 9 and 10 could be substituted for cylinder 200 .
[0048] As mentioned above, the support member 208 may comprise a buckstay similar to those shown in FIGS. 1 to 10 . However, FIG. 12 illustrates one variant of the binding system shown in FIG. 11 in which the support member 208 has a lower, pivoting end 212 pivotable about point P and an upper end 214 applying a compressive force to furnace wall 210 and hearth 216 . The cylinder 200 is located intermediate the lower and upper ends 212 and 214 and applies tension to tie member 202 extending between the cylinder 200 and a stationary retaining member 204 .
[0049] It will be appreciated that the arrangement illustrated in FIG. 12 is applicable to furnaces of any shape, including circular and rectangular. Furthermore, it will be appreciated that the relative positions of the cylinder 200 and pivot point P could be varied. For example, the pivot point P could be located between the cylinder 200 and the upper end 214 of support member 208 , similar to the configuration shown in FIG. 11.
[0050] Lastly, FIG. 13 illustrates a simplified arrangement in which the tie member 202 is eliminated and a fluid-pressurized cylinder 218 directly applies compressive force to the furnace sidewall 210 and hearth 216 .
[0051] Although the invention has been described in connection with certain preferred embodiments, it is not intended to be limited thereto. Rather, the invention includes all embodiments which may fall within the scope of the following claims. | A furnace binding and adjustment system for maintaining a refractory furnace hearth under compression utilizes a plurality of buckstays connected at their upper and lower ends by tie members. A fluid-pressurized tensioning device, preferably a hydraulics device, is provided at the ends of at least some of the tie members to permit some relative movement between the tie member end and the buckstay to permit adjustment of compressive forces applied to the refractory hearth. The use of multiple hydraulic devices permits simultaneous activation of the tensioning devices, and also permits the hydraulic pressure in the cylinders to be accurately adjusted and monitored from a remote location. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an electrophotographic apparatus; and more specifically, to an improved structural arrangement having a densitometer. Moreover, the densitometer arrangement achieves improved measuring of marking particle density on a substrate. Specifically, the densitometer is responsive to both changing environmental conditions and differences between individual machines.
2. Description of the Prior Art
It is known in the electrical graphic arts to use light sensors for measuring the density of a powderous substance or the like. One such sensor is a developability sensor, also known as a densitometer, used to monitor the "Developed toner Mass per unit of Area," referred to as DMA. Current developability sensors are optically based. The sensors are required to monitor the DMA of both black and colored toners. For example, in co-pending U.S. patent application Ser. No. 07/399,051, it describes a densitometer which measures the reduction in the specular component of the reflectivity of a portion of a surface having a liquid color material deposited thereon. Collimated light rays, in the visible spectrum, are projected onto the portion of the surface having the liquid thereon. The light rays reflected from the portion of the surface having the liquid deposited thereon are collected and directed onto a photodiode array. The photodiode array generates electrical signals proportional to the total flux and the diffuse component of the total flux of the reflected light rays. Circuitry compares the electrical signals and determines the difference therebetween to generate an electrical signal proportional to the specular component of the total flux of the reflected light rays.
Similarly, co-pending U.S. patent application Ser. No. 07/246,242, which is herein incorporated by reference in its entirety, describes an infrared densitometer which measures the reduction in the specular component of reflectivity as toner particles are progressively deposited on a moving photoconductive belt. Collimated light rays are projected onto the toner particles. The light rays reflected from at least the toner particles are collected and directed onto a photodiode array. The photodiode array generates electrical signals proportional to the total flux and the diffuse component of the total flux of the reflected light rays. Circuitry compares the electrical signals and determines the difference therebetween to generate an electrical signal proportional to the specular component of the total flux of the reflected light rays.
U.S. Pat. No. 4,950,905, which is herein incorporated by reference in its entirety, discloses a color toner density sensor. Where, light is reflected from a toner predominantly by either scattering or multiple reflections to produce a significant component of diffusely reflected light. Moreover, part of the sensor is arranged to detect only diffusely reflected light, and another part is arranged to detect both diffuse and specularly reflected light. In operation, the diffusely reflected light signals are used to identify increasing levels of diffusely reflected light which in turn indicates an increased density of toner coverage per unit of area.
U.S. Pat. No. 4,801,980, discloses a toner density control apparatus having a correction process. The object of the invention is to prevent a decrease in the image density even when the toner density sensor is contaminated with the toner particles. This is achieved by detecting the degree of contamination and thereby adjusting the light intensity of the reflective LED (light emitting diode) light source accordingly.
U.S. Pat. No. 4,676,653, discloses a method for calibrating the light detecting measuring apparatus and eliminating errors of measurement caused by variations of the emitter or of other electronic components. This is accomplished by using one light transmitter and two detectors. A first detector measures light that is diffusely reflected off of a sample. A second detector measures light that is emitted from the light transmitter. The second detector information is used to calibrate the apparatus and to eliminate errors of measurement caused by variations in the transmitter or other electronic components.
U.S. Pat. No. 4,553,033, describes an infrared densitometer which measures the reduction in the specular component of reflectivity as toner particles are progressively deposited on a moving photoconductive belt. Collimated light rays are projected onto the toner particles. The light rays reflected are collected and directed onto a photodiode array. The photodiode array generates electrical signals proportional to the total flux and the diffuse component of the total flux of the reflected light rays. Circuitry compares the electrical signals and determines the difference therebetween to generate an electrical signal proportional to the specular component of the total flux of the reflected light rays.
Another example is U.S. Pat. No. 4,502,778, which discloses digital circuitry and microprocessor techniques to monitor the quality of toner operations in a copier and take appropriate corrective action based upon the monitoring results. Patch sensing is used. Reflectivity signals from the patch and from a clean photoconductor are analog-to-digital converted and a plurality of these signals taken over discrete time periods of a sample are stored. The stored signals are averaged for use in determining appropriate toner replenishment responses and/or machine failure indicators and controls.
U.S. Pat. No. 4,462,680, discloses a toner density control apparatus which assures always the optimum toner supply and good development with toner, irrespective of the kind of original to be copied and/or the number of copies to be continuously made. The apparatus has a detector for detecting the density of toner. The quantity of toner supply is controlled using a value variable at a changing rate different from the changing rate of the density difference between the reference toner density and the detected toner density.
U.S. Pat. No. 4,318,610, discloses an apparatus which controls toner concentration by sampling two test samples. A first test is run with a large toner concentration, wherein a second test has a smaller concentration. Developer mixture concentration is regulated in response to the first test. Photoconductive surface charging is regulated in response to the second test.
U.S. Pat. No. 4,313,671, discloses a method for controlling image density in an electrophotographic copying machine. This method uses two detectors, one measures the toner density of a blank region on a photosensitive member, the second measures a reference toner image closely positioned to the first blank region. The method then compares the two densities and uses this information to control the quantity of toner deposited thereon.
U.S. Pat. No. 4,226,541, discloses illuminating a small area of a surface to be reflectively scanned. This is followed by detecting the intensity of the light reflected from the small area and generating a first signal proportional thereto. The nest step is detecting the intensity of the light reflected from an area at least partially surrounding the small area and generating a second signal proportional thereto. Followed by subtracting at least a fraction of the second signal from the first signal to produce a compensated signal which represents the reflectivity of the small area as compensated for the effects of scattered light. Finally, the process either uses the compensated signal directly as analog data or converting it to a digital output signal having a first state when the compensated signal is above a predetermined threshold and having a second state when the compensated signal is below that threshold.
An ideal goal in electrophotography is to have the correct amount of toner deposited onto a copy sheet on a continuous basis. With poor toner development control two situations occur. First, concerning a variability of toner quantity applied, too little toner creates lighter colors, where too much color toner creates darker colors. Second, concerning the machine, too much toner development causes excess toner waste which both increases the expense of running the machine and wears parts of the machine out sooner. Machines that can achieve precise control of the toner development system will have a tremendous competitive edge.
Typically, the electrophotographic machine, or just machine, utilizes a toner monitoring system. Most commonly, as exemplified by the prior described patents, a densitometer sensor is used to measure the quantity of toner applied in order to establish some feedback and control over the toner development. These machines have been successful to some extent. However, these prior toner monitoring systems have not been responsive to both changing environmental conditions and differences between individual machines. Environmental conditions are defined as, for example, relative humidity, temperature, dirt build-up on the densitometer sensors, and electronic circuit drift. Similarly, differences between individual machines, for example, involves characteristic variability between sensors, static and dynamic variations in mounting distances or angle settings of the sensor, and variability between photoreceptors and similar image bearing members; simply put, no two machines are alike. It is obvious to one skilled in the art, that these factors are responsible for skewing the readings from feedback toner monitoring control systems, which in effect, are directly responsible for regulating the amount of toner deposited on copy sheets.
In response to these problems, a need exists for a more precise toner development monitoring system which accounts for both the changing environmental conditions and the variable characteristics between individual machine components.
As a result, the present invention provides a solution to the described problems and other problems, and also offers other advantages over the prior art.
SUMMARY OF THE INVENTION
A first feature of the invention involves a densitometer capable of receiving electromagnetic energy input and, in response thereto, generating a diffuse component signal and a total flux component signal. This feature has a means for generating, responsive to a first electromagnetic energy input received by the densitometer, a first diffuse component signal and a first total flux component signal. Moreover, there is a means for generating a compensation factor signal, responsive to said first diffuse component signal and said first total flux component signal. Furthermore, there is a means for generating, responsive to a second electromagnetic energy input received by said densitometer, a second diffuse component signal and a second total flux component signal. Finally, there is a means for generating a specular component signal, responsive to said second electromagnetic energy input received by said densitometer, being a function of said second total flux component signal and said second diffuse component signal scaled by said compensation factor signal.
A second feature of the invention involves an electrophotographic machine capable of determining developed toner mass per unit of area on a substrate. This feature has a means for developing at least first and second toner areas on the substrate. Moreover, there is an electromagnetic energy source positioned to direct electromagnetic energy onto said first and second toner areas. Furthermore, there is a densitometer capable of receiving electromagnetic energy input reflected off of said substrate and, in response thereto, generating a diffuse component signal and a total flux component signal. The densitometer has a means for generating, responsive to a first electromagnetic energy input received by said densitometer, a first diffuse component signal and a first total flux component signal. Moreover, the densitometer has a means for generating, responsive to a second electromagnetic energy input received by said densitometer, a second diffuse component signal and a second total flux component signal. Additionally, the feature has a means for generating a compensation factor signal, responsive to said first diffuse component signal and said first total flux component signal. Also, this feature includes a means for generating a specular component signal, responsive to said second electromagnetic energy input received by said densitometer, being a function of said second total flux component signal and said second diffuse component signal scaled by said compensation factor signal. Finally, there is a means for calculating the developed toner mass per unit of area on a substrate, responsive to said specular component signal.
A third feature of the invention involves a method of measuring a material's mass per unit of area located on a substrate. This feature includes a step for depositing a first patch of said material, having a high density, onto the substrate. Moreover, another step generates a compensation ratio, from said first patch, substantially representative of changing environmental conditions. Also, there is a step for depositing a second patch of said material, having a lower density than said first patch, onto said substrate. Finally, there is a step for determining the mass per unit of area of the material from said second patch and said compensation ratio.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, like reference numerals indicate corresponding parts of preferred embodiments of the present invention throughout the several views, in which:
FIG. 1 is an electrophotographic color printing machine.
FIG. 2 is a schematic of a simplified densitometer.
FIG. 3 is a graph showing specular reflection signal versus toner density mass per unit of area.
FIG. 4 is a representation of a toner area coverage sensor.
FIG. 5 is a dirt covered toner area coverage sensor.
FIG. 6 is an electrical block diagram.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. Electrophotographic Printing Machine
Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the invention selected for illustration in the drawings, and are not intended to define or limit the scope of the invention.
For a general understanding of the features of the present invention, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate identical elements. FIG. 1 schematically depicts the various components of an illustrative electrophotographic printing machine incorporating the infrared densitometer of the present invention therein. It will become evident from the following discussion that the densitometer of the present invention is equally well suited for use in a wide variety of electrophotographic printing machines, and is not necessarily limited in its application to the particular electrophotographic printing machine shown herein.
Inasmuch as the art of electrophotographic printing is well known, the various processing stations employed in the FIG. 1 printing machine will be shown hereinafter schematically and their operation described briefly with reference thereto.
As shown in FIG. 1, the electrophotographic printing machine employs a photoreceptor, i.e. a photoconductive material coated on a grounding layer, which, in turn, is coated on an anti-curl backing layer. The photoconductive material is made from a transport layer coated on a generator layer. The transport layer transports positive charges from the generator layer. The generator layer is coated on the grounding layer. The transport layer contains small molecules of di-m-tolydiphenylbiphenyldiamine dispersed in a polycarbonate. The generation layer is made from trigonal selenium. The grounding layer is made from a titanium coated Mylar. The grounding layer is very thin and allows light to pass therethrough. Other suitable photoconductive materials, grounding layers, and anti-curl backing layers may also be employed. Belt 10 moves in the direction of arrow 12 to advance successive portions of the photoconductive surface sequentially through the various processing stations disposed about the path of movement thereof. Belt 10 is entrained about idler roller 14 and drive roller 16. Idler roller 14 is mounted rotatably so as to rotate with belt 10. Drive roller 16 is rotated by a motor coupled thereto by suitable means such as a belt drive. As roller 16 rotates, it advances belt 10 in the direction of arrow 12.
Initially, a portion of photoconductive belt 10 passes through charging station A. At charging station A, a corona generating device, indicated generally by the reference numeral 18, charges photoconductive belt 10 to a relatively high, substantially uniform potential.
Next, the charged photoconductive surface is rotated to exposure station B. Exposure station B includes a moving lens system, generally designated by the reference numeral 22, and a color filter mechanism, shown generally by the reference numeral 24. An original document 26 is supported stationarily upon transparent viewing platen 28. Successive incremental areas of the original document are illuminated by means of a moving lamp assembly, shown generally by the reference numeral 30. Mirrors 32, 34 and 36 reflect the light rays through lens 22. Lens 22 is adapted to scan successive areas of illumination of platen 28. The light rays from lens 22 are transmitted through filter 24 and reflected by mirrors 38, 40 and 42 on to the charged portion of photoconductive belt 10. Lamp assembly 30, mirrors 32, 34 and 36, lens 22, and filter 24 are moved in a timed relationship with respect to the movement of photoconductive belt 10 to produce a flowing light image of the original document on photoconductive belt 10 in a non-distorted manner. During exposure, filter mechanism 24 interposes selected color filters into the optical light path of lens 22. The color filters operate on the light rays passing through the lens to record an electrostatic latent image, i.e. a latent electrostatic charge pattern, on the photoconductive belt corresponding to a specific color of the flowing light image of the original document. Exposure station B also includes a test patch generator, to provide toner test patches, indicated generally by the reference numeral 43, comprising a light source to project a test light image onto the charged portion of the photoconductive surface in the inter-image or inter-document region, i.e. the region between successive electrostatic latent images recorded on photoconductive belt 10, to record a test area. It is noted that the test patch generator is not continuously operated. Toner test patches are only needed intermittently, to monitor the toner development. The test area, as well as the electrostatic latent image recorded on the photoconductive surface of belt 10, are developed with toner, either liquid or powderous, at the development stations (discussed later). A test patch is usually electrostatically charged and developed with toner particles to the maximum degree compatible with the dynamic range of the monitoring sensor so as to monitor as much of the process as practicable. Moreover, a separate test patch for each color toner is generated during operation.
After the electrostatic latent image and test area (or test patch) have been recorded on belt 10, belt 10 advances them to development station C. Station C includes four individual developer units generally indicated by the reference numerals 44, 46, 48 and 50. The developer units are of a type generally referred to in the art as "magnetic brush development units." Typically, a magnetic brush development system employs a magnetizable developer material including magnetic carrier granules having toner particles adhering triboelectrically thereto. The developer material is continually brought through a directional flux field to form a brush of developer material. The developer particles are continually moving so as to provide the brush consistently with fresh developer material. Development is achieved by bringing the developer material brush into contact with the photoconductive surface. Developer units 44, 46 and 48, respectively, apply toner particles of a specific color, which corresponds to the compliment of the specific color, onto the photoconductive surface. The color of each of the toner particles is adapted to absorb light within a preselected spectral reflection of the electromagnetic wave spectrum corresponding to the wave length of light transmitted through the filter. For example, an electrostatic latent image formed by passing the light image through a green filter will record the red and blue portions of the spectrums as an area of relatively high charge density on photoconductive belt 10. Meanwhile, the green light rays will pass through the filter and cause the charge density on the belt 10 to be reduced to a voltage level insufficient for development. The charged areas are then made visible by having developer unit 44 apply green absorbing (magenta) toner particles onto the electrostatic latent image recorded on photoconductive belt 10. Similarly, a blue separation is developed by developer unit 46, with blue absorbing (yellow) toner particles, while the red separation is developed by developer unit 48 with red absorbing (cyan) toner particles. Developer unit 50 contains black toner particles and may be used to develop the electrostatic latent image formed from a black and white original document. The yellow, magenta and cyan toner particles are diffusely reflecting particles. It is noted that the amount of toner deposited onto the photoconductive belt (or substrate) 10, is a function of the relative bias between the electrostatic image and the toner particles in the developer units. Specifically, a larger relative bias will cause a proportionately larger amount of toner to be attracted to substrate 10 than a smaller relative bias.
Each of the developer units is moved into and out of an operative position. In the operative position, the magnetic brush is closely adjacent to belt 10, while, in the non-operative position, the magnetic brush is sufficiently spaced therefrom. During development of each electrostatic latent image, only one developer unit is in the operative position, the remaining developer units are in the non-operative position. This insures that each electrostatic latent image, and successive test areas, are developed with toner particles of the appropriate color without commingling. In FIG. 1, developer unit 44 is shown in the operative position with developer units 46, 48 and 50 being in the non-operative position. After being developed, a test patch passes beneath a densitometer, indicated generally by the reference numeral 51. Densitometer 51 is positioned adjacent the surface of belt 10. The test patch is illuminated with electromagnetic energy when the test patch is positioned beneath the densitometer. Densitometer 51, generates proportional electrical signals in response to electromagnetic energy, reflected off of the substrate and toner test patch, that was received by the densitometer. In response to the signals, the amount of developed toner mass per unit of area for each of the toner colors can be calculated. It should be noted, that it would be obvious to one skilled in the art to use a variety of electromagnetic energy levels. The detailed structure of densitometer 51 will be described hereinafter with reference to FIGS. 2 through 6, inclusive.
After development, the toner image is moved to transfer station D, where the toner image is transferred to a sheet of support material 52, such as plain paper among others. At transfer station D, the sheet transport apparatus, indicated generally by the reference numeral 54, moves sheet 52 into contact with belt 10. Sheet transport 54 has a pair of spaced belts 56 entrained about three rolls 58, 60 and 62. A gripper 64 extends between belts 56 and moves in unison therewith. Sheet 52 is advanced from a stack of sheets 72 disposed on tray 74. Feed roll 77 advances the uppermost sheet from stack 72 into a nip, defined by forwarding rollers 76 and 78. Forwarding rollers 76 and 78 advance sheet 52 to sheet transport 54. Sheet 52 is advanced by forwarding rollers 76 and 78 in synchronism with the movement of gripper 64. In this way, the leading edge of sheet 52 arrives at a preselected position to be received by the open gripper 64. The gripper 64 then closes securing the sheet thereto for movement therewith in a recirculating path. The leading edge of the sheet is secured releasably by gripper 64. As the belts move in the direction of arrow 66, the sheet 52 moves into contact with belt 10, in synchronism with the toner image developed thereon, at transfer zone 68. Corona generating device 70 sprays ions onto the backside of the sheet so as to charge the sheet to the proper magnitude and polarity for attracting the toner image from photoconductive belt 10 thereto. Sheet 52 remains secured to gripper 64 so as to move in a recirculating path for three cycles. In this way, three different color toner images are transferred to sheet 52 in superimposed registration with one another. Thus, the aforementioned steps of charging, exposing, developing, and transferring are repeated a plurality of cycles to form a multi-color copy of a colored original document.
After the last transfer operation, grippers 64 open and release sheet 52. Conveyor 80 transports sheet 52, in the direction of arrow 82, to fusing station E where the transferred image is permanently fused to sheet 52. Fusing station E includes a heated fuser roll 84 and a pressure roll 86. Sheet 52 passes through a nip defined by fuser roll 84 and pressure roll 86. The toner image contacts fuser roll 84 so as to be affixed to sheet 52. Thereafter, sheet 52 is advanced by forwarding roll pairs 88 to catch tray 90 for subsequent removal therefrom by the machine operator.
The last processing station in the direction of movement of belt 10, as indicated by arrow 12, is cleaning station F. A rotatably mounted fibrous brush 92 is positioned in cleaning station F and maintained in contact with belt 10 to remove residual toner particles remaining after the transfer operation. Thereafter, lamp 94 illuminates belt 10 to remove any residual charge remaining thereon prior to the start of the next successive cycle.
II. Densitometer Background
Turning to FIG. 2, the following is a review of the principles of operation of a typical toner density sensor. Toner 95 is illuminated with a collimated beam of light 96 from an infrared LED (light emitting diode) 102. It is possible to discuss the interaction of this light beam with the toned photoreceptor sample with three broad categories. A portion of the light reflected by the sample is capture by light receptor 99. There is light that is specularly reflected, generally referred to as specular light component 98, from the substrate or photoreceptor belt 10. This is light that obeys the well known mechanisms of Snell's law from physics; the light impinging upon the surface is reflected at an angle equal to the angle of incidence according to the reflectivity of that surface. For a complex, partially transmissive substrate, the specularly reflected light may result from multiple internal reflections within the body of the substrate as well as from simple front surface reflection. Thus, an appropriately placed sensor will detect the specular light component. However, not all light will be specularly reflect. The second light component, known as diffuse light component 97, is ear to isotropically reflected over all possible angles. The light can be reflected as a result of either single or multiple interactions with both the substrate 10 and toner particles 95. Diffusely reflected light is scattered by a complex array of mechanisms. Finally, there is light that, by whatever mechanism, leaves this system of toned photoreceptor sample and light detector. The light may be absorbed by the toner or the photoreceptor, or be transmitted through the sample to be lost to the system by the mechanisms of absorption or reflection. As a result of toner development onto substrate 10, the intensity of the light specularly reflected 98 from the substrate 10 is increasingly attenuated, yielding a smaller and smaller specular component of light. The attenuation is the result of either absorption of the incident light 96, in the case of black toners, or by scattering of the incident light 96 away from the specular reflection angle, in the case of colored toners. Thus yielding a smaller specular light component being reflected off of substrate 10. It should be noted that it would be obvious to one skilled in the art to modify LED 102 to be most any electromagnetic energy level, and to modify toner 95 to be particles or liquid material.
As shown in FIG. 3, there is a relationship between the DMA and the specular signal detected by the densitometer. At a high DMA quantity, there is only a very small specular signal, at a low DMA quantity, there is a higher specular light signal. One particular point of interest on the graph shows a high density patch (HDP) location. HDP is the threshold DMA concentration required for a complete coverage of substrate 10. In effect, by achieving an HDP a solid picture is achieved on a copy sheet. The requisite DMA for a HDP may be typically around a quantity of 0.78 mg/cm 2 . The exact value of the DMA is primarily a function of the particle size of the toner and to a minor extent the reflectivity of the underlying substrate. It is found for all cases of interest that as the toner particle size varies, the DMA of the HDP scales in a manner proportional to changes in the maximum DMA required for printing. It is this relationship, as shown in the figure, that has allowed for easy monitoring of DMA concentrations for black toners. Specifically, black toners only allow the sensor to collect light reflected from the substrate since all light contacting the black toner is absorbed. As has been previously described, this absorption is not so for color toners, which creates difficulty in using the same techniques in monitoring color toner concentrations.
Turning our attention to FIG. 4, there is shown a toner area coverage sensor, generally referred to as sensor 104, which is used in the present invention. Sensor 104 uses a large aperture (not shown) relative to the incident beam spot size, this achieves greater mounting latitude (placement of the sensor in a proper coordinate location and with proper parallelism with respect to the photoreceptor). As a consequence, when used with color toners, central light reflection detector 106 (also referred to as the central detector) collects both specular and diffuse light components, or referred to as the total light flux. At most color toner DMA concentrations, a sensor which only measures total light flux degrades sensitivity and accuracy as a result of the increased percentage of diffusely reflected light which is also collected onto the sensor. Specifically, as described in FIG. 3, the specular light signals which indicate DMA concentrations will now be distorted. To remedy this specular-diffuse mixing situation, sensor 104 has an additional photodiode detector, which collects only the diffusely reflected light component, referred to as periphery detector 108. The advantage of the additional detector arrangement allows for separation of the specular light component from the total flux light component collected by the central detector. Specifically, in operation, the diffuse detector signal, from the diffuse-only detector 108, is subtracted from the total flux detector signal, from central detector 106 which has both specular and diffuse light components. Thus, the true specular signal can be determined. This is based on the assumption that diffusely reflected light is evenly distributed over the whole sensor 104. One such sensor that operates in the above described fashion is previously described co-pending U.S. patent application Ser. No. 07/246,242, which was incorporated by reference. It is noted that other arrangements of sensors will also work; such as an array of small light detectors as provided by a charge-coupled device (CCD) or the like.
III. Densitometer Operation Using A Compensation Factor
As has been discussed in the background of the invention, the prior densitometer calculations have not been responsive to both changing environmental conditions and differences between individual machines. As you will recall, for example, dust conditions in and on the densitometer are a changing environmental condition. To one skilled in the art, it is known that dust does not accumulate evenly on all objects; specifically, it has been found that dust can accumulate very unevenly upon lenses of a densitometer. For example, as shown in FIG. 5, dust 110 has been found to accumulate in a line running substantially over detector 106. If a densitometer does not take this environmental condition into account, the wrong DMA concentration will be calculated which will lead to improper adjustment of toner development.
For example, suppose the calculations for this densitometer were as follows:
CD-PD=SS
Where, CD is the signal from central detector 106 having both specular and diffuse light components, called the total flux; PD is the signal from the periphery detector 108, having only diffuse light components, and SS is the resulting specular signal. There are a few assumptions being made in this formula. First, the areas of the two detectors are corrected to be equal. Second, it is assumed that the diffuse light component is evenly distributed over the entire sensor. As a result of this calculation, signal CD is lower as a result of the environmental dust condition, yet signal PD remains the same (relatively higher). Therefore, a lower SS signal value will be calculated and used to adjust the toner development system to develop with a lower DMA than is required.
Referring to FIGS. 2-5, the current invention has proposed to incorporate a compensation ratio into the calculation. To calculate the compensation ratio, referred to as R in the following formula, the toner development system places on the substrate an HDP with a toner DMA density greater than the minimum value required to reduce the specular signal to a negligible value. As described earlier, a typical minimum value for the DMA would be 0.78 mg/cm 2 . Next, the HDP is illuminated via a light source. Detector 104 receives the light reflected off of the substrate 10 and HDP and generates two signals. One signal, being a total light flux signal generated by detector 106; the other signal being a diffuse light signal generated by detector 108. A ratio of these two signals, total light flux signal divided by the diffuse light signal, will yield the compensation ratio, R. For example, under typical conditions, as discussed in reference to FIG. 3, DMA concentrations around 0.78 mg/cm 2 and greater should result in an insignificant specular light component and a large diffuse light component. Thus, the central detector signal (CD) will only be a diffuse light component, for demonstrating purposes lets call it value x. Moreover, the periphery detector (PD) also is the diffuse light component, having the same value x. By taking a ratio of the two detector signals under ideal conditions the ratio should be equal to one.
CD=x
PD=x
R=CD/PD=X/X=1
Now, under normal conditions, it is understood that the compensation ratio will not be equal to one. The key to the calculations is that ratio R will vary depending upon the changing environmental conditions and differences between individual machines. For example, take the dirt deposit discussed in relation to FIG. 5. Dirt located on the central detector will decrease the signal received by the central detector which is the numerator in the ratio; thus lowering the value of R. A more complete discussion of an application of this variability follows. It is noted that for any DMA concentration over HDP, compensation ratio R will be a constant value.
Once R is calculated, the machine is now ready for standard operation to determine DMA concentrations using the compensation ratio or factor. It is noted that subsequent runs of toner test areas are initiated having a DMA concentration equal to or lower than 0.78 gm/cm 2 , the HDP concentration range. The use of a lower DMA is important, as discussed over FIG. 3, since both specular and diffuse light components can be sensed by the densitometer. As a result of these toner test runs, the central detector value will be different than the periphery detector value since there is a specular light component added to the central detector. However, and most significantly, the compensation ratio R is incorporated into the compensated calculation as follows:
CD-((R)(PD))=SS.
Therefore, with this compensated calculation, a true value of the specular signal SS can be more accurately calculated. Referring back to FIG. 5 and the dirt calculation discussion, the R ratio has a value less than one since the central detector was not receiving the full expected value. Similarly, the central detector's signal CD, in the second test run, will also have a lower signal than what it should have under ideal (clean) conditions. Similarly, the periphery detector's signal PD will proportionately be too high in comparison to the degraded central detector signal. However, by using the compensated calculation, PD will be lowered by the compensation ratio value of R (being less than one). Therefore, a true specular signal SS is calculated, and more significantly, the true DMA concentration is accurately identified which allows for proper adjustment of the toner developer of all the toner colors being tested.
One skilled in the art will appreciate that this compensation calculation will work for all of the above described changing environmental conditions and differences between individual machines which are related to the densitometer and marking particle development. This compensation is accomplished since we know that the specular signal is diminished essentially to zero and the ratio R becomes constant for all DMA values greater than the minimum HDP value. Any variation in this expected test will be accounted for in the compensation ratio to adjust the actual specular light component calculation in subsequent test patch runs.
Concerning the timing of the compensated specular signal and the compensation ratio, one skilled in the art will appreciate that there are many variations on when these operations may be executed. For example, the ratio could be calculated once a day when the machine is activated in the morning, or calculated after a certain number of copy sheets have been created, or even every time the toner development system is activated. Moreover, for example, the compensated specular signal could be calculated anywhere from every toner development use (given appropriate circuitry or potentially a second detector arrangement to measure only the HDP developed beside the low density patch), or spacing the calculations out over the use of the machine over an hourly or per count basis.
IV. Densitometer Circuitry
Tuning now to FIG. 6 and referring to the other figs. as well, there is a representation of a potential densitometer electronic circuitry. As shown in FIG. 6, there is a microcontroller 112, output signal 114, LED 116, substrate 10, detector 104, central detector (CD) 106, periphery detector (PD) 108, divider circuitry (a/b) 118, double throw switch 119, multiplication circuitry (×) 120, and a difference circuitry (-) 122. Microcontroller circuitry block 112 represents appropriate circuitry comprising analog to digital circuitry, digital to analog circuitry, ROM and RAM components, bus circuits, and the circuitry for timing of the activation between the components in the microcontroller circuitry and the components connected to the microcontroller circuitry shown in the figure. It is noted that one skilled in the art could design many variations in this circuitry. Similarly, it would be obvious to one skilled in the art to have a significant portion of the above described circuitry to be implemented into a single software program or other processing programs via semiconductors or other devices.
The following is a description of the operation of the whole process of determining a compensated specular signal in relation to the circuitry. First, the toner development system is activated to develop a high density patch (HDP) onto substrate 10. Next, LED 116 is activated when the HDP is positioned to receive the incident light from LED 116. Next, central and periphery detectors 106 and 108 receive reflected light from the toner and substrate 10. Then, there is generation of signals proportional to the total flux (detector 106) and diffuse light (detector 108) components. In response to microcontroller 112, switch 119 directs the signals only to divider circuitry 118 on the HDP DMA concentration test run to generate the compensation ratio/factor. Once the compensation ratio/factor signal is calculated it is sent to microcontroller 112 for storage and ready for use in preceding toner DMA concentration calculations. Next, microcontroller 112 is ready to perform the standard DMA concentration determination tests for various color toners. The first steps are the same as before, except that subsequent toner development test patches are at concentrations below HDP concentrations. Again, detectors 106 and 108 generate proportional signals from the reflected light. Switch 119 is then directing the signals to the remaining circuitry, comprising multiplier 120 and difference 122 circuitry, the divider circuitry is by-passed. Next, the periphery detector signal and the compensation ratio (generated during the compensation factor determination) are sent to multiplication circuitry 120 and multiplied to create a multiplier signal. Next, the multiplier signal and central detector signal are sent to difference circuitry 122 where a compensated specular light component signal is calculated by subtracting the multiplier signal from the central detector signal. This difference signal is sent to microcontroller 112. Finally, microcontroller 112 calculates the DMA concentration from the compensated specular light signal from difference circuitry 122 and comparison to the DMA values know from FIG. 3. Now, appropriate output signals 114 are sent to adjust the electrophotographic machine to achieve proper DMA concentrations ranges.
It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative, and changes in matters of order, shape, size, and arrangement of parts may be made within the principles of the invention and to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | An electrographic apparatus having a densitometer, which achieves improved measuring of marking particle density on a photoreceptor or the like. The measuring method detects both specular and diffuse light reflected off of the photoreceptor containing marking particles. A compensation ratio is generated from a high density marking particle patch, and is used to compensate the marking particle density to both changing environmental conditions and differences between individual machines. Thus, a more accurate specular signal is calculated which is an accurate indicator of toner density of mass per unit of area concentration. These concentration measures enable accurate adjustments of the electrographic apparatus color toner development systems. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims priority under 35 U.S.C. §119(e) from U.S. Provisional Application No. 60/649,202 filed Feb. 2, 2005, entitled “Low-Profile, Power-Integrated Actuator for Structural Vibration and Noise Abatement”, the contents of which are hereby incorporated in its entirety by reference thereto.
FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] One or more of the inventions disclosed herein were supported, at least in part, by a grant from the National Aeronautics and Space Administration (NASA), Contract No. NNL04AB14P awarded by NASA, Langley Research Center. The Government has certain limited rights to at least one form of the invention(s).
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention generally relates to a low-profile, fully-integrated active control device. Specifically, the invention is a flexible, thin-film actuator wherein the active material layer also functions as the substrate for control circuitry and sensors. The layered arrangement of thin-film actuator, control circuitry, and sensors retains the flexibility of the actuator substrate.
[0005] 2. Description of the Related Art
[0006] Vibration and noise remain a substantial problem to airplanes, helicopters, tilt-rotor craft, automobiles and other vehicles. Aircraft applications are particularly challenging because the source of vibration and noise is disturbances produced by continuous pressure fluctuations.
[0007] While vibration and noise remission systems are known, practical applications of these externally controlled and powered technologies are not possible. In general, active damping devices are too large because of the size of the switching power electronics required to drive the actuators within the damping device. Furthermore, active damping requires large linear amplifiers and them management devices which are likewise difficult to accommodate within the volume constraints of most air and ground vehicles. A consequence of large control circuitry is that it precludes its direct integration onto an actuator, since to do so would inhibit the flexibility required of the actuator to properly damp targeted vibrations and noises.
[0008] Therefore, what is required is an active damping/control device comprising a flexible, thin-film actuator and drive electronics, wherein the drive electronics is dimensionally compatible with and integral to the form-factor of the actuator mechanism.
[0009] What is also required is a fully-integrated, actuator-controller-power-sensor package having a thin, flexible format, so as to be easily applied to a structure wherein access and volume are limited.
SUMMARY OF INVENTION
[0010] An object of the present invention is to provide an active damping/control device comprising a flexible, thin-film actuator and drive electronics, wherein the drive electronics is dimensionally compatible to and integral with the actuator mechanism.
[0011] Another object of the present invention is to provide a fully-integrated, actuator-control-power-sensor package having a flexible format which avoids compromising the performance of the active material layer and sensors therein.
[0012] The present invention includes an active material substrate that forms an actuator mechanism which is electrically coupled to a contiguous driver circuit, controller circuit, power converter circuit, and including at least one sensor. The multilayer flexible circuitry integrates interconnected power electronics to include miniaturized digital architecture. DC-to-DC converter, inverter, and controller are components with a total footprint contiguous with the active material substrate. These components are mounted onto the active material substrate which may be rigid, semi-rigid or flexible. The modular nature of the present invention enables a fully-integrated active device that is either semi-flexible or flexible so as to easily conform to and allow attachment to planar and non-planar structures.
[0013] The flexibility and modular design of the present invention is achieved in a low-profile integrated active device package. In preferred embodiments, the low-profile active substrate includes a flexible or semi-rigid piezoelectric composite.
[0014] Drive and control circuitry, namely, Isolation Device Technology or IDT and digital signal processor or DSP circuits, enable a low-noise, power amplifier solution wherein actuator control elements are directly integrated onto a low-profile actuator mechanism. The IDT drive employs a segmented load decoupling output filter within its low-profile packaging. The digital core within the power amplifiers facilitates distributed systems wherein two or more actuators may be controlled by a single master controller. A master/slave control architecture eliminates a wiring harness and ensures scalability.
[0015] The flexibility of the thin-film actuator substrate in the layered arrangement of actuator, control circuitry, and sensors is achieved via flex power electronics, flex electrical interconnections, and flex mounted power conversion block. An interdigitated electrode pattern communicates an electric field into the piezoelectric wafer or fibers, comprising the flexible actuator, thus enabling the primary piezoelectric effect within the wafers and fibers. The conformability and flexibility of flexible fiber piezo-composite actuators are typically achieved via an ordered arrangement of piezoelectric wafers or fibers, preferably extruded piezoceramics, within a pliable protective matrix communicating with interdigitated electrodes applied directly onto the matrix, preferably epoxy, or via a polyimide, oppositely disposed about the matrix. Strain energy density is enhanced via interdigitated electrodes which induce in-plane electrical fields along the actuator, thus producing nearly twice the strain actuation and four times the strain energy density of through-plane poled piezoceramic devices.
[0016] The electrical traces and components, comprising the control circuitry of the present invention, are deposited and patterned onto the exterior of the actuator via known techniques, including solution-based, direct-write printing and photolithography. For example, solution-based, direct-write printing is a method in which materials are deposited additively only where passive electrical components and interconnections (conductive traces) are required. This method of printing is performed at low-temperatures, thus avoiding temperature and mechanical stability problems inherent with writing circuitry onto a flexible polymer substrate. Furthermore, this method is compatible with continuous roll-to-roll processing and more scalable than lithographic methods.
[0017] Several advantages are noteworthy for the present invention. The invention provides complete functionality within a single, yet flexible, package, including integrated power source, drive electronics, sensing, control and actuation that can achieve dynamic flexing requirements. The package can move, bend and even slightly twist without damage to its functional integrity. The invention provides a low-cost, flexible activation mechanism that can be directly coupled to a DC power source. The invention provides structural actuation and sensing that enables directional, conformable actuation in a simple, cost-effective and fully-integrated device. The direct coupling of drive circuitry to interdigitated electrodes in the present invention enhances electrical performance and efficiency. The invention provides an autonomously responsive active mechanism that is conducive to being integrated to conformal (non-flat) surfaces in ships, aircraft and spacecraft. The flex interconnected power/control architecture simplifies connection of the actuator to external instrumentation. The form factor of the present invention is determined solely by the footprint of the active material layer, rather than the footprint of the drive/control circuitry.
REFERENCE NUMERALS
[0000]
1 Flexible actuator
2 Active substrate
3 Drive circuit
4 Controller circuit
5 Power converter circuit
6 Power buss supply
7 a - 7 d Flexible sensor
8 Potting material
9 a - 9 e Piezoelectric elements
10 Controller stage
11 Power stage
12 Filter stage
13 Signal conditioner and feedback
14 Modulator
15 a - 15 b Gate drive
16 MOSFETs
17 Filter
18 Output and feedback
19 Feedback loop
20 DC block converter
21 Command signal
22 Output signal
23 Command signal
24 Tunable modulator
25 Gate drive
26 Power stage with IDT circuit
27 Multi-segmented load decoupling filter
28 Output signal
29 Controller
30 Master communication controller
31 a - 31 c Sensor controller
32 a - 32 c Flexible actuator
33 Command and feedback signal
34 Voltage input
35 Output command
36 DC Power command
37 Signal conditioner
38 DSP control laws
39 Signal conditioner
40 Segmented filter
41 a, 41 b Power stage interface
42 a, 42 b FET half-bridge with IDT
43 a, 43 b PWM signal
44 DC buss
45 Structure
46 Thin film
47 Thin film
48 a - 48 e First electrode
49 a - 49 e Second electrode
40 a, 50 b Flexible interconnect
51 Driver circuit
52 Power signal
53 Matrix
BRIEF DESCRIPTION OF THE DRAWINGS
[0071] The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which:
[0072] FIG. 1 is a top view of a schematic representation for one embodiment of the present invention.
[0073] FIG. 2 is partial section view of the schematic representation in FIG. 1 showing the flexibility and conformal aspects of the present invention.
[0074] FIG. 3 is a perspective view of an exemplary active substrate onto which a drive circuit, controller circuit, power circuit, and sensors are applied.
[0075] FIG. 4 is a perspective view of another embodiment of the present invention showing controller, power, and filter stages without flexible substrate interconnected on separate flexible printed circuit boards showing flexibility provided by interconnections between boards.
[0076] FIG. 5 is a functional block diagram for the three-stage flex circuit shown in FIG. 4 .
[0077] FIG. 6 is a block diagram for an exemplary driver circuit.
[0078] FIG. 7 is a block diagram for an exemplary system compliant driver.
[0079] FIG. 8 is a block diagram for an exemplary network of flexible actuators.
[0080] FIG. 9 is a block diagram for an exemplary power converter circuit.
[0081] FIG. 10 is a histogram plot showing signal-to-noise ratios for output waveforms at first four harmonic frequencies.
DETAILED DESCRIPTION OF THE INVENTION
[0082] Referring now to FIGS. 1-2 , a top-level block diagram of an exemplary flexible actuator 1 is shown and described. The flexible actuator 1 is a fully-functional, patch-like device of arbitrary shape having drive, power, control, and sensing functionality within the lateral extents of the device. The compliant nature of the flexible actuator 1 allows it to conform to the shape of an existing structure 45 , so that it is easily mountable thereon and attachable thereto. Components identified in each of the circuits described herein are commercially available devices unless otherwise indicated.
[0083] In certain applications, it may be advantageous to partially or completely embed a flexible actuator 1 within a laminate composite or molded polymer of arbitrary shape via laminating and molding methods of manufacture understood within the art. The composite or molded structure should minimize stiffening of the flexible actuator 1 so as to avoid impeding both sensing and shape changing performance characteristics.
[0084] The flexible actuator 1 may be mechanically attached, laminated or embedded within a structure 45 or adhesively bonded thereto via a variety of commercially available glues, adhesives or other similar bonding materials. Adhesive material may be pre-applied to the flexible actuator 1 during its manufacture or applied immediately prior to its application onto a structure 45 . It is preferred for the adhesive layer to be located along the active substrate 2 opposite of the drive, power, control, and sensing devices, as represented in FIG. 2 .
[0085] The flexible actuator 1 comprises an active substrate 2 having thereon a drive circuit 3 , a power converter circuit 5 , an optional controller circuit 4 , one or more optional flexible sensors 7 a - 7 d, and a power buss supply 6 . Circuits 3 - 5 and flexible sensors 7 a - 7 d are mounted to the exterior of the active substrate 2 , preferably along a common surface, as represented in FIG. 2 . A variety of configurations are possible for the arrangement of circuits 3 - 5 and flexible sensors 7 a - 7 d to optimize sensing fidelity, to minimize communication pathways, and to minimize stiffening of the active substrate 2 .
[0086] The active substrate 2 is a piezoelectric device capable of changing shape when exposed to an electric field, as described in U.S. Pat. Nos. 5,869,189 and 6,048,622 to Hagood, IV et al., and U.S. Pat. No. 6,629,341 to Wilkie et al.
[0087] Referring now to FIG. 3 , the active substrate 2 in the present invention is shown comprised of a plurality of piezoelectric elements 9 a - 9 e in an ordered arrangement within a matrix 53 of generally planar extent. Piezoelectric elements 9 a - 9 e may include a variety of shapes, designs, and materials; however, it is preferred to have flexible fibers electrically poled lengthwise so as to expand and contract axially and composed of a piezoceramic, one example being PZT, or an electrostrictive material. The matrix 53 is likewise compliant so as to change shape in response to dimensional changes in the piezoelectric elements 9 a - 9 e. The matrix 53 may be composed of a polymer, elastomer, or the like; however, it is preferred for the matrix 53 to be a non-rigid epoxy. Piezoelectric elements 9 a - 9 e are encased within the protective matrix 53 via methods understood in the art.
[0088] In some embodiments, it is advantageous to also provide a pair of optional thin films 46 , 47 that are either adhesively or otherwise bonded to the matrix 53 in a parallel arranged fashion with respect to the piezoelectric elements 9 a - 9 e. Thin films 46 , 47 are likewise compliant so as to change shape in response to dimensional expansion and contraction of the piezoelectric elements 9 a - 9 e. Thin films 46 , 47 may be composed of a polyester, one example being Mylar®, a registered trademark of the E.I. DuPont De Nemours and Company located in Wilmington, Del., a polyimide, one example being Kapton®, a registered trademark of the E.I. DuPont De Nemours and Company located in Wilmington, Del., and other flexible polymer material.
[0089] A plurality of first electrodes 48 a - 48 e and second electrodes 49 a - 49 e are required to electrically activate the piezoelectric elements 9 a - 9 e. One first electrode 48 a - 48 e and one second electrode 49 a - 49 e are coupled at opposite ends of each piezoelectric element 9 a - 9 e. Electrodes 48 a - 48 e, 49 a - 49 e may be directly integrated into the matrix 53 via flat wires or the like, or printed, etched or deposited, via methods understood in the art, onto each of the thin films 46 , 47 so as to provide an interdigitated arrangement.
[0090] Circuits 3 - 5 may be fabricated and mounted to the active substrate 2 via a variety of methods. For example in FIG. 4 , controller stage 10 , power stage 11 , and filter stage 12 may be fabricated onto separate flexible circuit boards and electrically coupled with commercially available flexible interconnects 50 a, 50 b in the order described. Thereafter, the circuit boards are each separately bonded via an adhesive onto the active substrate 2 . The controller stage 10 is also electrically coupled so as to receive a command and feedback signal 33 from one or more flexible sensors 7 a - 7 d disposed along the compliant actuator 2 . Command and feedback signal 33 facilitates the shape adjustments required along the active substrate 2 to achieve the desired abatement or mitigation function. The power stage 11 is also electrically coupled to a DC power source so as to receive a voltage input 34 which is modified prior to its communication to the active substrate 2 so as to effect the required shape change within the active substrate 2 . The filter stage 12 is electrically coupled to the first electrodes 48 a - 48 e and second electrodes 49 a - 49 e so as to communicate an output command 35 in the form of a voltage signal which causes the active substrate 2 to distort.
[0091] In yet another method, circuits 3 - 5 may be deposited or patterned directly onto either the matrix 53 or the thin films 46 , 47 disposed about the matrix 53 . As such, electrical interconnects or traces within and between circuits 3 - 5 and passive electrical components comprising the circuit 3 - 5 , namely, resistors, capacitors and the like, are printed, etched or deposited via known techniques, examples including solution-based, direct-write printing and photolithography. Other components comprising the circuits 3 - 5 are bonded onto the matrix 53 and thin films 46 , 47 via techniques understood in the art.
[0092] Flexible sensors 7 a - 7 d include a variety of commercial devices capable of measuring strain, stress, shear stress, pressure, velocity, and acceleration. Flexible sensors 7 a - 7 d and electrode patterns (interdigitated and wheatstone bridge) are either bonded to or printed, etched or deposited on, via methods understood in the art or referred to herein, onto the active substrate 2 . For example, flexible sensors 7 a - 7 d may be attached to the active substrate 2 via potting materials 8 understood in the art, as represented in FIG. 2 .
[0093] Referring now to FIG. 6 , an exemplary driver circuit 51 is shown having the components and electrical connections described therein. The driver circuit 51 includes a DC block converter 20 , a controller stage 10 , a power stage 11 , and a filter stage 12 . The controller stage 10 is a digital signal process (DSP) device including a signal conditioner and feedback 13 , electrically coupled so as to receive a command signal 21 , and a modulator 14 . The power stage 11 includes a pair of gate drives 15 a, 15 b electrically coupled to the modulator 14 and power MOSFETs 16 . The filter state 12 includes a filter 17 electrically coupled to the power MOSFETs 16 and an output and feedback 18 , also electrically coupled so as to communicate an output signal 22 and a control signal via a feedback loop 19 to the signal conditioner and feedback 13 .
[0094] In the present invention, the driver circuit 51 is required to drive capacitance loads in the range of 0.01 to 20.0 μF at efficiencies greater than 95% over a broad range of bandwidths from low (sub-hertz to kilohertz and tonal) to high (megahertz). In order to ensure that the driver circuit 51 fits within the planar form factor of most typical active substrates 2 , it is generally required to deliver voltages from near-DC to ±100 V ac ; however, larger field effect transistor (FET) components may be used to allow for the efficient delivery of ±500 V ac .
[0095] Isolation Device Technology (IDT) architecture, described in Non-Provisional patent application Ser. No. 11/201,567 entitled “High Frequency Switch Control” and hereby incorporated in its entirety by reference thereto, ensures the signal-to-noise ratio required to meet the operational performance of the power stage 11 . The IDT circuit is a commercial device, one example being circuit model no. IDT-50 sold by QorTek, Inc. located in Williamsport, Pa. The present invention includes a full-bridge output with IDT architecture to significantly improve switching performance by isolating the high and low side devices. As such, inner-bridge coupling of noise and transients are eliminated so as to allow each device to function in a decoupled fashion.
[0096] Switching waveforms are likewise tailored to the specific application based upon loads, device type and performance, and noise level. Tailored waveforms ensure the driver circuit 51 functions within a safe operating area (SOA) and exhibits less device dissipation because of the reduced presence of extraneous losses from poor switching practices. The ability to drive devices within their appropriate SOA affords several primary benefits, namely, less output noise, reduced output filtering, higher switching frequencies, and higher overall efficiencies.
[0097] Referring now to FIG. 7 , a top-level block diagram is shown for an exemplary driver for the active substrate 2 . The driver includes a tunable modulator 24 , a gate drive 25 , a power stage with IDT circuit 26 , and a multi-segmented load decoupling filter 27 electrically connected in the order described. A command signal 23 is communicated into the tunable modulator 24 and an output signal 28 is communicated from the multi-segmented load decoupling filter 27 .
[0098] A converter may be coupled to the IDT circuit described above to facilitate the step-up conversion of a 28 V dc buss to a 150 V dc drive voltage for the active substrate 2 . While a three-stage control system is preferred, single and other multi-stage systems are possible. The switching DC power supply converts the 28 V dc to the input voltage required by control system and signal conditioner.
[0099] Referring again to FIGS. 1 and 2 , the controller circuit 4 obtains measurements from one or more flexible sensors 7 a - 7 d and thereafter communicates command signals to the power converter circuit 5 and drive circuit 3 to control the excitation of one or more active substrates 2 . The controller circuit 4 may also control and interrogate flexible sensors 7 a - 7 d and active substrates 2 within an array of such devices. While a variety of commercially available controller circuits 4 are applicable to the present invention, microprocessors with a re-configurable core sold by Silicon Laboratories, Inc., having a corporate address in Austin, Tex., with multi-channel analog-to-digital converters, digital-to-analog converters, comparators, and interface busses (one example being a Controller Area Network), Serial Peripheral Interface (SPI), and 12C (Inter-IC) external interface are preferred. The described controller circuit 4 eliminates external hardware and reduces system weight while providing a simplified means for interfacing flexible sensors 7 a - 7 d, compliant actuator 2 , and power converter circuit 5 .
[0100] Referring now to FIG. 8 , sensor controllers 31 a - 31 c and flexible actuators 32 a - 32 c, or a like number and arrangement of active substrates 2 , may be concatenated in a pair-wise arrangement to form one-dimensional and two-dimensional arrays. A master communication controller 30 is electrically connected to two or more sensor controllers 31 a - 31 c and thereby capable of interrogating one or more sensor controllers 31 a - 31 c for data collection purposes and communicating command data to the flexible actuators 32 a - 32 c. The master communication controller 30 is likewise connected to a controller 29 which directs the function of the former.
[0101] Each sensor controller 31 a - 31 c has a communications pathway to receive control commands and transmit drive information to and from the master communication controller 30 . An exemplary sensor controller 31 a - 31 c is a C2000 model DSP sold by the Texas Instruments Company. Preferred devices included a 16-bit, 40 MHz DSP with embedded PWM, analog-to-digital converters, serial communications interface, internal RAM, and internal program FLASH ROM. A small DSP allowed more sensor controllers 31 a - 31 c for greater sensing fidelity.
[0102] The primary responsibility of each sensor controller 31 a - 31 c is to digitally stabilize the power driver based upon commands it receives from the master communication controller 30 and feedback from an output driver card. Commands are transmitted from the digital-to-analog converter within the master communication controller 30 . Voltage and current feedback signals are routed back to an analog-to-digital convert within each DSP.
[0103] In some embodiments, it may be preferred to have a DSP with a faster clock speed and capable of generating a pulse width modulated (PWM) signal upwards of 150 kHz so as to reduce the power supply output filter requirements. It is likewise preferred for the DSP to be signal processing capable and, if applicable, to allow multiple flexible actuators 32 a - 32 c to be controlled by one DSP. For example, the DSP sub-system in FIG. 8 employed a C2810 DSP sold by the Texas Instrument Company. The C2810 DSP enables sixteen analog input channels to provide additional feedback points for evaluation purposes. The C2810 DSP has the communication performance of a LF2401 DSP, yet with a Serial Peripheral Interface (SPI), thus enabling data communication back to the master communication controller 30 .
[0104] Preferred embodiments of the present invention include selectable feedback allowing a function generator or accelerometer as the feedback source. Signal conditioning may be required prior to analog-to-digital conversion so that high-frequency or out-of-band noise is removed. Filtering prevents aliasing and extraneous noise from occurring. After the command signal is digitized, it is used as the command for the proportional-integral (PI) control algorithm. The PI control algorithm either recreates the command at the power supply output, when the feedback source is a function generator, or nulls any motion, when the feedback source is an accelerometer. Two additional feedback channels for voltage and current may be used for feedback from the power supply so as to allow the command signal from a function generator to be accurately recreated at the flexible actuators 32 a - 32 c. Protection also is incorporated into the control so that power supply and flexible actuators 32 a - 32 c are not overdriven.
[0105] Identified DSPs maximize flexibility, robustness, and re-configurability in the control algorithm. A further advantage of the identified DSPs is quick and easy software modifications and improvements to adjust algorithm parameters or to alter the control approach. Although analog PWM controllers may provide acceptable performance, their adaptability and re-configurability are limited thereby preventing additional functionality after a design is implemented. Another limitation of analog controllers is that non-linear functions, such as adaptive least-mean-square (LMS) filters, are difficult to achieve with analog components and often approximated thereby. Software implementations of non-linear features are simpler and more precise with software in digital DSPs. While preferred embodiments of the present invention include a control algorithm current that is primarily linear, non-linear control functions are preferred for scalability and upgradeability purposes.
[0106] Referring now to FIG. 9 , an exemplary topology for a Texas Instrument DSP for control of the power stage 11 is shown. A DC power supply 36 is electrically connected to a pair of FET half-bridges with IDT 42 a, 42 b via a DC buss 44 . DSP control laws 38 are algorithms embedded within DSP firmware. DSP algorithms independently control the two half-bridges to implement a POLYBRIDGE®, a registered trademark of QorTek, Inc., circuit. The DSP control laws 38 generate independent PWM signals 43 a, 43 b electrically communicated to a pair of FET half-bridges with IDT 42 a, 42 b through a level-shifting power stage interface 41 a, 41 b. The output from each FET half-bridge with IDT 42 a, 42 b is communicated to a multi-pole, segmented filter 40 which combines the half-bridge outputs. The resulting output is a power signal 52 used to drive one or more active substrates 2 directly or one or more flexible actuators 1 . Voltage and current feedback signals from each of the FET half-bridges with IDT 42 a, 42 b are communicated to a signal conditioner 39 and thereafter to the DSP control laws 38 . Likewise, voltage and current feedback signals from the DC power supply 36 are communicated to a signal conditioner 37 and thereafter to the DSP control laws 38 .
[0107] Feedback signals to the DSP control laws 38 are analyzed to stabilize drive signals to loads, as well as, to maintain circuit protection and health monitoring. The DSP control laws 38 employ multi-staged proportional integral control loops for each half bridge to recreate input command signals. Loops are coupled with non-linear functions, such as signal limiting and command shut-down, for system protection. Algorithms are coded and assembled to maximize efficiency and execution speed and enable multi-channel capability. The described methodology allows for an adaptive LMS noise cancellation algorithm within the DSP driver for the power stage 11 . As such, functionality is directly implemented into the controller without requiring a bulky external PC or embedded computer.
[0108] In some embodiments, a converter having an operational frequency above 100 kHz may be required to eliminate noise generated by the step-down DC-to-DC converter. In yet other embodiments, it may be required to damp interactions between the active substrate 2 and output filter to eliminate extraneous noise and bring the single-to-noise ratio into an acceptable range. It is likewise possible to reduce DC-to-DC converter noise by having the drive operate at a nominal 28 V dc . As such, the duty cycle is in a range typically associated with efficient power conversion. The power stage DC buss voltage is also stepped up, which is generally an easier, low-noise task.
[0109] In some embodiments, a voltage of 150 V dc is used to directly supply the power stage 11 with some filtering and control system voltages are stepped down. In yet other embodiments, it may be required to step up the power stage buss voltage. The step-up conversion of the 150 V dc buss may be performed via a commercially available converter, one example being Converter Model No. SRC-50, sold by QorTek, Inc.
[0110] Exemplary signal-to-noise ratios (SNR) are shown in FIG. 10 for output voltage waveforms at four buss voltages, namely, 25 V dc , 60 V dc , 100 V dc , and 125 V dc for one embodiment of the present invention. SNRs are shown in decibels (dB) for the first four incremental harmonic frequencies of the fundamental 1-kHz drive waveform. SNR data demonstrates the described circuitry is capable of achieving an SNR of 60 dB and that 70 to 80 dB is attainable.
[0111] The description above indicates that a great degree of flexibility is offered in terms of the present invention. Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. | A low-profile, actively-controllable flexible piezo-composite actuator with flexibly mated drive, control, and power circuit architecture is presented. The low-profile, functionally-integrated actuator package retains the flexible nature of the actuator while not increasing the overall footprint of the device. The functionally integrated package incorporates flexible structural sensors and embedded control as to enable either active or autonomous control of a unified flexible package that can be installed conformally to non-planar structures. Integral flexible sensors include strain, normal stress, shear stress, pressure, velocity, and acceleration. The invention has immediate applicability to vibration and noise abatement, strain-based compensation, shape control, and structural damping within a variety of aircraft, ships and ground vehicles. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of Korean Patent Application No. 2003-40098, filed on Jun. 20, 2003, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION 1. Field of the Invention
[0002] The present invention relates to a power supply apparatus used with a display system and a method of designing the same, and more particularly, to a high-efficiency power supply apparatus used with a driving system of a display panel and a method of designing the same to improve a power efficiency by supplying a non-isolated direct current (DC) power from an input alternating current (AC) power directly to a display driving circuit. 2. Description of the Related Art
[0003] Generally, display panels, such as plasma display panels (PDPs) or ferro electric liquid crystal (FLC) panels, are driven in a digital way.
[0004] An alternating current plasma display panel (AC PDP) is a next-generation flat panel display for displaying texts or images using plasma formed by a discharging gas. Tens to hundreds of millions of pixels are arranged in a matrix form according to a size of the AC PDP.
[0005] The AC PDP has the following advantages: wide view angle, large size, long lifespan, high contrast ratio, and super-thin shape. Common disadvantages of the AC PDP are high cost and high power consumption.
[0006] [0006]FIG. 1 shows a conventional power supply apparatus used for an AC PDP.
[0007] Referring to FIG. 1, the power supply apparatus includes an AC power source 110 , a rectifier circuit 120 , a power factor correction circuit 130 , first and second DC-DC conversion circuits 104 - 1 and 140 - 2 , and a display panel driving circuit 150 .
[0008] An output voltage of the second DC-DC converting circuit 140 - 2 is supplied to a signal and data processing circuit, such as a video signal processing circuit, and a microprocessor.
[0009] The circuit of the power supply apparatus in the conventional AC PDP is configured in a serially connected 2-stage configuration (hereinafter, referred to as a two-stage configuration) such that a DC output voltage of the power factor correction circuit 130 is supplied as an input voltage to the first and second DC-DC conversion circuits 140 - 1 and 140 - 2 , and output voltages of the first and second DC-DC conversion circuits 140 - 1 and 140 - 2 are supplied to various loads.
[0010] The power supplied to the display panel driving circuit 150 is configured in the two-stage serial connection to improve the power factor and to regulate an output voltage. However, an independent DC-DC conversion circuit of a 2-TR forward or a half-bridge type should be used for the display panel driving circuit 150 . The display panel driving circuit 150 uses 75% of an entire output power of the system.
[0011] However, when the power for the display panel driving circuit 150 is configured in the two-stage serial connection, the size of a plasma display panel (PDP) increases, and power efficiency is lowered since power conversion is performed twice. For example, if the efficiency of the power factor correction circuit 130 is 95% and the efficiency of the first DC-DC conversion circuit 140 - 1 is 95%, the efficiency of the display panel driving circuit 150 is lowered to 90%.
SUMMARY OF THE INVENTION
[0012] Accordingly, it is an aspect of the present invention to provide a power supply apparatus used with a driving system of a display panel and a method of designing the same to minimize lost of power by supplying a non-isolated direct current (DC) power from an alternating current (AC) power directly to a display panel driving circuit without passing through a DC-DC converting circuit.
[0013] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
[0014] In order to achieve the foregoing and/or other aspects of the present invention, there is provided a high-efficiency power supply apparatus used with a display panel driving system, comprising: a direct current (DC) power supplying circuit to improve a power factor by rectifying alternating current power and generating a DC power, which is not isolated from the alternating current power, and an isolated DC power, which is isolated from the alternating current power; a display panel driving circuit to generate various driving signals to drive the display panel with the non-isolated DC power; and a video signal processing circuit to perform a predetermined video signal processing to generate data used to drive the display panel with the isolated DC power.
[0015] In order to achieve the foregoing and/or other aspects of the present invention, there is also provided a method of designing a high-efficiency power supply apparatus in a display panel driving system, the method comprising: providing a non-isolated DC power, which is not isolated from an input alternating current (AC) power, directly to a display panel driving circuit; providing an isolated DC power, which is isolated from the input AC power, to a video signal processing circuit which performs a predetermined video signal process to generate data used to drive a display panel; and isolating the display panel driving circuit and the video signal processing circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above and/or other aspects, features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
[0017] [0017]FIG. 1 is a block diagram showing a conventional power supply apparatus used for an alternating current plasma display panel (AC PDP);
[0018] [0018]FIG. 2 is a block diagram showing a high-efficiency power supply apparatus used with a display panel driving system, according to an embodiment of the present invention;
[0019] [0019]FIG. 3 is a detailed block diagram showing a rectifier circuit and a power factor correction circuit of the power supply apparatus shown in FIG. 2;
[0020] [0020]FIG. 4 is a detailed block diagram showing the rectifier circuit of the power supply apparatus shown in FIG. 2;
[0021] [0021]FIG. 5 is a detailed block diagram showing a ripple filter of the power supply apparatus shown in FIG. 2; and
[0022] [0022]FIG. 6 is a view showing a ground system of a plasma display panel driving system according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0024] A high-efficiency power supply apparatus used with a driving system of a display panel uses a non-isolated output voltage of a power factor correction circuit as a power supplied to the display panel driving circuit. That is, the non-isolated output voltage of the power factor correction circuit is directly supplied to the display panel driving circuit without passing through a direction current (DC)-DC conversion circuit to improve power efficiency.
[0025] Especially, a sustain driving circuit consumes about 75% of an entire power in the plasma display panel driving system. Therefore, when the present invention is applied to thesustain driving circuit, the power efficiency can increase.
[0026] However, in order to supply the output voltage of the non-isolated power factor correction circuit directly to the display panel driving circuit without passing through the DC-DC conversion circuit, the following items should be considered.
[0027] First, the voltage outputted from the power factor correction circuit and the voltage used in the display panel driving circuit should have the same value.
[0028] Second, since the output voltage of the power factor correction circuit includes lower frequency ripple voltage twice as much as the alternating current (AC) power frequency, the power factor correction circuit does not have good regulation features.
[0029] Third, since the output voltage of the power factor correction circuit, that is, the DC-DC converter is not isolated from the used AC power, an electrical isolation between the display panel and the driving circuit should be properly solved to satisfy an electricity safety standard.
[0030] The present invention that solves the above problems will be described with reference to the accompanying figures.
[0031] As shown in FIG. 2, the power supply apparatus for the display panel driving system, according to the present invention, includes an AC power 210 , a rectifier circuit 220 , a power factor correction circuit 230 , a ripple filter 240 , a DC-DC conversion circuit 250 , a display panel driving circuit 260 , and a video signal processing circuit 270 .
[0032] The rectifier circuit 220 , the power factor correction circuit 230 , the ripple filter 240 , and the DC-DC conversion circuit 250 are referred to as a DC power supplying circuit 1000 .
[0033] The video signal processing circuit 270 processes an input broadcasting signal or a video signal to generate data used to drive the display panel, and an isolated DC power output from the DC-DC conversion circuit 250 is used as a driving power of the video signal processing circuit 270 .
[0034] Detailed circuit configurations of the rectifier circuit 220 and the power factor correction circuit 230 are shown in FIG. 3.
[0035] Referring to FIGS. 2 and 3, the rectifier circuit 220 rectifies an input from an AC power 210 using a bridge diode circuit configuration having diodes D 1 -D 4 , and outputs a DC voltage according to the rectified input.
[0036] Then, the power factor correction circuit 230 receives the DC voltage, improves a power factor using a pulse width modulation (PWM) controlling signal, and outputs an output voltage into a capacitor C 1 according to the improved power factor. After that, the voltage charged in the capacitor C 1 is discharged and supplied to a load (Z), such as the display panel driving circuit 260 or the video signal processing circuit 270 , as a stabilized DC voltage.
[0037] That is, in a high state section of the PWM controlling signal (CTL), a switch S 1 is turned on, a magnetic energy is charged in an inductor L 1 , and the energy charged in the capacitor C 1 is transferred to the load (Z).
[0038] In addition, in a low state section of the PWM controlling signal, the switch S 1 is turned off and the magnetic energy charged in the inductor L 1 is transferred to the capacitor Cl and charged therein.
[0039] The power factor is improved through the above charging/discharging processes by the PWM controlling signal.
[0040] The voltage output from the power factor correction circuit 230 and the voltage used in the display panel driving circuit should have the same value.
[0041] Therefore, the voltage output from the power factor correction circuit 230 and the voltage used in the display panel driving circuit 260 are equalized by changing the display panel driving voltage.
[0042] That is, as an example, the output voltage of the power factor correction circuit 230 applied to the plasma display system is designed to be about 360˜400V DC generally, and a sustain driving voltage of the sustain driving circuit is designed to be about 160V.
[0043] Accordingly, in the present invention, the output voltage of the power factor correction circuit 230 should be lowered, or the sustain driving voltage should be increased.
[0044] In order to lower the output voltage of the power factor correction circuit 230 , a single ended primary inductance converter (SEPIC) including a converter controlling a level of the output voltage shown in FIG. 4 can be applied. The SEPIC includes inductors L 41 , L 42 , and L 43 , a transistor S 41 , resistors R 41 and R 42 , capacitors C 41 , C 42 , and C 43 , and a diode D 41 . That is, the output voltage can be lowered using a secondary winding, such as the inductor L 42 or L 43 , in the power factor correction circuit 230 . Also, the sustain driving voltage can be increased by changing the sustain driving circuit.
[0045] The low frequency ripple voltage and the regulation feature of the ripple filter 240 of the power supply apparatus can be improved in the following ways.
[0046] The low frequency ripple and the regulation features can be improved by increasing the capacity of the output capacitor C 1 of the power factor correction circuit 230 shown in FIG. 3.
[0047] Also, the ripple filter 240 is inserted between the power factor correction circuit 230 and the display panel driving circuit 260 for more improved functions. FIG. 5 shows an example of the ripple filter 240 .
[0048] The output electrical power of the power factor correction circuit 230 shown in FIG. 5 is P 0 =v 0 i 0 , and it is divided into two parts. That is, P 01 =v 0 i 0 is converted into P 02 =v 0 i 02 with efficiency η c . Therefore, a final output electrical power of a serial type ripple filter is P oss=V oss i 02 =V oc i o2 +V o i o2 . Here, if v 0C i 02 =V o i 01 ·η C , it is the output electrical power of the DC-DC converter used in the serial type switching ripple filter, and an actual change of the electrical power is only generated on the above DC-DC converter. When it is assumed that the serial type switching ripple filter circuit is in one electrical power conversion stage, an entire efficiency η SS can be calculated using the following equation 1.
η SS = 1 + v oC v 0 1 + v 0 C v 0 η C ( 1 )
[0049] Therefore, in order to obtain high efficiency, the efficiency η C of the DC-DC converter should increase, and a ratio of the voltage converted into the electric power for the output voltage of the power factor correction circuit 230 should decrease.
[0050] The electric isolation between the display panel and the driving circuit can be solved in the following ways.
[0051] [0051]FIG. 6 is a view showing a ground system to solve the isolation problem in the plasma display panel driving system applied by the present invention.
[0052] The video signal processing circuit 270 processes the input broadcasting signal or the video signal to generate the data used to drive the display panel, and the isolated DC power output from the DC-DC conversion circuit is used as the driving power of the video signal processing circuit 270 .
[0053] In addition, the power of the video signal processing circuit 270 is isolated by the DC-DC conversion circuit 620 from a scan and address driving circuit 640 using high voltage, and a data line is isolated by a photocoupler 630 .
[0054] In the AC plasma display panel driving system, voltages larger than 160V are applied alternatively in the sustain driving operation and a lamp voltage is applied in a resetting operation, and therefore, it is similar to that the address and the scan driver IC is operated in an electrically floated status. Thus, the DC-DC conversion circuit 620 and the photocoupler 630 are used to isolate the circuit.
[0055] Also, since a large current of nearly 100 A flows through the sustain driving circuit 260 - 1 with high frequency, the ground potential around the display panel changes a lot so that a mis-operation may be generated on a ground of the video signal processing circuit 270 .
[0056] Therefore, it is required that the plasma display panel driving circuit and the video signal processing circuit 270 are isolated by the DC-DC conversion circuit 620 and the photocoupler 630 for a stabilized operation.
[0057] Thus, a ground (first ground) of an output circuit of the non-isolated power factor correction circuit 230 , a ground (first ground) of the sustain driving circuit 260 - 1 , a ground (first ground) of an output circuit of the DC-DC conversion circuit 660 , and a ground (first ground) of the scan and address driving circuit 640 are electrically connected together. In addition, a ground (second ground) of the output circuit of the DC-DC conversion circuit 250 and a ground (second ground) of the video signal processing circuit 270 are electrically connected together.
[0058] Next, the grounds are designed so that the first grounds and the second grounds are electrically blocked from each other.
[0059] Accordingly, the ground of the video signal processing circuit 270 is isolated from the ground of the AC power by the DC-DC conversion circuit 250 , and isolated from the ground on the display panel driving circuit by the DC-DC conversion circuit 620 and the photocoupler 630 . Thus, if a user touches a metal portion which is connected to the ground on the video signal processing circuit 270 and exposed outward, the user is not electrocuted, and the international electricity safety standard IEC 60035 can be satisfied.
[0060] In addition, the plasma display panel 610 itself is in non-isolated status, however, since a special glass, which is a superior insulating material, is generally used as the plasma display panel, there is no problem about the non-isolated plasma display panel. However, outer cases for an exposed electrode portion of the plasma display panel and printed circuit board (PCB) mounted portion should be prepared.
[0061] Therefore, the above described three problems which may be generated according to the circuit configuration in which the output voltage of the non-isolated power factor correction circuit is transferred directly to the display panel driving circuit without passing through the DC-DC conversion circuit can be dealt with according to above method.
[0062] In an aspect of the present invention, the ripple filter 240 is inserted between the power factor correction circuit 230 and the display panel driving circuit 260 , however, the ripple filter 240 may be omitted and the capacity of the output capacitor C 1 of the power factor correction circuit can be increased to improve the low frequency ripple and the regulation features.
[0063] As described above, according to the present invention, the output voltage of the power factor correction circuit is directly applied to the display panel driving circuit or applied to the display panel driving circuit after being passed through the ripple filter without 2-stage serially configuring the power used in the display panel driving circuit. Thus, an electrical power efficiency can be improved, reliability of the circuit can be improved by simplifying the electrical circuits, and material costs can be lowered by reducing the number of semiconductor elements.
[0064] While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims. | A high-efficiency power supply apparatus used with a driving system of a display panel and a method of designing the same to improve an electrical power efficiency by providing a non-isolated direct current (DC) power directly to a display panel driving circuit comprise: a DC power supplying circuit to improve a power factor by rectifying an alternating current (AC) power and generating the non-isolated DC power, which is not isolated from the AC power, and an isolated DC power; a display panel driving circuit to generate various driving signals for driving the display panel with the non-isolated DC power; and a video signal processing circuit to perform a predetermined video signal processing for generating data to drive the display panel with the isolated DC power. | 8 |
This application is a continuation of application Ser. No. 538,355, filed Oct. 3, 1983, abandoned, which is a continuation of Ser. No. 211,525, filed Dec. 1, 1980, abandoned.
BACKGROUND OF THE INVENTION
The present invention relates generally to the fabrication of lightweight structural elements and more particularly concerns a method of welding hollow elongated beams.
In the fabrication of large load supporting and lifting devices such as heavy duty cranes and the like, it is desirable to utilize components which have high strength to weight ratios. Generally, these requirements are best met by hollow tubular members of substantial depth and width relative to their wall thickness. The fabrication of large elements of the foregoing nature, in the past has been both difficult and costly. Hollow steel members of substantial cross-section cannot be directly formed at steel rolling mills except with the installation of very expensive equipment which must be altered for each different cross-section to be formed. This makes the per unit cost of such hollow members essentially prohibitive.
Post forming of large size hollow elongated members such as by welding also has been generally unacceptable due to warpage and deflections induced or created during fabrication of the members. The prior art has, of course, recognized some of the problems which occur during welding beams, frames and other structural elements and certain solutions to these problems have been suggested. Nilsson et al. U.S. Pat. No. 3,199,174, for example, suggests uniformly heating the web of an I-beam while the flanges are welded to the web to prevent cross-sectional sagging of the web during cooling. Seedorff et al. U.S. Pat. No. 3,516,147 teaches simultaneously spot-welding the corners of a lightweight metal frame to insure cross-sectional accuracy. Yancey U.S. Pat. No. 3,882,654 teaches the use of an angle reinforcing bar welded into the corner of two abutted plates to prevent welding "blow-through" and to reduce stress concentrations at the corner. However, none of these references deal with the problem of longitudinal warpage and deflection of hollow elongated beams during fabrication by welding.
SUMMARY OF THE INVENTION
Accordingly, it is the primary aim of the present invention to provide a novel method and apparatus for welding hollow elongated structural elements without warpage or deflection resulting from localized or asymetrical heating. More particularly, the welding technique of this invention provides for simultaneously and continuously welding all of the corners of the hollow elongated beam members. Generally, the relatively thin strips of metal which are to form the top, sides and bottom of the beam are first accurately positioned with respect to one another and then tack-welded together. A welding apparatus with multiple welding heads--one at each corner of the beam--is moved along the beam so as to continuously and simultaneously weld all of the beam corners. This substantially equalizes the heat applied along each of the beam corners and prevents distortion of the plates and warpage of the beam which would otherwise occur.
These and other objects and advantages of the present invention will become apparent upon reading the following detailed description and upon reference to the attached drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat simplified end view, with certain portions in section, of the method and apparatus for simultaneously welding the corners of hollow elongated beams of the present invention;
FIG. 2 is an enlarged perspective view, with portions broken away for clarity, of the hollow elongated beam welded by the method and apparatus illustrated in FIG. 1;
FIG. 3 is a cross-section of the beam substantially as seen along line 3--3 in FIG. 2; and,
FIG. 4 is a cross-section, similar to FIG. 3, of an alternative embodiment of the welded beam.
While the invention will be described and illustrated in connection with certain preferred embodiments and procedures, it should be understood that there is no intention to limit the invention to such specific embodiments and procedures. Rather, it is intended to cover all alternatives, modifications and equivalents as may properly fall within the spirit and scope of the invention as defined in the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings, there is shown in FIG. 1 an exemplary support fixture 10 and an automatic welding apparatus, generally indicated at 11, for carrying out the method of simultaneously welding the corners of a hollow elongated beam 12 of the present invention. As illustrated, the support fixture 10 includes a flat, generally planar, welding table or work surface 15 supported by legs 16 secured to the shop floor. It should be understood, however, that the work surface 15 of the support fixture 10 could be mounted directly on the shop floor with suitable leveling plates and anchor bolts (not shown).
Referring also to FIGS. 2 and 3, it will be seen that the exemplary beam 12 includes a bottom plate 21, side plates 22 and 23 and a top plate 24 welded at the corners designated a, b, c and d. In the embodiment shown here, the side plates 22 and 23 are abutted against the upper surface of the bottom plate 21 slightly inboard of the edges thereof and the top plate 24 is dimensioned to just span the distance between the side plates 22 and 23. To insure that the plates 21-24 are held square and in proper alignment with respect to each other, the plates may be initially tack-welded to light weight metal cross webs or diaphram elements 25 from which the center has been cut out to further reduce weight.
Additionally, the corners of the plates may be tack-welded at spaced intervals along their length to further assist in maintaining alignment of the plates. Further, small metal backing strips 26 and 27 are desirably tack-welded inside upper corners a and b to prevent "blow-through" during welding. It should also be understood that the tack-welding of the plates 21-24, diaphrams 25 and backing bars 26 and 27 may be done at a separate set-up location with the aid of appropriate jigs and clamping fixtures (not shown) to properly locate the components with respect to one another.
The size and length of the beam 12, of course, will depend on its intended use or application. One example of such a beam is made of 1/4" high strength T1 plate and the beam has square inside dimensions of 8". Thus, in the embodiment shown in FIGS. 1-3, the side plates 22, 23 and top plate 24 are 8" wide and the bottom plate 21 is 9" wide. The diaphrams 25 can be cut from 1/8" plate and the backing members can be formed from 3/16" bar stock. If heavier plate is used, such as 1/8" or more, the top plate 24 can be dimensioned to partially overlap the upper edges of the side plates 22 and 23 and tack-welded directly thereto. In that event, the cross diaphrams 25 and backing bars 26 and 27 may be eliminated. The length of the beam can also vary from 15' to 30' or more as needed.
In FIG. 4 an alternate beam configuration 12a is shown. Assuming the same inside dimension and plate thickness as in the embodiment shown in FIGS. 1-3, the beam 12a would have a 9" wide bottom plate 21, an 8" wide top plate 24 and side plates 22, 23 that are 81/2" wide. Because the sides extend above the top plate, the square backing members in the corners may be eliminated. It should further be appreciated that heavier plate such as 1/2" could be used and that the beam could have a different cross-section, e.g. 6" square, if desired.
In accordance with the present invention, the corners a, b, c and d of the beam 12 are continuously and simultaneously welded by the method and apparatus 11 shown in FIG. 1. To this end, the beam 12 with tack-welded panels is secured to the surface of the welding table 15 by suitable shims and clamps (not shown) to insure that the beam is level, straight and true. The welding apparatus 11 includes a movable frame or carriage 30 which carries a plurality of welding heads 31a, b, c and d, one for each corner of the beam, which simultaneously weld the corners a-d of the beam 12 as the carrier is moved longitudinally relative to the beam. By welding all four corners simultaneously, warpage and heat induced deflection of the beam 12 is substantially entirely eliminated. Thus, the fabricated beam 12 is straight, true and structurally strong.
To support the welding carriage 30, the support 10 includes a pair of side rails 32 having flanged tracks 33 which are engaged by vertical support rollers 34 journaled in guide brackets 35 secured to the welding frame 30. Preferrably, the guide brackets 35 also include a plurality of upper and lower side thrust rollers 36 to keep the carriage accurately centered on the tracks 33. The carriage 30 also carries a drive motor 37 which engages a pinion 38 in mesh with a rack 39 on one of the tracks 33 for propelling the welding carriage 30 along the length of the beam 12.
In the illustrative embodiment, the welding heads 31a-31d are of the shielded-arc type continuous wire feeder which are shown schematically at 40a-40d. Such wire feeders are known in the art, one example being model WC-50S manufactured by Chemtron Corporation. The welding wire may be on the order of 1 mm. in diameter and the welding arc is preferrably shielded by a protective gas such as a mixture of 75% Argon and 25% CO 2 , or the like, supplied from tanks 41 through control valves 42 and suitable piping 43 to the welding heads 31a-31d.
The drive motor 37 is preferrably of the variable speed type so that the travel speed of the welding carriage 30 can be controlled, for example, on the order 12 to 16 in/min. Likewise, the welding heads 31a-31d are adjustably mounted as at 44a-44d on the carriage 30 so that both the angle and clearance of the welding arc at each corner of the beam 12 can be individually adjusted. Generally an angle between 30 degrees and 45 degrees is preferred. It will also be appreciated that each welding head 31a-31d is individually electrically controlled by suitable switches and circuit means (not shown). For welding of the type described herein an arc voltage on the order of 24-28 volts has been found to be satisfactory.
From the foregoing, it will be appreciated that the welding method and apparatus of the present invention is well suited for welding hollow elongated beams 12 while minimizing warpage and deflection in the beam. A finished beam 12 is illustrated in FIG. 2 with continuous open corner filet welds in the upper corners a and b and continuous regular filet welds at the lower corners c and d. In this embodiment, backing strips 26, 27 are tack-welded in the upper corners a and b to prevent "blow-through" of the open corner filet welds. Also cross webs or diaphrams 25 are utilized to initially locate and securely hold the plates 21-24 for the continuous welding operation. If desired, the corners of the diaphrams 25 may be removed so that continuous backing strips 26 and 27 may be used. As previously noted, such backing strips are not required for the beam 12a shown in FIG. 4 and, if the top plate 24 partially overlaps the side plates 22 and 23, it is not necessary to employ the diaphrams 25. | A method and apparatus for welding hollow elongated beams wherein the plates forming the beam are tack-welded together in proper relationship and all corners of the beam are simultaneously and continuously welded by moving a multiple head welding carriage along the length of the beam in order to minimize warpage and longitudinal deflection of the beam due to the welding heat. | 1 |
BACKGROUND OF THE INVENTION
This application is a continuation-in-part of U.S. application Ser. No. 819,605, filed on Jan. 17, 1986 now U.S. Pat. No. 4,773,953. U.S. application No. 819,605 is a continuation-in-part of U.S. application No. 703,529 filed on Feb. 20, 1985, now abandoned.
The present invention relates to a method for electronically and manually creating graphics, images or creative designs on a fabric. More specifically, the present invention relates to a method of creating personalized graphics, images or other creative designs using an electronic device such as a personal computer or photocopier and thereafter transferring those graphics, images or designs to a fabric such as a tee shirt or the like.
In recent years, tee shirts with a variety of designs thereon have become very popular. A large number of tee shirts are sold with pre-printed designs to suit the various tastes of consumers. In addition, many customized tee shirt parlors have appeared, particularly in resort areas, which permit customers to select designs of their choice. Processes have also been proposed for permitting customers to create their own designs on transfer sheets for application to tee shirts by use of a conventional iron, such as described in U.S. Pat. No. 4,224,358, issued Sept. 23, 1980, to the present inventor.
Simultaneous with the development of the tee shirt rage, there is a growing popularity for equipment and processes for creating personalized graphics or designs. Many products are available for permitting such graphics or designs to be created, including video cameras; keyboards, "mice", joysticks, light pens or other input devices used with personal computers; and electronic photocopier machines.
Printers have conventionally used two alternative methods for creating designs for iron-on transfers. However, neither method has been effective in the creation of personalized designs because of both the cost associated with the method or the poor image reproduction.
First, many iron-on transfer designs are made with conventional type printing presses. Such methods include litho, offset and screen printing. These methods are impracticable because of the high cost associated with creation of the design unless several transfers are created. Thus, this method is ill-suited for creating unique personalized designs.
Second, some personalized iron-on transfers are created using sublimation ribbons to replace standard ribbons used with dox matrix impact printers. However, this method produces a low quality image.
SUMMARY OF THE INVENTION
It is primary object of the present invention to provide a product and a method which will attract the interest of consumer groups which are already captivated by the tee shirt rage described above; as well as the creative graphics rage utilized in connection with personal computers; video cameras; photocopiers and other electronic devices for creation of personalized designs.
Accordingly, it is an object of the present invention to provide a method permitting the creation of personalized designs, images or graphics either manually or using an electronic device; printing of the design, images or graphics so created on a transfer sheet; and ironing of the personalized designs or graphics on the transfer sheet onto a conventional tee shirt or other fabric.
It is a further object of the present invention to provide a method which enlarges the present uses of graphic techniques developed for personal computers.
It is another object of the present invention to provide an improved transfer sheet which is receptive to the inks used in personal computers.
It is still another object of the present invention to provide a method which creates a more entertaining way to make one's own personalized tee shirt than known heretofore, through conventional, manual operations.
It is yet another object of the present invention to provide a new form of entertainment for personal computers and other electronic devices such as photocopiers and video cameras.
It is still another object of the present invention to provide a method which can be practiced in a coin-operated, arcade environment to permit customers to electronically create their own personalized tee shirts through a coin-operated computer system containing the required graphics capabilities.
The objects of the present invention are fulfilled by providing a method for applying a creative design image or graphics to a fabric or a shirt, or the like, comprising the steps of:
(a) generating said image on an obverse surface of a transfer sheet, said transfer sheet including a substrate with a first coating thereon transferable therefrom to said fabric by the application of heat or pressure, and a second coating on said first coating, said second coating defining said obverse face and consisting essentially of a mixture of resin and abrasive particles to form an abrasive surface for increasing the receptivity of the transfer sheet;
(b) positioning that obverse surface of said transfer sheet against said fabric; and
(c) applying energy to the rear of said transfer sheet to transfer said image to said fabric.
The image may be electronically generated by a video camera or a photocopier, so the image may be a picture of one self or a family member, which may be printed on a fabric.
The steps of electronically generating the creative design may also be performed by manually manipulating a cursor across the screen of a visual monitor to create the design, the pattern of movement of the cursor being stored in the memory of an associated personal computer, to enable the pattern to be displayed on a cathode ray tube thereof.
The electronic manipulation of the cursor may be performed on a "Koala Pad", by a "mouse", "joystick", keys on a keyboard, light pen, or by moving one's finger across a touch-sensitive, monitor screen.
The printer utilized may be a multi-color printer or one that simply prints black on white. In the latter case, the creative design would comprise only the outline or shapes of objects and color could be added directly to the transfer sheet following printing by the printer, by the use of heat-transferable, color crayons, such as ordinary was crayons (e.g., CRAYOLA), permanent markers, or oil-base paints.
Various conventional printers can be used to achieve quality results including laser printers and impact dot matrix printers.
Additionally, an electronic photocopier can also be used to create either a black on white or color image on the transfer sheet.
If a message is to be included in the creative design, such as a word of the alphabet, software may be provided within the personal computer which permits the image created on the screen to be horizontally reversed. The reversed image would then be transferred to the printer and printed in reverse form onto the transfer sheet. One could then simply iron from the back of the transfer sheet and transfer the original, unreversed image from the screen directly onto the fabric of the tee shirt or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow, and the accompanying drawings which are given by the way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a sectional side view of a transfer sheet;
FIG. 2 is a diagrammatic illustration of an exemplary personal computer system which might be used for practicing the method of the present invention;
FIG. 3 is an enlarged view of the exemplary, personalized, creative design illustrated on the monitor screen in the system of FIG. 1;
FIG. 4 illustrates a transfer sheet printed with the design created on the screen of FIG. 1 with the message thereon horizontally reversed;
FIG. 5 illustrates the step of ironing the design created on the transfer sheet onto a tee shirt or the like; and
FIG. 6 is an illustration of the final design as it would appear on a tee shirt.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As shown in FIG. 1, a preferred embodiment of the transfer sheet 50 comprises, in part, a transfer paper manufactured by Kimberly-Clark Corporation under the trademark "TRANSEEZE". Any other commercially-available transfer sheet may be utilized which has a substrate with a coating which is transferable to a receptor sheet upon the application of heat or pressure to the back of the substrate. It is a discovery of the present invention, however, that the transferable coating of "TRANSEEZE", and other commercially-available transfer sheets, are not sufficiently receptive, or absorbent with respect to either the inks normally used in computer-type printers or ordinary wax crayons (e.g. CRAYOLA) to facilitate the printing-coloring of a good-quality, clearly recognizable image or the transfer sheet and the subsequent transfer of the image to a fabric. This problem has been solved in accordance with the present invention by coating the transferable layer of conventional transfer sheets with an overcoating of resin mixed with abrasive particles in a manner described in the following Example.
EXAMPLE
The transfer layer 43 of a transfer sheet 50, comprised of latex saturated paper with a polymer coating of polyethylene base, such as "TRANSEEZE" manufactured by Kimberly-Clark Corporation, may be spray-coated or applied via commercial offset or litho printers with an overcoating of resin mixed with abrasive particles. The entire transfer sheet 50, including the substrate 42, heat transferable coating 43 and overcoating 47, may then be run through a hot air drier to remove tackiness. This will permit stacking and slip-sheeting of the resulting products.
The overcoating 47 of the transfer sheet 5 includes a mixture of resin with abrasive particles. The abrasive particles are added to the resin in order to form an abrasive surface on the face of the transfer sheet once the drying process is complete. The abrasive surface serves to enhance receptivity of the transfer paper to deposits of color from thermal ribbon printers or ordinary wax crayons.
In one embodiment, an overcoat 47 of Singapore Dammar Resin mixed with very fine sugar granules has been found by the present inventor to exhibit excellent receptivity and non-smudge characteristics with respect to a wide variety of commercially-available printing inks utilized in state-of-the-art computer printers. The transfer sheet of the present invention has been successfully tested with the inks used in computer printers, such as the OKIMATE 10 by OKIDATA, and the TOSHIBA 5400; thermal ribbon transfer printers using wax-based pigment inks on polyester ribbon substrates. Successful tests has also been performed using dot matrix printers with matrix inks or nylon ribbon, such as used in the entire line of Epson and IBM printers and modern laser printers.
In a second embodiment, white silica sand can be used as abrasive particles with resin to form the overcoating 47.
The overcoating 47 is also receptive to wax-based crayons, permanent markers, and oil paints, so it may be readily hand-colored as described hereinbelow.
Referring in detail to FIG. 2, there is generally illustrated a personal computer system which may be utilized for practicing the method of the present invention. This computer system is generally illustrated 10, and includes a central processing unit (CPU) 12 of any commercially-available type such as an IBM PC, an APPLE MCINTOSH, or any other suitable type. The computer system further includes a monitor 14 having a display screen 22, a keyboard 20, and a matrix/graphics printer 16 Printer 16 may be any commercially-available printer, and in a preferred embodiment is a "OKIMATE 10", manufactured by Okidata Company, which is capable of printing graphics in approximately twenty-six colors. The computer system 10 further includes a graphics input pad 18 such as a "KOALA PAD TOUCH TABLET" manufactured by Koala Technologies. This graphics input pad permits one to create, by hand, any desired pattern on the pad by means of a stylus "S" and the pattern so created on the pad is electronically transferred through an appropriate cable to the screen of monitor 14 through the CPU 12.
As further illustrated in FIG. 2, the creative design or pattern being created on graphics input pad 19 is the design 24 illustrated on screen 22, including an illustration of a smiling sun in the upper left-hand corner, and a heart with an arrow through it bearing appropriate initials. This design 24 is illustrated in more detail in the enlarged view of FIG. 2.
It should be understood that this design 24 can be created on screen 22 by various means other than the graphics input pad 18. For example, it could be created by use of a well-known "mouse" which is also electronically coupled to the CPU 12; a "joy stick" electrically coupled to the CPU 12; by means of keys on the keyboard 20; a hand-held light pen which is moved across the face of screen 22; or screen 22 may be a touch sensitive screen so that a pattern may be created thereon by movement of one's finger across the screen.
In the preferred embodiment where the KOALA GRAPHICS INPUT PAD is utilized, this device has the capability of selecting colors for portions of the pattern created. For example, if the outline of the sun with the face is to be orange, an appropriate color selection key would be actuated in the control position of pad 18. Likewise, the internal portion of the sun symbol could be colored a solid yellow, and the background around the sun could be colored sky blue. Of course, the colors selected by pad 18 would be appropriately displayed in those colors on the screen 22 and the same color selection information would be transferred to the printer 16 so that the final image printed on transfer paper 50, to be described hereinafter, would be printed thereon in inks of the selected colors for the corresponding portions of the design of pattern.
In an alternative embodiment, it may be desirable to merely draw the outline in black and white of the pattern 24, print the same on transfer sheet 50 with the aid of printer 16, and then handcolor the transfer sheet 50 with heat-transferable, colored crayons, such as ordinary wax crayons (e.g., CRAYOLA), permanent markers, or oil paints which then become transferable with heat, to achieve a transfer pattern of a desired color distribution.
When it is desired to create alphabetical message, such as "W.Jr. H.S.", as part of the design 24, it is necessary to have some means of reversing the image from left to right within the CPU 12 before it is printed onto the transfer sheet 50 by printer 16. This is best illustrated by the combination of the illustration in FIGS. 3 and 4. FIG. 3 shows the image of the design 24 as it appears on screen 22 of monitor 14 and FIG. 4 shows the design 24 as it would be printed as a reverse image on transfer sheet 50. The purpose of reversing the image from left to right, or vice versa, is so that when one applies a source of heat energy, such as from an iron, to the backside 50A of transfer sheet 50, the image which is transferred to a tee shirt or fabric 62 is the reverse image of that of FIG. 4, which corresponds to the same image that was originally created on screen 22 of monitor 14. This horizontal flip or image reversal within the CPU 12 may be easily accomplished by commercially-available software to make it possible to create alphabetical messages on the surface of fabrics without writing the message backwards initially, such as by means of stylus "S" on the graphic input pad 18.
FIG. 5 illustrates how the final step of heat transfer from transfer sheet 50 to a tee shirt or fabric 62 is performed. The tee shirt 62 is laid flat, as illustrated, on an appropriately colored, either by preselection of colors, by use of the graphics input pad 18 and the associated controls in conjunction with the multi-color printing capability of printer 16, or the colors of design 24 on tee shirts 62 may be the result of hand-coloring a black and white outline which was printed on transfer sheet 50.
FIG. 6 illustrates the completed transfer of the personalized design onto a tee shirt.
An alternative method for creation of a design using the disclosed transfer sheet is with electronic photocopiers. An image, photograph, outline or picture can be electronically reproduced on the transfer sheet 50 either black on white or in multi-color. Similar to the computer printer inks and wax based crayons, the transfer sheet is equally receptive to photocopier toners. Once printed, the image can then be colored or modified manually to add personalized additions.
The invention being thus described, it may be obvious that the same may be varied in many ways. Such variations are not to be recorded 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. | A method and transfer sheet for transferring creative and personalized designs onto a tee shirt or similar fabric is described. The design can be created manually, electronically or a combination of both using personal computers, video cameras or electronic photocopiers. The transfer sheet includes a polymer-based iron-on transfer sheet supplied with an additional overcoating of resin mixed with abrasive particles. When cured, the abrasive particles in combination with the resin serve to enhance the receptivity of the transfer sheet to various inks and wax based crayons used in the creation and coloring of the designs. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a Coriolis mass flowmeter with at least one sensor arrangement and at least one housing, wherein the sensor arrangement includes at least one measuring tube, at least one oscillation generator and at least one oscillation sensor, and wherein the measuring tube can be excited by the oscillation generator in at least one operating frequency.
2. Description of Related Art
Coriolis mass flowmeters of the above-mentioned type are known, for example, from German Patent Application DE 10 2008 007 742 A1. In Coriolis mass flowmeters in general, the measuring tube that can have flow from a medium is excited to oscillation by an oscillation generator, preferably in a certain eigenform in resonance frequency—operating frequency, wherein the operating frequency is adapted to the measuring tube together with the medium flowing through the measuring tube. On the input and output sides, inertial forces act differently on the flowing medium in the measuring tube excited to oscillation, and thus, on the measuring tube, so that the deflection of the measuring tube is influenced differently on the input and output sides, and in this manner, the oscillation of the measuring tube detected on the input and output sides with oscillation sensors has a phase shift, which is a direct variable for the mass flow of interest. The derived variable to be detected—the mass flow—is determined using the phase shift by the evaluation electronics.
Depending on the mass flow to be detected, Coriolis mass flowmeters are available with different cross-sections, wherein the size of the measuring device increases overall with an increasing tube cross-section. In order to guarantee sufficient stability of the housing, in particular large housings, so that possible oscillations of the housing during operation do not have negative effects on the quality of the measurement, housings of such Coriolis mass flowmeters are designed with appropriately thick walls. This thick-walled construction is particularly positive in terms of stability, but, as noted by the present inventors, causes the measuring device to become unexpectedly heavier and more expensive to produce that necessary.
SUMMARY OF THE INVENTION
Thus, a primary object of the present invention is, namely, to provide a Coriolis mass flowmeter of the type described above, which is easy to produce and whose weight is optimized in respect to the size of the measuring device.
The above-mentioned object is surprisingly met with a Coriolis mass flowmeter according to said type in that, additionally, at least one reinforcement element is arranged in the housing and the reinforcement element is joined to the housing in such a manner that the implemented eigenfrequencies of the housing are shifted away from the operating frequency of the measuring tube. The reinforcement element is arranged with the measuring tube within the housing of the Coriolis mass flowmeter, and preferably, is linked to the housing at a plurality of contact areas or contact points. Preferably, opposing walls of the housing are interlinked with the reinforcement element, so that the walls are stabilized overall due to the inner mechanical coupling using the reinforcement element and the housing is reinforced collectively. Due to the housing being interlinked with the reinforcement element, the freely-swinging sections of the housing are shortened, through which the implemented eigenfrequencies of the housing are surprisingly increased, in particular in such a manner that the eigenfrequencies of the housing are shifted away from the operating frequency, i.e., away from the operating frequency area of the measuring tube.
That the reinforcement element is linked to the housing does not have to mean that, in fact, a mechanical connection is produced between the reinforcement element and the housing, but can also mean that the reinforcement element is linked by contact, for example via a contact force, and the reinforcement element interacts with the housing in such a manner that the effect according to the invention, namely, the shift of the implemented eigenfrequencies of the housing away from the operating frequency of the measuring tube, is achieved. By the excitation frequency is meant the operating frequency of the measuring tube, which is used for oscillation excitation of the measuring tube by the oscillation generator, wherein this excitation frequency is preferably adjusted to the measuring tube with the medium.
A Coriolis mass flowmeter designed according to the invention can be implemented regardless of the number of measuring tubes actually present in the Coriolis mass flowmeter, so that the following designs having a particular number of measuring tubes is always only to be understood in the manner of an example and a measuring device according to the invention or a measuring device according to the following descriptive designs can always be implemented with a single measuring tube, or also two, three, four or more measuring tubes.
The interaction between the reinforcement element and the housing leads to the oscillation of the housing occurring during operation of the Coriolis mass flowmeter being minimized by the reinforcement element, since the eigenfrequency of the housing is sufficiently far from the operating frequency of the measuring tube—with the measuring medium included therein. The “eigenfrequencies of the housing” describe, here, the eigenfrequencies of all components that are joined with each other and can be attributed to the housing. Depending on the design of the Coriolis mass flowmeter, “housing” can simply mean the actual protective cover or also, for example, the protective cover with attached components that correspondingly “oscillate with” an—undesired—oscillation excitation of the housing.
Due to the additional reinforcement element, the housing is stabilized in such a manner that the wall thickness of the housing can be reduced overall, which leads to a substantial reduction of the weight of the Coriolis mass flowmeter, in particular, in large Coriolis mass flowmeters having large measuring tube cross sections. The reinforcement element can, for example, be designed as an interconnected structure or, alternatively, can be formed of a plurality of individual reinforcement elements, which are arranged rectified in respect to their ability to stabilize within the housing of the Coriolis mass flowmeter and which interact. The reinforcement element, here, does not have direct contact with the measuring tube.
According to a first advantageous design of a Coriolis mass flowmeter according to the invention, it is provided that the measuring tube is bent, in particular, is essentially bent into a U- or V-shape. Preferably, in Coriolis mass flowmeters of this type, two—running parallel—bent measuring tubes are provided that oscillate opposed to each other during operating, so that at least one oscillation can be tapped between the measuring tubes with the oscillation sensor. Due to the bent shape of the measuring tube, the housing of the Coriolis mass flowmeter has to necessarily be larger, so that the reinforcement element has a particularly advantageous effect in such a design, namely leads to a considerable stabilization of the large-volume housing of the Coriolis mass flowmeter, in that the eigenfrequency of the housing is shifted away from the operating frequency of the measuring tube. Due to the large effect on measurement that is achieved with bent measuring tubes as opposed to straight measuring tubes, a simultaneous, increased stability of the housing having eigenfrequencies shifted away from the operating frequency due to the reinforcement element becomes advantageous in that an otherwise present oscillation of the housing does not negatively effect the results of the mass flow measurement or interfere in any other manner.
In order to implement a particularly preferred shift of the implemented eigenfrequencies of the housing away from the operating frequency of the measuring tube, it is provided that the reinforcement element has a basic shape that is arched, wherein the reinforcement element is arranged, in particular, in such a manner in the housing that the curvature of the measuring tube is opposite the curvature of the reinforcement element. The measuring tube has an essentially U- or V-shaped bent course between measuring tube input and measuring tube output. The reinforcement element also has an essentially arched basic shape, wherein “arched basic shape” does not only mean that the reinforcement element follows a constant arc, but can also mean that the reinforcement element, for example, is comprised of a plurality of straight individual parts so that a constant arc-shape is only approximately implemented. In the mounted state, the reinforcement element is, thus, preferably arranged in the housing in such a manner that the curvature of the measuring tube extends opposite to the curvature of the reinforcement element, consequently, the curvatures are arranged opposed to one another in the housing, from which a higher-than-average increase of the stability of the housing is achieved.
The reinforcement element is preferably designed in such a manner that it extends along the measuring tube on at least two longitudinal sides of the housing. Most preferably, the reinforcement element forms a closed outline in a plane, through which the measuring tube passes so that, in the mounted state, the reinforcement element completely surrounds the curvature of the measuring tube and is linked all around on all four sides—longitudinal and narrow sides—to the housing of the Coriolis mass flowmeter, wherein, due to the reinforcement element, not only are the opposing walls of the housing interlinked, but all walls are linked to one another via the reinforcement element. The arc shape of the reinforcement element is optimized using mathematical calculations and formed in such a manner that the eigenfrequencies of the housing are shifted away from the operating frequency of the measuring tube in an advantageous manner.
A connection between the reinforcement element and the housing, which allows for a mechanical interaction between the housing and the reinforcement element, is advantageously implemented in that the reinforcement element is affixed to at least one wall of the housing, in particular is affixed with surface contact, preferably, is adhesively joined to the wall. Due to the attachment of the reinforcement element on at least one wall of the housing, the freely-swinging sections within the housing are shortened. Preferably, however, the reinforcement element is linked with all of the walls of the housing surrounding the reinforcement element, so that a consistent mechanical interaction is implemented between the housing and the reinforcement element. An advantageous attachment of the reinforcement element on the housing can occur advantageously independent of the type of attachment—friction-locked, form-locked or adhesively joined. Screwing, welding and soldering have been shown to be of particular advantage, here.
An adhesively joined attachment between the housing and the reinforcement element can be implemented here, advantageously, in the housing having openings—holes or slits—at the chosen attachment points, so that the walls of the housing can be welded from the outside through the openings to the reinforcement element positioned on the inside, wherein the openings in the housing are closed with welding material during the welding process.
According to a particularly preferred design of the Coriolis mass flowmeter, it is provided that the reinforcement element is formed of at least one hollow body, so that a closed volume is defined within the reinforcement element and a medium can be conveyed within the reinforcement element. The reinforcement element consequently forms an inner volume within the housing separate from the volume of the housing, so that a medium can be conveyed within the reinforcement element and the medium cannot unintentionally come out of the reinforcement element—into the housing.
This design is particularly suitable for applications in which, for example, the measuring tube or the housing has to be brought to a temperature, i.e., either the housing itself or the measuring medium within the measuring tube has to be adjusted to or kept at a certain temperature. Here, such applications are conceivable in which heating is necessary, as well as cryogenic applications where cooling is necessary. A heating medium, e.g., hot water or steam, can then be conveyed through the reinforcement element, so that the thermal energy from the heating medium is transferred to the Coriolis mass flowmeter—to the housing and/or the measuring tube. Heating the Coriolis mass flowmeter is necessary, in particular, when a hot medium is conveyed within the measuring tube, which has to be kept at a certain temperature, so that it does not become solid—tar, wax, etc.—and/or temperature-induced friction has to be avoided in the Coriolis mass flowmeter.
Consequently, this design has the advantage that it combines a heating unit for the Coriolis mass flowmeter with a reinforcement element for the housing, through which additional weight and space are saved. It is no longer necessary to have space outside the measuring device for a heating unit, since the heating unit is advantageously integrated on the inside of the housing.
In order to guarantee accessibility of the volume of the reinforcement element, it is provided according to a further development that the volume of the reinforcement element has at least one input opening and at least one output opening, so that a medium can be conveyed into the volume or can be conveyed out of the volume. The input opening and the output opening of the volume of the reinforcement element are preferably accessible from outside of the housing of the Coriolis mass flowmeter, in that the input opening and the output opening extend through the housing of the mass flowmeter as connecting pieces and are positioned at accessible points.
A medium, e.g., a heating or cooling medium is introduced into the volume of the reinforcement element through the input opening, wherein the medium releases, for example, thermal energy to the housing or to the measuring tube on its path through the volume of the reinforcement element within the housing and then exits again out of the volume through the output opening in a cooled state. Thus, it is advantageous for an optimal thermal transfer between the housing and the reinforcement element when the reinforcement element lies against the walls of the housing with as much surface as possible, so that an optimal thermal transfer between the reinforcement element and the housing of the Coriolis mass flowmeter can occur. An adhesively joined attachment between the housing and the reinforcement element also positively effects the thermal transfer. It should, thus, be taken into consideration when choosing a form of attachment that the type of attachment between the housing and the reinforcement element positively effects the thermal transfer as well as the mechanical interaction between reinforcement element and housing.
A particularly stable reinforcement element exists when the reinforcement element is designed as a welded hollow frame structure, preferably is welded together of essentially straight single parts and has, in particular, vertical and/or horizontal cross beams. The design of the reinforcement element becomes very flexible due to this type of construction, since the reinforcement element can be adapted to the individual conditions of the corresponding measuring device and a mathematically optimized form during its production. The volume is designed as a canal system due to the hollow frame structure within the reinforcement element, through which a medium can be conveyed. Preferably, all individual parts are linked to one another within the welded hollow structure via a common volume. The reinforcement element can have additional vertical and/or horizontal cross beams through the design as welded structure, which additionally support or stabilize the housing.
Alternatively, a design of the reinforcement element is also provided in which, for example, two independent hollow frame structures are provided above one another or next to one another within the housing for reinforcing the housing, wherein, for example, a medium can be conveyed through only one or also through both reinforcement elements.
As a further alternative to the design of the reinforcement element, it is also provided that the reinforcement element is formed from a plurality of interlinked canals, which—each on their own—are welded to the walls of the housing and for a common volume, so that the walls are stabilized and an advantageous thermal transfer is possible.
Within the cage-like construction of the reinforcement element from the welded hollow frame structure, it is also necessary that the individual elements of the reinforcement element are additionally stabilized among themselves, so that it is provided by a further design of the invention that the reinforcement element has flat reinforcement means reinforcing the reinforcement element in at least one corner region. These reinforcement means are, for example, provided on a joint of two individual parts of the welded hollow frame structure and stabilize the angle between the two elements, in that a plate-shaped reinforcement plate is welded into the angle as a reinforcement means.
In particular, in a Coriolis mass flowmeter with arcuate measuring tubes, it has been shown to be advantageous when the reinforcement element and the measuring tube cross each other essentially orthogonally at least one point in the housing. The design has the advantage that a thermal transfer can occur from the reinforcement element to the measuring tube—using convection and radiation—wherein, at the same time, an advantageous stabilization of the housing occurs. The cross-beams of the reinforcement element are provided so that they are both vertical and parallel within the oscillations plane of the measuring tube.
In order to optimize the thermal transfer between the reinforcement element and the measuring tube, for example, for applications in which the medium conveyed in the measuring tube has to be heated so that it does not become solid, it is provided that at least one section of the reinforcement element extends essentially parallel to the measuring tube, so that an intensive thermal transfer between the reinforcement element and the measuring tube occurs. Preferably, for example, the reinforcement element is lead parallel to the measuring tube in a very large section, so that a thermal transfer can occur between the reinforcement element and the measuring tube by convection and radiation in a large area. Here, the reinforcement element is designed, for example, so that individual elements of the reinforcement element are provided solely for mechanically stiffening the housing and other elements of the reinforcement element are solely for the purpose of optimizing the thermal transfer between the reinforcement element and the measuring tube or the housing, i.e. convey a medium.
The thermal transfer between the reinforcement element and the housing or the measuring tube is optimized in that the reinforcement element is made of a material with a high thermal conductivity, so that the thermal path through the reinforcement element occurs with as little loss as possible. The reinforcement element is made, for example, of stainless steel, titanium or tantalum, wherein copper or aluminum may also be used.
For the operation of the above-described Coriolis mass flowmeters, a method is particularly suitable in which a medium brought to a pre-determined temperature is conveyed within the volume of the reinforcement element. In particular, for applications in which the medium within the measuring tube has a defined temperature, this method is suitable either for keeping the medium at this temperature or for heating or cooling it. For this purpose, the temperature of the medium being introduced into the volume of the reinforcement element is given in a corresponding setting with the specifications for the temperature of the measuring medium. In particular, for example, applications with a heating medium are possible in which the medium conveyed in the measuring tube cannot be allowed to cool down, since it would then become solid. Alternatively, cryogenic applications are possible, in particular in the food industry, in which the medium to be measured has to be kept at a very low temperature or has to be cooled down to a very cool temperature.
In detail, there are multiple possibilities for designing and further developing the Coriolis mass flowmeter according to the invention. Here, reference is made to following detailed description of embodiments in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective side view of an embodiment of a Coriolis mass flowmeter partially in section,
FIG. 2 is a perspective side view of a further embodiment of a Coriolis mass flowmeter in a partial section,
FIG. 3 is transverse sectional view of the embodiment of a Coriolis mass flowmeter taken along line in FIG. 1 and
FIGS. 4 a - 4 e are perspective side views different alternative designs for the reinforcement elements of a Coriolis mass flowmeter.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a Coriolis mass flowmeter 1 having a sensor arrangement 2 and a housing 3 , wherein the front-most side wall of the housing 3 is cut away in the representation in FIG. 1 . The sensor arrangement 2 includes two measuring tubes 4 , an oscillation generator 5 and two oscillation sensors 6 , wherein the oscillation generator 5 and the oscillation sensor 6 each are comprised of two interacting elements, and respectively, one element of the oscillation sensor 6 or the oscillation generator 5 is attached to one of the measuring tubes 4 . The housing 3 is attached to a support bridge 7 , wherein the support bridge 7 extends between the input flange 8 and the output flange 9 of the Coriolis mass flowmeter. The input flange 8 and the output flange 9 are also attached to the support bridge 7 . The transfer between input flange 8 and the measuring tubes 4 occurs on—shown on the left in FIG. 1 —the end of the support bridge 7 , wherein the measuring tubes 4 are designed as bent measuring tubes in this embodiment and extend upward out of the support bridge 7 , execute the essentially U- or V-shaped course and—shown on the right in FIG. 1 —finally extend back into the support bridge 7 , where the measuring tubes 4 are linked to the output flange 9 of the Coriolis mass flowmeter.
Within the housing 3 —surrounding the measuring tubes—a reinforcement element 10 is provided in the housing 3 , which has surface contact with all walls of the housing 3 and is welded to the walls of the housing 3 . The reinforcement element 10 that is formed of a welded hollow frame structure having a rectangular cross-section, in profile, so that the reinforcement element 10 makes surface contact with the walls of the housing 3 . The reinforcement element 10 has an essentially arcuate basic form in a longitudinal direction, and wherein the reinforcement element 10 is attached in the housing 3 of the Coriolis mass flowmeter 1 in such a manner that the curvature of the measuring tube 4 is opposite the curvature of the reinforcement element 10 . Due to this positioning of the reinforcement element 10 in the housing 3 , an advantageous shift of the eigenfrequency of the housing away from the operating frequency of the measuring tubes 4 is achieved.
The reinforcement element 10 is produced of hollow individual parts 10 a , 10 b , 10 c and 10 d , so that a closed volume 11 is formed within the hollow reinforcement element 10 , in which a medium can be conveyed. The volume 11 is accessible from outside of the housing 3 in the assembled state through an input opening 12 or through an output opening 13 . The output opening 13 or the input opening 12 extend through the wall of the housing, so that a medium can be conveyed in or conveyed out for heating or cooling.
FIG. 2 shows a further embodiment of a Coriolis mass flowmeter 1 , wherein the embodiment according to FIG. 2 differs from the embodiment in FIG. 1 essentially in that it has a first reinforcement element 10 which an essentially arcuate basic form that is produced as a welded hollow frame structure from a plurality of straight individual parts, and in addition, has a second reinforcement element 14 that is attached to the support bridge 7 and extends between the two flat side walls of the housing 3 essentially orthogonal to the support bridge 7 . The second reinforcement element 14 links the opposing side walls to one another, stabilizes the housing and changes the eigenfrequencies of the housing through this internal mechanical coupling.
The reinforcement elements 10 , 14 are positioned independent of each other, adjacent to one another in the housing 3 ; however, both reinforcement elements 10 , 14 aid in the reinforcement of the housing 3 and the shift of the eigenfrequency of the housing away from the operating frequency of the measuring tubes 4 . In this embodiment, only a medium can be conveyed in the first reinforcement element 10 being introduced at the input opening 12 in the first reinforcement element 10 and can be expelled at the output opening 13 in the first reinforcement element 10 . While the first reinforcement element 10 is completely welded with the walls of the housing 3 —also with the front-most wall that is not shown—the second reinforcement element 14 is only screwed together with the side walls of the housing 3 .
FIG. 3 shows the embodiment according to FIG. 1 in a partial section, front view, wherein the measuring tubes 4 are only shown in the area of the support bridge 7 . The reinforcement element 10 has surface contact with all walls of the housing 3 with its rectangular cross-section and is welded to the walls of the housing 3 , so that an optimal thermal transfer can occur between the medium conveyed in the volume 11 of the reinforcement element 10 and the walls of the housing 3 . In the mounted state, the arc-shaped measuring tubes 4 normally run between both individual parts 10 c and 10 a of the reinforcement element 10 arranged on the sides.
FIGS. 4 a to 4 e show different embodiments of reinforcement elements 10 , wherein a medium can be conveyed only in the embodiments shown in FIGS. 4 a to 4 c ; a medium cannot be conveyed in the embodiments shown in FIGS. 4 d and 4 e.
The reinforcement element shown in FIGS. 4 a to 4 e have in common that they all—in respect to their longitudinal sides—have an essentially arcuate basic shape formed of welded hollow frame structures. In FIG. 4 a , the reinforcement 10 of FIG. 2 is supplemented by the provision of horizontal cross beams which additionally support or stabilize the housing.
The reinforcement means 15 shown, for example, in FIG. 4 b is provided to stabilize the reinforcement means 10 , being arranged at the joints of two individual parts of the reinforcement element 10 and welded thereto, so that a supporting effect occurs in the angles via the flat reinforcement means 15 shown here as triangular plates.
FIG. 4 d , two hollow frame structures are provided one above the other within the housing for reinforcing the housing. In this case, a medium can be conveyed through only one or also through both reinforcement elements 10 . Furthermore, the two hollow frame structures can be connected as shown or can be independent of each other.
In addition to the normally horizontally and diagonally extending individual parts of the reinforcement element 10 , the embodiment shown in FIG. 4 e additionally has vertical individual parts 10 e on each longitudinal side, which aid in the transfer of force in the vertical direction and further stabilization of the reinforcement element 10 .
All of the embodiments for reinforcement elements 10 shown in FIGS. 4 a to 4 e are provided for use in a Coriolis mass flowmeter 1 according to FIGS. 1 and 2 . | A Coriolis mass flowmeter ( 1 ) with at least one sensor arrangement ( 2 ) and at least one housing ( 3 ), in which the sensor arrangement ( 2 ) includes at least one measuring tube ( 4 ), at least one oscillation generator ( 5 ) and at least one oscillation sensor ( 6 ), and the measuring tube ( 4 ) being excited by the oscillation generator ( 5 ) in at least one operating frequency. To optimize production costs and weight relative to the size of the measuring device is implemented by at least one reinforcement element ( 10 ) being arranged in and joined to the housing ( 3 ) in such a manner that the implemented eigenfrequencies of the housing ( 3 ) are shifted away from the operating frequency of the measuring tube ( 4 ). | 6 |
FIELD OF THE INVENTION
The present invention concerns a method for obtaining a solid polycrystalline material with orientated monocrystalline grains. More particularly, it can be applied in the field of non-linear optics for the conversion of optical frequencies (obtaining an optical radiation from two radiations of different frequencies) for the electro-optical modulation of a luminous radiation (phase modulation or light polarization). In particular, the materials obtained can be used as static phase shifters in interferometers, as polarizers in display devices, as switches in pulsed lasers, or as integrated optical light guides.
BACKGROUND OF THE INVENTION
Generally speaking, the method according to the invention allows for the polycrystalline growth of any organic compound comprising molecules having a dipole moment according to an axis of symmetry generally known as a polar axis.
In known electro-optical modulators, monocrystals of mineral materials are generally used, said materials being, for example, potassium diphosphate (KDP), lithium niobate, and lanthanum, lead and zirconium titanate (PLZT).
These mineral materials present the drawback of lacking effectiveness, which requires that they must be used with large thicknesses. Furthermore, the electro-optical effect of these materials owing to their ferroelectricity results in a variation of the crystalline mesh involving high stresses inside the crystals, which generally provokes a separation of the electrodes required for modulation, as well as a premature wear of the material.
In addition, these minerals have a tendency for their refraction index to change in the course of time owing to photorefraction leading to a possible voltage drift of the electro-optical devices comprising these materials.
The manufacture of these monocrystals from mineral materials also requires high temperatures and thus a high energy consumption and significant production stresses.
Also, for a number of years now, research has been centered on the production of monocrystals from organic molecules. These monocrystals have the advantage of offering improved effectiveness as compared with mineral monocrystals, of being able to be produced at relatively low temperatures, and of presenting a wide pass-range of the transparence windows situated in the visible and near-infrared range.
The electro-optical properties of organic monocrystals are due to electronic displacements and not to variations of the crystalline mesh as in the case with mineral crystals, which provides them with improved mechanical behaviour and increases their lifetime.
For more specific details concerning the electro-optical properties of certain organic materials, reference should be made to the article by K. D. SINGER and others which appeared in the publication entitled "Non-Linear Optical Properties of Organic Molecules and Crystals", vol. 1 (1978), pp 437-467, D. Chemla and J. Zyss, Eds., AT&T Labs.
Unfortunately, it is currently extremely difficult to produce large organic material monocrystals able to be used industrially. The methods currently known for manufacturing organic material monocrystals (growth according to the Bridgmann technique or from a vapor) are difficult to implement and in particular can hardly be reproduced.
The difficulty of obtaining large orgainc crystals is more particularly described in the article by SINGER mentioned above.
The difficulty of obtaining large crystals from an organic material is not a specific property of materials having electro-optical properties. In fact, it is difficult to produce any large monocrystal from an organic material.
Finally, there currently does not exist any reliable commercial electro-optical device as regards organic materials.
SUMMARY OF THE INVENTION
The aim of the present invention is to provide a method to obtain a polycrystalline material comprising elongated monocrystalline grains orientated along a given direction, this material being formed of a molecular organic compound whose molecules have at least one axis of symmetry along this direction and at least one dipole orientated along this axis, this method including the following stages:
a)--preparation of a fine powder of said compound having a size grading less than one micrometer,
b)--drying the powder under vacuum,
c)--compression along said direction under vacuum of the dried powder.
This obtaining method is relatively simple and does not include any critical stage. Moreover, it allows for the embodiment of large organic pellets or small bars.
The inventors have found that an orientated polycrystalline material of a molecular organic compound having non-linear optical properties could replace the mineral materials currently used for electro-optical modulation and that the electro-optical responses of these materials were comparable to those of the best responses of inorganic materials. In fact, if the polycrystalline material is monophase, there will be no diffusion of light, but merely losses or attentuations of the latter derived from the refraction or reflection of the light by the pores of the material owing to the monocrystalline grain pore refraction index, reflection and refraction of light due to the anisotrophy of the grains and possibly optical absorption in the wavelength range used.
To this effect, the grain joints must be as unobstructive as possible to allow for transmission of light. Also, it is possible to advantageously use grains whose smallest dimension is of the same order of magnitude as the wavelength of the light to be modulated, indeed at least equal to this wavelength.
If the same material is to be used to modulate various wavelengths, the smallest dimension must be close to the maximum wavelength to be transmitted. For example as regards hexamethylene-tetramine (HMT), 800 nm is the maximum wavelength transmitted; also, the smallest dimension of the monocrystalline grains must be close to 800 nm so as to provide transparance on a smaller wavelength, for example 450 nm for HMT.
With the method according to the invention, it is possible to obtain organic polycrystalline small bars having a luminous transmission coefficient of 89.8% in the visible spectrum.
So as to improve orientation of monocrystalline grains, the method according to the invention advantageously includes a stage for heating under vacuum the dried powder.
The heating and drying temperatures of the powder depend on the organic compound and in particular on its steam pressure.
The heating stage can be carried out at the same time as the uniaxial under vacuum compression stage or even before this compression stage. In this latter case, sublimation of the powder is obtained and then the depositing of small crystals on the piston being used to compress the powder, the small crystals then being used as germs for the growth of the larger monocrystalline grains at the time of the uniaxial compression stage.
The small loss or attenuation of the luminous intensity traversing the polycrystalline material is directly linked to the size and shape of the elementary grains of the powder. The latter play a determining role in obtaining a material having a densification close to the theoretical value represented by the monocrystal of the same composition. Also, the powder must have a space density as low as possible and the elementary grains must have a sub-micronic size ranging, for example, from 500 to 800 nm.
The use of conglomerated particles, namely slightly dispersed, affect the sinterability of the material and result in a distribution of non-uniform porosity. Also, drying of the powder must be efficient, as the humidity of the powder retains a state of aggregation or physical condition adversely affecting sinterability. It is desirable to have a residual water content of less than 10 ppm.
Moreover, the powder needs to be extremely pure when needing to work under vacuum so as to avoid any pollution by the ambient atmosphere.
The initial idea of the invention is to reduce a compound into a powder by grinding it mechanically. Unfortunately, this method does not currently make it possible to obtain a powder having a size grading of less than one micrometer. Furthermore, as grounding is effected in the open air in a humid environment, the powder obtained is too polluted.
Also according to the invention, the powder is obtained either by atomization or by freeze drying. This latter method is more particularly adapted to a low steam pressure organic compound. Atomization and freeze drying consist of dissolving the organic compound in a slightly or averagely polar solvent at a concentration ranging from 2 to 40% by weight of the compound and, for example, from 10 to 30% by weight.
The solvent used may be an aqueous or non-aqueous solvent, such as alcohols (methanol, ethanol, pentanol, amylic alcohol, glycerol), chloroform, acetone, carbon tetrachloride or any other averagely polar organic solvent, provided the latter has a high steam pressure at the used temperatures and pressures with a view to its subsequent elimination. Moreover, as the freeze drying stage includes a freezing up stage, the solvent used for freeze drying must be able to frozen easily. Also, the solvent has, for example, a freezing temperature which is relatively low and especially not less than the temperature of liquid nitrogen.
So as to obtain good dispersion of the powder obtained, it is possible to advantageously use a eutentic mixture of the solvent and the organic compound. This eutentic mixture is then sprayed with the aid of a nozzle whose diameter of the drops obtained ranges from 0.5 to 2 micrometers. The use of a smaller nozzle may result in too great a loss of the compound, the spray or fog obtained having a tendency to fly everywhere and especially outside the vessel used to recover the powder. Moreover, a nozzle with a larger diameter does not make it possible to obtain a powder with a size grading of less than one micrometer.
A further factor involved in an extremely fine powder by means of atomization is the flowrate of spraying of the organic solution. Also, the flowrate of the compressed gas used for spraying the solution is advantageously between 500 and 600 l/h.
In the case of atomization, spraying of the solution is carried out hot, namely at a temperature allowing for evaporation of the solvent. This temperature depends therefore on the solvent, but also on the organic compound. The use of an organic solvent has the advantage of lowering the temperature to which the compounds are exposed. On the other hand, when the atomization stage is carried out hot, it is necessary to use an inert gas (nitrogen, rare gas) so as to avoid lighting of the organic solvent.
In the case of water used as a solvent, spraying is effected at a temperature ranging from 70° to 150° C. With ethanol used as a solvent, heating of the solution to be sprayed may range from 50° to 70° C.
In particular, the method according to the invention makes it possible to obtain polycrystalline materials having non-linear light propagation properties. This optical non-linearity is due to a system of delocalized electrons π, as well as the presence of a non-centrosymmetrical crystalline structure.
The organic molecular compounds have an electro-optical response of about one picosecond instead of about one microsecond for mineral compounds used in non-linear optics. This is in particular due to the mechanism based on displacement of the electron cloud. Thus, the organic materials according to the invention may be used in ultra-rapid electro-optical circuits. Moreover, no voltage drift of the electro-optical devices including the monocrystals of organic materials has been observed.
Furthermore, the organic compounds have wide molecular susceptibilities. Advantageously, delocalization of the electrons π is intensified by the adding of load transfer or polar groupings. In addition, the presence of a dipole along at least one axis of symmetry of the molecule or preferably along a symmetry plane of the molecule favors the growth of large elongated monocrystalline grains orientated along a given direction, this direction being that of the polar axis of the molecules.
The system of delocalized electrons π is in particular due to the presence according to the invention of at least one heteroatom in the carbon-containing chain of the organic material. These heteroatoms form part of a cycle, possibly aromatic, or are directly linked to the carbon of an aromatic cycle. As is the case with heteroatoms, it is possible to cite nitrogen, oxygen, sulfur or phosphorus. As regards the heteroatom cycle, one could cite other cycles, namely pyridine, furan, pyrrole, thiopene, oxazole, pyrazine, thiazole, pyrimidine, purine, pyridazine, piperidine, pyran cycles, etc.
Preferably, the compounds able to be used in the invention comprise at least one atom of nitrogen or at least one atom of oxygen or both. To this effect, it can be noted that the compounds comprising one nitrogen atom and one oxygen atom in a para position of a benzole cycle make it possible to obtain high conjugation and a large load transfer conferring on these compounds extremely high optical non-linearity.
In order to be used in non-linearity optics, the materials according to the invention must present high chemical stability during interaction with light. To this effect, substituted heteroatoms, that is not linked to hydrogens, ensure sound chemical stability. In particular, it is preferable to avoid using compounds comprising too many N--H linkages.
The use of a compound whose crystalline structure is non-centrosymmetrical makes it possible to obtain second order non-linearity. This structure is generally due to the presence of an asymmetrical carbon.
The organic compounds of the invention must in addition be resistant to optical damage so as to avoid any irreversible change of the refraction index.
The following compounds can be used in the invention: urea; hexamethylene-tetramine (HMT); derivatives of pyridine-N-oxide such as 3-methyl-4-nitropyridine-1-oxide (POM) and 3.5 dimethyl-4-nitropyridine-1-oxide; metanitroaniline (mNA); the derivatives of 4-nitroaniline such as 2-methyl-4-nitroaniline (MNA), 2-chloro-4-nitroaniline, 2-bromo-4-nitroaniline and dimethylamino-4-nitrobenzene; 4-N-dimethylaminobenzaldehyde (AMA); 2-(2.4-dinitrophenyl)-methyl aminopropanoate (MAP), 4-N-N-dimethylamino-4'-nitrostilbene (DANS) or even 4-N(nitrophenyl)-2(hydroxymethyl)pyrrolidine (NPP).
It is preferable to use compounds deprived of the N--H linkage, compounds such as HMT, 4-nitropyridine-1-oxide and its derivatives, dimethylamino-4-nitrobenzne, AMA, DANS and NPP.
The polycrystalline material according to the invention may advantageously be used in an electro-optical modulator in order to either modulate the phase or the polarization of a luminous beam. To this effect, the polycrystalline material must be transparent to the wavelength of the beam to be modulated and the grains may be orientated according to the direction of this beam. In addition, two electrodes must be provided on the upper surface of the material, these electrodes being disposed perpendicular to the monocrystalline grains.
this electro-optical modulator may be advantageously used in a large wavelength range extending from ultraviolet to infrared. There are numerous applications of the electro-optical modulator according to the invention. In particular, this modulator can be used when:
polarization or the phase of the light needs to be modulated,
the power of the beam to be modulated is relatively high, this applying as regards laser beams,
the passband required is greater than 50 MHz (video sphere),
the frequency of the modulated beam does not have to be translated (the frequency of the incident beam is equal to the frequency of the beam transmitted by the modulator),
the colinearity of the incident beam and the transmitted beam is required,
the diameters of the beams to be modulated are large.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the invention shall appear more readily from reading the following description, given by way of illustration and being in no way restricrtive, with reference to the annexed figures in which:
FIG. 1 is a diagram giving the various stages of the method according to the invention,
FIG. 2 shows the starting defrosting curve of an aqueous solution of HMT,
FIG. 3 shows a starting defrosting curve of an aqueous solution of urea,
FIG. 4 gives an HMT freeze-drying curve,
FIG. 5 gives the HMT steam pressure variations with the powder drying temperature,
FIG. 6 shows the mould used for pressing of the powder so as to obtain a polycrystalline material according to the invention,
FIG. 7 is an example of a material obtained showing the monodirectional orientation of the monocrystalline grains,
FIG. 8 shows a further example of the material obtained according to the invention,
FIG. 9 is a skeleton diagram of the device used to detect the electro-optical effect in a material according to the invention, and
FIG. 10 shows the operating principle of a polarizer using a polycrystalline material according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a diagram giving the various stages of the method according to the invention.
The method of the invention includes a stage for preparing a fine powder from an organic compound and bearing the reference 1, a stage for drying this powder under vacuum and bearing the reference 2, a pre-pressing stage bearing the reference 3, a heating under vacuum stage 4 and a generally hot uniaxial under vacuum pressing stage 5.
With a view to simplification, the method according to the invention shall be described for the production of an HMT polycrystalline material and a urea material.
So as to obtain an ideal transparent electro-optical material, this material needs to be dense, have a transmission loss minimum figure and have a maximum number of grains oriented along a given direction. One of the most important points is the quality of the starting powder and it is illusory to want to obtain a sound transparent material from a powder not responding to certain criteria. Also, this of necessity involves a powder:
with high purity and every effort must be made to retain this purity during the various operations for obtaining the polycrystalline material,
whose grain size is the smallest possible, less than one micrometer and especially of the same order of magnitude as the wavelength of the best transmitted radiation,
whose grain size distribution is narrow. In fact, despite certain earlier theories, it is preferable to have an extremely constrained size grading distribution (D/d=2 where D represents the maximum diameter of the grains and d represents the average diameter of these grains) so as to reduce porosity of the final material and control growth of the grains,
with non-agglomerated particles and thus well-dispersed and dry, as the humidity retains a state of aggregation or physical condition which affects the sinterability of the final material, and with a distribution of non-uniform porosity,
grains of the equiaxed powder. In effect, the tridimensional shape of the grains is important for simpler future stacking of grains with a simple hot pressing,
with possibly a bevelled morphology of the grains.
A polycrystalline material, transparent in the visible spectrum, and according to the invention must transmit light with a minimum amount of transmission losses. Now, one of the possible causes of transmission loss is the presence of impurities in the material. Also, at least a purity of 99.5% is required for the starting product.
The annexed table gives the various properties of HMT and urea.
In this table, r 41 represents the value of the electro-optical linear coefficient (Pockels coefficient) expressed by a reduced tensorial notation. For details concerning the definition, reference should be made to the article by K. D. Singer and others.
Furthermore, HMT sublimates at 263° C. without melting with a partial decomposition. It is volatile at a lower temperature (steam pressure of 27 Pa at 100°-110° C.). Also the crystals are hygroscopic. Thus precautions need to be taken for polishing surfaces and conversion of the final material. This material presents both a longitudinal and a transverse electro-optical effect.
As regards urea, there is a melting point of 132.7° C. Moreover, it is sublimated under vacuum at temperatures below the melting point. Finally, urea is stable at ambient temperature and at atmospheric pressure, but is less hygroscopic and absorbs the humidity of the atmosphere.
1. OBTAINING A FINE POWDER OF THE ORGANIC COMPOUND
According to the invention, the fine powder is obtained by atomizing (or spraying an aqueous or alcoholic solution of the organic compound by means of a nozzle, diameter 0.5 mm, and is sprayed inside a compressed hot air current. The solvent evaporates immediately and envelops the vapor product, thus protecting it against the effects of excessive heat. The product passes from the liquid phase to a state of aggregation in the form of a fine dry powder without deteriorating. X-ray analysis has enabled this to be confirmed.
Atomization is a method for obtaining a fine dry powder whose size grading is less than one micrometer and thus proving to be satisfactory for obtaining the polycrystalline material according to the invention. The powder obtained is very slightly polluted.
The annexed table II gives the various operating conditions for atomization.
A further method for obtaining a powder according to the invention is freeze-drying which includes the dissolving of the organic product in an aqueous or alcoholic solvent; this is followed by freezing this solution and then its sublimation under vacuum with a view to eliminating its solvent.
The solvent able to be used for freeze-drying must be able to be solidified by cooling and must have in its solid condition a steam pressure sufficiently high so as to allow for its extraction by sublimation under a moderated vacuum and at a reasonable speed. Although the water does not constitute the perfect solvent for freeze-drying, it is this solvent which has been selected owing to its relatively high solidification temperature (0° C.).
Freeze-drying results in a dry powder being obtained. The solvent content of the powder is highly-reduced (less than 0.02%) and it is preferable to use it immediately for compression.
So as to avoid polluting the powder, the most pure as possible solvents are used. For water used as a solvent, it is possible to use the water supplied by a MilliQ purification unit sold by the Millipore company and has a minimum resistivity of 18 M.Ω.cm. This water contains at the most 12 ppm of mineral impurities.
So as to prevent separation of the solution, during freezing it is preferable to use an eutectic composition, thus conferring greater latitude as regards the rate of cooling. It is also possible to carry out extremely fast freezing with the desired concentration solutions and, especially if required, with highly-diluted solutions.
In order to obtain a satisfactory quality product by means of freeze-drying, it firstly is necessary to know the freezing temperature and the starting defrosting temperature of the organic solution (solvent+ organic compound), this starting defrosting temperature not to be reached for correct freeze-drying without passing to the intermediate liquid state. The sublimation temperature is about from 5° to 10° C. less than the starting defrosting temperature.
The starting defrosting temperatures and the concentrations of eutectic solutions may be determined by means of differential thermal analysis at a low temperature for the various concentrations of the compound in the solution. For example, it is possible to use the Setaram differential thermal microanalyzer suitable for low temperatures, this device being cooled by liquid nitrogen.
FIG. 2 gives the differential thermal analysis of a 20% weight of HMT of an aqueous solution indicating that the starting defrosting temperature is equal to -13° C. This curve gives in abscissae the temperature in °C. and in ordinates the temperature variation ΔT.
In these same conditions, a differential thermal analysis is carried out on a 20% weight of urea aqueous solution. This analysis is represented on FIG. 3. The curve shows a starting defrosting temperature at -14° C. The temperature measurement is evaluated to within 1° C.
The morphology and crystalline size of the powder is solidified upon freezing and, for a large part, conditions the direction of sublimation and the qualities of the final product. A morphology in small equiaxed crystals is desirable for easy sublimation and a more homogeneous final product.
Freezing may be carried out in bulk in a Petri box placed in the vessel of the Serail RP 2 V type freeze dryer.
The freezing rate is that of the device and the refrigerating agent fluid is Freon R502. In these conditions, one hour is required so as to lower the ambient temperature to -45° C., a temperature which is sufficient in order to freeze an aqueous solution of HMT and an aqueous solution of urea.
It is also possible to freeze the solution by means of atomization in liquid nitrogen and then transferring the frozen product into a Petri box placed in the freeze-dryer vessel already brought down to -45° C. In these conditions, freezing is immediate.
Atomization in liquid nitrogen is described in detail in the document FR-A-2 251 535 by M. PAULUS. The hollow cone type spraying nozzle has a diameter of 0.41 mm.
Freeze-drying is continued by sublimating the solvent of the organic compound. This sublimation is effected at a pressure of less than the steam pressure of the solvent to the selected freeze-drying temperature by taking account of the obtained results of differential thermal analysis.
At any moment, the solid state must remain and thus prevent any physical transformation with deliquescence of the powder. This physical transformation must strictly be avoided so as to preserve homogeneity of the powder.
For HMT and urea, sublimation may be carried out at a temperature ranging from -23° C. to -18° C.; the steam pressure of the water used as a solvent at -20° C. is about 100 Pa (0.8 torrs). Also, once the vacuum in the vessel reaches a pressure of more than 100 Pa, ice starts to sublime.
In practice, it is possible to limit the pressure in the vessel of the freeze-dryer to 16 Pa (0.16 mbars) during sublimation. A higher vacuum does not improve the rate of evaporation and proves to be more of an obstacle in transferring calories from the bottom of the vessel towards the product.
This pressure of about 16 Pa makes it possible to keep the temperature of the product below the defrosting temperature and is nevertheless sufficiently high to allow for a correct rate of evaporation, namely one which is not too fast so as to avoid the powder becoming too light outside the freeze-dryer and one which is not too slow for a relatively short freeze-drying period.
At the end of the sublimation stage, a higher vacuum is re-established so as to facilitate extraction of the residual humidity contained in the product obtained. In particular, a pressure of 5 Pa (0.05 mbars) may be used.
By way of example, FIG. 4 shows an HMT freeze-drying curve. The abscissae give the time t in hours and the ordinates give the temperature T in degrees C.
The final freeze-drying stage and that of atomization concerns elimination of the residual water, namely the water molecules retained by absorption inside the apparently dry powder.
Also, the method according to the invention comprises a drying stage.
2. DRYING OF THE POWDER
The temperature of drying varies for each product and depends on its steam pressure and the desired degree of desiccation. Given the fact that the organic products have high steam pressures at relatively low temperatures, it is necessary to heat the material to a temperature at least equal to 60° C.
According to the product, the maximum drying temperature may be determined by observing deterioration of the vacuum according to the temperature in the vacuum chamber in which is the mould to be used to produce the solid material. The product must be firstly manually pressed so as to avoid any product loss at the time it is placed in a vacuum. The pressure values P are then raised according to the temperature and are marked on a semi-logarithmic paper.
By way of example, FIG. 5 gives the variations of the steam pressure of pre-pressed HMT with the drying temperature. The pressure, expressed in Pas, is laid off as ordinate in the form of a logarithm, and the temperature, expressed in degrees C., is laid off as absciss.
This curve shows that the maximum drying temperature is equal to 35° C.
This technique for determining the maximum drying temperature has been carried out in the same way for urea and a value of 50° C. was obtained.
The dried powder thus obtained can then be pressed in order to obtain a polycrystalline material.
3. PRESSING
Pressing is effected with the mould shows diagrammatically on FIG. 6. This mould 11 is made of structural hardening martensitic steel, usually known as Maraging steel. It includes a hollow cylinder 10 in which a piston 12 moves along the axis 13 of the cylinder 10. The base 14 of the piston is polished. The base of the cylinder 10 rests on a mounting plate 16. Inside the cylinder 10 and in support on the mounting plate 16, there is a support 18 whose upper face 20 is polished and is parallel to the base 14 of the piston. The support 20 is designed to receive the previously obtained powder 22 to be compressed.
The mould 11 is placed between two heating resistor type plates, namely one fixed plate 24 and one mobile plate 26, the resistors of the fixed plate being connected to a first electric power supply source 28, and the resistors of the mobile plate being connected to a second electric power supply source 30.
The cylinder 10 is provided with several openings 32 disposed radially and making it possible to draw out the air in the compression chamber 34 and in the powder 22; the compression chamber 34 is defined by the internal walls of the cylinder 10, the face 20 of the support 18 and the base 14 of the piston 12. So as to keep the chamber 34 in a partial vacuum, an O-ring seal 36 encompassing the piston 12 is provided at the upper part of the cylinder 10.
Filling of the mould is effected with a completely dry funnel placed in the center of the mould so as to allow for even distribution of the powder.
So as to know the temperature existing in the compression chamber 34, a thermoelement 38 connected to an electronic measuring device 40 is housed opposite the support 18.
Part A of FIG. 6 represents the position of the mould at the time of being placed under vacuum prior to pressing, and part B shows the position of the mould during pressing.
This uniaxial press type device with heating plates enables maximum temperatures of 250° C. to be reached on the plates.
The heating plates 24 and 26 are made of copper, the press providing a uniaxial pressure shown on the diagram by the arrow F by means, for example, with a Basset press. Placing the compression chamber 34 under vacuum can be provided with an Alcatel primary pump having an air flowrate of 8 cubic meters per hour and an Edwards secondary diffusion pump having a pumping rate of 3001/second and a final vacuum of less than 10 -5 Pa (10 -7 torrs).
Pressing first of all comprises a hot or cold prepressing stage. This prepressing must be carried out at a pressure allowing the powder to be transformed into a compact, but this pressure must not be too high so as to retain open porosity of the compact. In fact, a closed porosity prevents a supposed correct vacuuming of the powder and an evacuation of the gases occuring inside the compact. As these gases are unable to leave at the time of hot pressing (or sintering), large pores shall be left which constitute a diffusion and thus a non-transparence source of the final material, or even a cracking source if the gases happen to escape from the final product.
This prepresssing may be carried out at a pressure ranging from 6.25.10 4 to 17.5.10 5 Pa and especially equal to 12.5.10 4 Pa. This prepressing is carried out at ambient temperature for 15 mns under secondary vacuum of about 8.10 -5 Pa (6×10 -7 torrs).
There then follows the actual pressing stage. The uniaxial pressure applied to the material must not exceed the elastic limit of the material. Moreover, the pressing rate must be less than 25 micrometers/s and for example equal to 20.
This pressing stage is mainly effected hot. However, the HMT may be pressed cold under a pressure of 2.4.10 7 Pa with a vacuum of 0.6 Pa (5.10 -2 torrs), provided the diameter of the pellet is no more than 13 mm.
The hot pressing stage may be controlled in two different ways.
The first way consists of heating the plate 26 to a temperature of more than 50° C., such as for example 60° C., the plate 24 being kept at ambient temperature. Then a temperature gradient is created between the base 14 of the piston and the support 18. The vacuum inside the compression chamber 34 is kept at 5 Pa. The piston 12 is kept in the top position, as shown on part A of FIG. 6. Under the effect of the temperature gradient, the powder sublimes and the volatilized molecules come and are secured in contact with the piston 12 at a temperature lower than the support 18. Then microcrystals of about 10 micrometers and of uniform size are formed.
The growth of the microcrystals inside the mould naturally starts at the coldest location. These microcrystals serve as germs and a continuous front is formed by the adjacent crystalline grains. Gradually, the number of crystals emerging from the front decreases, whereas the surface contributed by each crystal increases.
In this "competition" to obtain a place on the first row of the front, the crystals orientated so that the fastest direction is the normal one at the advance front shall those which shall survive. Consequently, after a covered distance which exceeds the average distance between the monocrystalline grains (≦1 μm), all the crystals developed inside the material have an elongated form seen as a vertical section and are almost parallel with respect to each other. Thus, the transformed column-shaped texture (see FIGS. 7 and 8) is obtained in one section of the final material, provided the lateral thermal gradient is nil or negligible.
In this crystalline growth, it has been seen that the thicker the final material is with respect to the average initial size of the elementary grain of the powder, the more reduced shall be the resulting number of crystals and equally their development shall be closer to normal in the compact.
When all the powder has been sublimated, the heating plate 24 is heated to a temperature of more than about 50° C. then a pressing is made at 1.7 MPa for about 15 mins with a controlled air leak of 2.5.10 -2 Pa resulting in the growth of the microcrystals into larger transparent and monocrystalline crystals.
An X-ray analysis via the Laue method will have confirmed the monocrystalline nature of the crystals. In addition, a transparence or polarized light examination with a Zeiss microscope enables one to see the extinction of these crystals.
FIG. 7 shows the polycrystalline material obtained. The lower face 42 of the polycrystalline material, which corresponds to the one in contact with the piston 12, comprises monocrystalline grains 44 much smaller than the grains 46 situated on the upper face 48 of the obtained polycrystalline material. It is these smallest grains which have been used as germs for the growth of the monocrystals 46.
In accordance with the invention, the monocrystalline grains 46 of the material are orientated along a given direction D perpendicular to the surface of the piston 12. So as to eliminate the lower part of the polycrystalline material, a machining is carried out followed by an optical polishing. Similarly, the upper face of the material undergoes an optical polishing.
According to the invention, it is possible to suppress the sublimation stage and thus to directly compress the powder 22 hot under vacuum.
The compactness of the polycrystalline materials obtained shall have been measured by the geometrical method, namely a non-destructive method. The compactness of the products obtained varies from 98.3 to 99.2 and the maximum density attained is 1.318, which is relatively close to the density of a monocrystalline material. Moreover, the transparance of these materials shall have been measured by a light transmission method and by spectrophotometry.
The results are entered on the annexed table III and give the conditions for hot pressing of the HMT powder, its optical density and its transmission coefficient T% for various wavelengths in the visible spectrum.
The sample 3, which has been treated in the same way as for sample 2, except for the fact that hot pressing has been carried out 72 hours after formation of the powder, has transmission coefficients smaller than those of the sample 2. This is linked to the fact that HMT is hygroscopic and that its transparance is not preserved indefinitely. Also, so as to obtain a polycrystalline material according to the invention as HMT, the pressing stage has to be carried out after the powder has been formed.
Furthermore, in order to retain this transparance, it is desirable to protect the polycrystalline material obtained immediately after it has been produced. This can be effected by using an encapsulating agent in which the HMT is dissolved and which does not attenuate the transparence of the polycrystalline material. By way of example, the protective product could be Siceront KF1280 protective varnish, which is a petroleum ether-based varnish.
Samples 1 to 4 of table III relate to HMT polycrystalline materials whose diameter is 13 millimeters and thickness is 0.580 mm.
With the previously-described method, pellets are also embodied being 25 mm in diameter and having a thickness of 543 micrometers. The transparence and pressing conditions of the product obtained and the optical density for different wavelengths are entered on the final line of table III.
Unlike the case with HMT, cold pressing under vacuum of urea is unsuitable for obtaining the transparent polycrystalline material according to the invention. Also a hot pressing, possibly preceded by a hot prepressing under vacuum, is necessary.
Different conditions for the hot pressing of an urea powder shall have been carried out and the results are entered on the annexed table IV. The last line of the table gives as a comparison the transmission percentage of a PLZT pellet. It should be noted that the transmission coefficient is higher as regards the latter. This is certainly due to excessive heating during pressing and also to the smallest thickness of the PLZT pellet used.
The average optical density obtained for the sample 7 is 2.62 and may reach 2.66.
Table IV relates to urea pellets 18 mm in diameter and having undergone a prepressing at 12.5.10 4 Pa under primary vacuum (5×10 -3 Pa) at a temperature of 50°-60° C.
With the method according to the invention, it has been possible to obtain an HMT polycrystalline material 50 with a transformed column-shaped structure having a thickness of 580 micrometers, as shown on FIG. 8. The monocrystalline grains 51 orientated perpendicular to the largest surface 52 of the material (along the direction D) have a length equal to the thickness of the polycrystalline material.
Revealing the electro-optical effect of the polycrystalline materials according to the invention has been detected and displayed by means of the device represented on FIG. 9. The polycrystalline material 50 according to the invention and whose thickness is about 580 micrometers is placed on a glass sample-carrier 53 comprising an opening 54 opposite the material 50 to be analysed. Two electrodes 56 are glued onto the upper face of the material 50 and are separated from a distance×by 0.5 mm. These two electrodes 56 are parallel to each other and are made of copper. The sample-carriers and the material 50 are looked at under an optical microscope (Zeiss Universal), the light polarization vector shown by the arrow 58 and the electric field created between the two electrodes 56 being parallel. Voltage is applied by means of a d.c. electric power supply source 59 at one kHz during observation with the microscope.
After extinction between two crossed polarizers 60 and 62, transparence through the material 50 can be observed from a threshold voltage. The threshold voltage values found for an HMT material according to the invention vary from 900 to 1100 volts. These threshold voltages have been compared with those obtained for the PLZT samples, this material having for an equivalent thickness threshold voltages varying from 2300 to 2900 V.
These threshold voltage differences are due to the fact that the electrodes 56 were simply glued onto the polycrystalline material of the invention (where there is poor electric contact and a poor electricity conductive glue) whilst the PLZT electrodes were evaporated gold electrodes. As a result, the value of the measured threshold voltage on the HMT can be improved considerably by especially embodying an electro-optical modulator with evaporated gold electrodes.
Whichever case applies, following application of the threshold voltage, the material 50 according to the invention has become transparent in the area 64 situated between the two electrodes 56.
In these experimental conditions, there occurs an electro-optically induced refraction index variation for HMT of 6.4.10 -6 and 5.4.10 -6 for urea. These recorded refraction index changes dn introduce a phase shift p of the light traversing the polycrystalline material given by the equation: p=(2π/1).dn.e, where dn represents the index difference induced electro-optically, 1 the wavelength of the light transmitted and e the thickness of the polycrystalline material.
In these conditions, for a wavelength of 600 nanometers, there occurs a phase shift of 4.02.10 -5 for HMT and 3.39.10 -5 for urea.
The material according to the invention may also be used as an electro-optical modulator and in particular as a polarizer whose functioning is shown on the diagram on FIG. 10.
A material according to the invention 66 is equipped with two evaporated gold electrodes 68 and 70 on one of the faces 71 of the material. These electrodes are connected to a d.c. electrical power supply source 72. A circuit switch K makes it possible to close or open the electric circuit.
When the circuit is open, part A of FIG. 10, the light (h ) arriving on the upper face 71 of the material and orientated parallel to the monocrystalline grains 74 of the material according to the invention is transmitted and stands out by the lower face of the material. When the electric circuit is closed, part B of FIG. 10, the incident luminous beam (h ) arriving parallel to the monocrystalline grains 74 of the material is thus absorbed by the non-transmitted material.
By way of example, three examples are shown below for obtaining a urea and HMT transparent pellet having a diameter of 13 mm and a thickness of 580 micrometers.
EXAMPLE 1
An aqueous solution with 20% weight of HMT is prepared from water originating from a Millipore and HMT unit (Milliq model) commercialized by Merck with a minimum purity of 99.5%. The solution obtained is bulk-frozen thoroughly flat inside a Petri box in a freeze-dryer commercialized by Serail at -44° C. for 4 hours. The pressure is then lowered to 20 Pa (0.2 mb) and the temperature is brought down to -20° C. so as to embody freeze-drying.
After desiccation under a vacuum of 50 Pa (0.5 mb) for about one day, the powder is taken out of the freeze-dryer, the final temperature being 20° C. and the pressure being 50 Pa. The freshly obtained powder is then crushed in a mortar and is then introduced into the pressing mould 11 (FIG. 6) whose internal diameter is 13 mm and thus equal to the diameter of the future pellet.
This powder is kept in a low vacuum (6×10 -3 Pa) for 3 to 4 hours in the pressing mould at ambient temperature (20° C.). An uniaxial pressure of 2.4.10 7 Pa (according to the reading of the pressure gauge) is applied by means of a Perkin-Elmer press for 15 minutes.
The transparence of the pellet obtained has been verified by visual inspection and transmission measured by the VIS/IR spectrophometry technique. The highest value obtained after attenuation correction by multiple reflections on the HMT-air interface is 95%.
A check is made of the bi-modal distribution of the monocrystalline grains. Grains with a sub-micronic diameter have been determined by a technique using Rayleigh diffusion of the light and those grains of supra-micronic dimension have been determined by X-ray diffusion. The monocrystalline grains had a dimension ranging from 800 to 5000 nm.
EXAMPLE 2
An aqueous HMT solution is prepared according to the same conditions as in example 1. This solution is then atomized with a Be,uml/u/ chi laboratory atomizer (with a nozzle with a 0.5 mm diameter). The input temperature of the atomization gas is kept at 116° C. and the outlet temperature at 74° C. with a compressed air flowrate of 500 to 600 liters per hour. The freshly obtained powder is then crushed in a mortar and introduced into the same pressing mould as in example 1. This powder is kept under a low vacuum for 3 to 4 hours at ambient temperature. A uniaxial pressure of 2.4.10 7 Pa is then applied for 15 minutes. Transparence has been verified as in example 1.
The yield obtained in 40%.
EXAMPLE 3
An aqueous solution of 4% Aristar BDH urea with a purity of 99.9% is prepared from water derived from the above-mentioned Millipore unit. The solution obtained is frozen by atomization in liquid nitrogen through an Emani nozzle with a nitrogen pressure of 6.10 5 Pa (6 bars). The frozen solution is gathered into a Petri box placed inside the vessel of a Serial freeze-dryer cooled to -46° C. Freezing is carried out for 3 to 4 hours.
Then a low vacuum of 2.10 -3 Pa is carried out for 25 minutes. Freeze-drying is continued under a reduced vacuum of 16 to 17 Pa until attaining ambient temperature of 20° C. Then drying under vacuum is carried out at 4.5 Pa for one day without heating and then with progressive heating until about 30° C. is reached.
The freshly obtained powder is then crushed in a mortar and is then introduced into a pressing mould as described previously. After desiccation at 47° C. under a low vacuum with a controlled leak of 2.5.10 -2 Pa for 3 hours (time required to increase the temperature), a prepressing of 0.1 tons under a low vacuum is carried out for 10 minutes at a temperature of 20° C. followed by a uniaxial pressing of 2.4.10 7 Pa for 15 minutes at 50° C. and under a pressure of 17.10 5 Pa. Transparence has been verified by visual inspection and transmission measured by the VIS/IR spectrophotometry technique.
The highest value obtained for transmission, after attenuation correction by multiple reflections of the air-urea interface, was 51%.
TABLE I______________________________________ HMT UREA______________________________________Space groups of 143 m 42 mcrystalsmesh cubic quadratic body-centered a = 0.5645 nm a = 0.7021 nm c = 0.4704 nm 0 0density at 20° C. 1.33 1.323transparence 300-2200 nm 210-1400 nmrefraction index 1.5936 at 25° C. 1.484 at 20° C. for λ = 633 nmr.sub.41 (experimental) 0.72 × 10.sup.-12 mV.sup.-1 1.86 × 10.sup.-12 mV.sup.-1______________________________________
TABLE II______________________________________Operating conditions for atomization Atomi- Input Output Com- zation Atomi- T° T° pressed time zationSample (°C.) (°C.) air flow-rate yield (%)______________________________________Alcoholic 116 74 500-600HMT solution(10%)Alcoholic 70 56 500 16 mns 21HMT solution(2% ethanol)Alcoholic 62-64 54-50 500 50 mns 28HMT solution(2% ethanol)Aqueous 148 100 600 8 m 30 s 30 to 40*urea solution(10%)______________________________________ (*the 40% yield takes account of the powder collected in the cyclone dust catcher.)
TABLE III__________________________________________________________________________HMT PRESSING PERKIN-ELMER TRANSMISSION ACCORDING TO WAVELENGTH VACUUM PRESS 400 nm 480 nm 560 nm 650 nm 750 nm 800 nmHMT SAMPLE PRESSING CONDITIONS D.opt T % D.opt T % D.opt T % D.opt T % D.opt T D.opt T__________________________________________________________________________ %1 heating plate dried 0.39/ 0.31/ 0.27/ 0.235/ 0.205/ 0.185/(13 mn) powder: 40.73 49.1 53.76 58.14 62.34 65.36 drying: low vacuum 6.5 pressing: 15 mins + vacuum: 6.52 outgoing freshly powder 0.255/ 0.25/ 0.24/(13 mm) drying: low vacuum 6.5 5 h 55.86 56.18 57.8 pressing: 12.5 MPa 15 mins + vacuum: 83 same pellet as 2 0.355/ 0.36/ 0.36/(13 mm) (72 hrs after pressing) 44.25 43.67 43.674 outgoing freshly powder 0.2725/ 0.217/ 0.175/ 0.1425/ 0.1125/ 0.1/(13 mm) drying: low vacuum 6.5 4 h 53.39 60.64 66.8 72.04 77.22 79.43 pressing: 12.5 MPa 15 min + vacuum: 6.55 outgoing freshly powder 0.43/ 0.36/ 0.30/ 0.25/ 0.23/(25 mm) drying: low vacuum 37.17 43.67 50.25 56.18 58.82 2 × 10.sup.-3 5 h presing 15 MPa + vacuum 6.5__________________________________________________________________________
TABLE IV______________________________________TreatmentsundergoneUREA T° vacuum thickness % transmissionsample (°C.) Pressure (Pa) (in mm) Ave Max Min______________________________________6 60 5T 15 mn 4.10.sup.-3 0.580 49 51 467 60 5T 1 h 8.6.10.sup.-3 0.580 49 51 478 90 5T 15 mn 8.9.10.sup.-3 0.580 47 49 449 60 5T 3/4 h 7.9.10.sup.-2 0.290 35 45 32C 0.205 72 72 72______________________________________ | Method for obtaining an organic polycrystalline material having in particular electro-optical properties, said material obtained and an electro-optical modulator comprising said material.
This method includes a stage (1) for preparing a powder having a size grading of 500 to 800 nm of an organic compound having a delocalized system of electrons π and presenting a non-centrosymmetrical crystalline structure, as well as intramolecular load transfer groupings, a stage (2) for drying the powder under vacuum, a stage (3) for pre-pressing the powder under vacuum, and a hot stage (5) for the uniaxial compression of the dried powder under vacuum.
This method enables polycrystalline materials to be obtained, said materials comprising elongated monocrystalline grains orientated according to a given direction. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to semiconductor fabrication, and particularly to fabricating transistor devices comprising epitaxial source and drain regions disposed in recessed regions of a semiconductor substrate that undercut an overlying gate structure to increase the stress applied to the channel region.
[0003] 2. Description of Background
[0004] Integrated circuits often employ active devices known as transistors such as field effect transistors (FETs). A FET includes a silicon-based substrate comprising a pair of impurity regions, i.e., source and drain junctions, spaced apart by a channel region. A gate conductor is dielectrically spaced above the channel region of the silicon-based substrate. The junctions can comprise dopants which are opposite in type to the dopants residing within the channel region interposed between the junctions. The gate conductor can comprise a doped semiconductive material such as polycrystalline silicon (“polysilicon”). The gate conductor can serve as a mask for the channel region during the implantation of dopants into the adjacent source and drain junctions. An interlevel dielectric can be disposed across the transistors of an integrated circuit to isolate the gate areas and the junctions. Ohmic contacts can be formed through the interlevel dielectric down to the gate areas and/or junctions to couple them to overlying interconnect lines.
[0005] Demands for increased performance, functionality, and manufacturing economy for integrated circuits have resulted in extreme integration density and scaling of devices to very small sizes. Transistor device scaling has restricted operating margins and has adversely affected the electrical characteristics of such devices. As such, more emphasis has been placed on achieving higher operating frequencies for transistor devices through the use of stress engineering to improve the carrier mobility of such devices rather than through the use of scaling.
[0006] Carrier mobility in the channel of a FET device can be improved by applying mechanical stresses to the channel to induce tensile and/or compressive strain in the channel. The application of such mechanical stresses to the channel can modulate device performance and thus improve the characteristics of the FET device. For example, a process-induced tensile strain in the channel of an n-type (NFET) device can create improved electron mobility, leading to higher saturation currents.
[0007] One method used to induce strain in the channel region has been to place a compressively strained nitride film close to the active region of the FET device. Another approach taken to induce strain in the channel of a p-type (PFET) device has been to epitaxially grow silicon germanium (e-SiGe) in the source and drain regions of the silicon-based substrate. When epitaxially grown on silicon, an unrelaxed SiGe layer can have a lattice constant that conforms to that of the silicon substrate. Upon relaxation (e.g., through a high temperature process) the SiGe lattice constant approaches that of its intrinsic lattice constant, which is larger than that of silicon. Consequently, physical stress due to this mismatch in the lattice constant is applied to the silicon-based channel region.
SUMMARY OF THE INVENTION
[0008] The shortcomings of the prior art are overcome and additional advantages are provided through the provision of stress enhanced transistor devices and methods of fabricating the same. In one embodiment, a transistor device comprises: a gate conductor disposed above a semiconductor substrate between a pair of dielectric spacers, wherein the semiconductor substrate comprises a channel region underneath the gate conductor and recessed regions on opposite sides of the channel region, wherein the recessed regions undercut the dielectric spacers to form undercut areas of the channel region; and epitaxial source and drain regions disposed in the recessed regions of the semiconductor substrate and extending laterally underneath the dielectric spacers into the undercut areas of the channel region.
[0009] In another embodiment, a method of fabricating a transistor device, comprises: providing a semiconductor topography comprising a gate conductor disposed above a semiconductor substrate between a pair of dielectric spacers; anisotropically etching exposed regions of the semiconductor substrate on opposite sides of the dielectric spacers to form recessed regions in the substrate spaced apart by a channel region; selectively etching exposed sidewalls of the channel region to undercut the dielectric spacers; and growing epitaxial source and drain regions in the recessed regions of the semiconductor substrate such that the epitaxial source and drain regions extend underneath the dielectric spacers.
[0010] In yet another embodiment, a method of fabricating a transistor device, comprising: providing a semiconductor topography comprising a gate conductor disposed above a semiconductor substrate between a pair of dielectric spacers; selectively etching exposed regions of the semiconductor substrate on opposite sides of the dielectric spacers to form recessed regions in the substrate that undercut the dielectric spacers and define a channel region between the recessed regions comprising undercut areas; and growing epitaxial source and drain regions in the recessed regions of the semiconductor substrate such that the epitaxial source and drain regions extend underneath the dielectric spacers into the undercut areas of the channel region.
[0011] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0013] FIGS. 1-6 illustrate another example of a method for fabricating a stress enhanced transistor device; and
[0014] FIGS. 7-12 illustrate another example of a method for fabricating a stress enhanced transistor device.
[0015] The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Stress enhanced FET devices can be fabricated by forming epitaxially grown source and drain regions in recessed regions of a semiconductor substrate that extend laterally underneath the overlying gate structure into undercut areas of the channel region. As such, the epitaxially grown material is strategically placed as close as possible to the channel (even partially underneath the channel) to maximize the stress applied to the channel and thus enhance the carrier mobility in the channel.
[0017] Turning now to the drawings in greater detail, it will be seen that FIGS. 1-6 illustrate a first exemplary embodiment of a method for fabricating stress enhanced FET devices. As shown in FIG. 1 , a bulk semiconductor substrate 10 comprising single crystalline silicon that has been slightly doped with n-type or p-type dopants is first obtained to form the FET device. Alternatively, a semiconductor layer 10 can be formed upon an insulation layer (not shown) to create a silicon-on-insulator FET device. Shallow trench isolation structures 12 can be formed in the semiconductor substrate 10 on opposite sides of the ensuing FET device to isolate it from other active areas in the substrate 10 . A gate dielectric 14 comprising e.g., thermally grown silicon dioxide (SiO 2 ) or hafnium-based oxide (such as HfO 3 ) deposited by chemical vapor deposition (CVD), can be formed across the semiconductor substrate 10 . A gate conductor layer 16 comprising, e.g., polycrystalline silicon (“polysilicon”), can then be deposited across the gate dielectric 60 . Dielectric capping layers, such as silicon dioxide (“oxide”) layer 18 and silicon nitride (“nitride”, Si 3 N 4 ) layer 20 , can then be deposited across the gate conductor layer 16 .
[0018] Next, the gate conductor layer 16 , the gate dielectric 14 , the oxide layer 18 , and the nitride layer 20 can be patterned using lithography and an anisotropic etch technique, e.g., reactive ion etching (RIE), to form the gate conductor structure shown in FIG. 2 . Dielectric spacers 22 comprising a dielectric such as nitride can be formed upon the opposed sidewall surfaces of the gate conductor 16 via CVD of a dielectric followed by an RIE process, which etches the dielectric at a faster rate in the vertical direction than in the horizontal direction.
[0019] Turning now to FIG. 3 , recessed regions 24 can subsequently be formed in the semiconductor substrate 10 using lithography and an RIE process. The formation of the recessed regions 24 clearly defines the channel region 26 . Next, as shown in FIG. 4 , ion implantation (illustrated by arrows 28 ) can be used to form etch stop regions 30 in the semiconductor substrate 10 beneath the recessed regions 24 . In one embodiment, p-type dopants can be implanted if the transistor being formed is an NFET device, whereas n-type dopants can be implanted if the transistor being formed is a PFET device. Examples of n-type dopants include, but are not limited to, arsenic, phosphorus, and combinations comprising at least one of the foregoing dopants. Examples of p-type dopants include, but are not limited to, boron, boron difluoride, and combinations comprising at least one of the foregoing dopants. It is to be understood that both NFET and PFET devices can be formed in the semiconductor substrate 10 to form a CMOS (complementary metal-oxide semiconductor) integrated circuit. By way of example, boron (B) can be implanted at a low energy of less than about 10 keV and a dosage of about 2×e 14 ions/cm 2 to about 2×e 15 ions/cm 2 , more specifically about 5×e 14 ions/cm 2 to about 2×e 15 ions/cm 2 . Similarly, boron difluoride (BF 2 ) can be implanted at a low energy of less than about 10 keV and a dosage of about 2×e 14 ions/cm 2 to about 1×e 15 ions/cm 2 , more specifically about 5×e 14 ions/cm 2 to about 1×e 15 ions/cm 2 . In a preferred embodiment, BF 2 is implanted at an energy of about 3 keV and a dosage of about 5×e 4 ions/cm 2 .
[0020] In an alternative embodiment, electrically inactive species or amorphizing species capable of damaging the crystallinity of the silicon can be implanted into the recessed silicon to form etch stop regions 30 . Examples of electrically inactive species include, but are not limited to, silicon, germanium, carbon, xenon, and combinations comprising at least one of the foregoing species. As an example, xenon can be implanted at an energy of about 5 keV and a dosage of about 5×e 14 ions/cm 2 .
[0021] As depicted in FIG. 5 , after the ion implantation step, sidewalls 32 of the channel region 26 can be etched using an isotropic wet etch chemistry that is selective to silicon. For example, the recessed regions 24 of the substrate 10 can be contacted with a hydroxide etchant such as tetramethylammonium hydroxide (TMAH), ammonium hydroxide (NH 4 OH), sodium hydroxide (NaOH), potassium hydroxide (KOH), etc. The doped etch stop regions 30 can inhibit etching of those areas of substrate 10 beneath recessed regions 24 . Further, the oxide and nitride layers 18 and 20 can protect the gate conductor 16 from being etched. As a result of being subjected to an isotropic etch, which etches at the same rate in the vertical and horizontal directions, the sidewalls 32 of the channel region 26 can become indented as shown such that the channel region 26 is substantially shaped as an hourglass. The etch is performed for a period of time effective to cause the recessed regions 24 to undercut the dielectric spacers 22 and thus form undercut areas in the channel region 26 .
[0022] As shown in FIG. 6 , epitaxially grown source and drain regions 34 can subsequently be formed in the recessed regions such that they extend laterally under the dielectric spacers 22 into the undercut areas of the channel region 26 . The epitaxial growth can be performed at a temperature of about 500° C. to about 900° C. and a pressure of about 1 Torr to about 100 Torr using precursors such as SiH 4 , SiH 2 Cl 2 , GeH 4 , HCl, B 2 H 6 , SiH 3 CH 3 , etc. In a preferred embodiment, the epitaxial growth is performed at a temperature of about 700° C. and a pressure of about 10 Torr. When forming a PFET device, the epitaxial source and drain regions 34 can comprise, e.g., silicon germanium (SiGe), and when forming an NFET device, the epitaxial source and drain regions 34 can comprise, e.g., silicon carbide (SiC). The nitride and oxide capping layers 18 and 20 can then be removed to allow metal silicide contact areas and then metal contacts to be formed on the gate conductor 16 and the epitaxial source and drain regions 34 . One method that can be employed to remove the capping layers 18 and 20 can be through the use of an isotropic etch that also removes the dielectric spacers 22 , which can be reformed as described previously. On the other hand, the capping layers 18 and 20 can be removed using an RIE process.
[0023] FIGS. 7-12 illustrate a second exemplary embodiment of a method for fabricating stress enhanced FET devices. As shown in FIG. 7 , a gate dielectric layer 54 , a gate conductor layer 56 , an oxide capping layer 58 , and a nitride capping layer 60 can be formed upon a semiconductor substrate 50 in the same manner as described in the first embodiment. The shown section of the semiconductor substrate 50 can be isolated from other areas of the substrate 50 by, e.g., trench isolation regions 52 . Next, the gate dielectric layer 54 , the gate conductor layer 56 , and the capping layers 58 and 60 can be patterned using lithography and an anisotropic etch technique to form the gate conductor structure shown in FIG. 8 . It is recognized that the gate dielectric 54 could alternatively be patterned later during a later stage of the fabrication method. Dielectric spacers 62 can further be formed on the sidewall surfaces of the gate conductor 56 in the same manner as described in the first embodiment.
[0024] Turning now to FIG. 9 , a deep ion implantation process (illustrated by arrows 64 ) can be used to form etch stop regions 66 in the semiconductor substrate 50 a spaced distance below the surface of the substrate 50 in the same manner that the etch stop regions are formed in the first embodiment except that a higher implantation energy is employed. That is, p-type species, n-type species, or an electronically inactive species can be implanted in regions of the substrate 50 below where source and drain regions are to be subsequently formed. By way of example, B can be implanted at an implantation energy of about 10 keV to about 100 keV and a dosage of about 2×e 14 ions/cm 2 to about 2×e 15 ions/cm 2 , more specifically about 5×e 14 ions/cm 2 to about 2×e 15 ions/cm 2 . Similarly, BF 2 can be implanted at an energy of about 10 keV to about 100 keV and a dosage of about 2×e 14 ions/cm 2 to about 1×e 15 ions/cm 2 , more specifically about 5×e 14 ions/cm 2 to about 1×e 15 ions/cm 2 . In one particular embodiment, B can be implanted at an energy of about 25 keV and a dosage of about 1×e 15 ions/cm 2 . At this point, the gate dielectric 54 can be removed from above regions of the substrate 50 outside of the dielectric spacers 62 if not previously removed.
[0025] As illustrated in FIG. 10 , the exposed surfaces of the substrate 50 can be subjected to an isotropic wet etch selective to silicon to form recessed regions 68 . For example, the substrate 50 can be contacted with a hydroxide etchant such as TMAH, NH 4 OH, NaOH, KOH, etc. As shown in FIG. 11 , this etch of substrate 50 can be continued for a time effective to extend recessed regions 68 well below the substrate surface and to undercut dielectric spacers 62 , thereby defining a channel region 70 having undercut areas. Due to the isotropic nature of the etch, the sidewalls 72 of the channel region 70 become slanted in an outward direction from the surface of the channel region 70 toward the base of recessed regions 68 . The doped etch stop regions 66 can inhibit etching of those areas of substrate 50 beneath recessed regions 68 , while the oxide and nitride layers 18 and 20 can protect the gate conductor 16 from being etched.
[0026] As shown in FIG. 12 , epitaxially grown source and drain regions 74 can then be formed in the recessed regions such that they extend laterally under the dielectric spacers 62 into the undercut areas of the channel region 70 . The epitaxial growth can be performed at a temperature of about 500° C. to about 900° C. and a pressure of about 1 Torr to about 100 Torr using precursors such as SiH 4 , SiH 2 Cl 2 , GeH 4 , HCl, B 2 H 6 , SiH 3 CH 3 , etc. In a preferred embodiment, the epitaxial growth is performed at a temperature of about 700° C. and a pressure of about 10 Torr. When forming a PFET device, the epitaxial source and drain regions 74 can comprise, e.g., SiGe, and when forming an NFET device, the epitaxial source and drain regions 74 can comprise, e.g., SiC. The nitride and oxide capping layers 58 and 60 can then be removed in the same manner as described in the first embodiment to allow metal silicide contact areas and then metal contacts to be formed on the gate conductor 56 and the epitaxial source and drain regions 74 .
[0027] As used herein, the terms “a” and “an” do not denote a limitation of quantity but rather denote the presence of at least one of the referenced items. Moreover, ranges directed to the same component or property are inclusive of the endpoints given for those ranges (e.g., “about 5 wt % to about 20 wt %,” is inclusive of the endpoints and all intermediate values of the range of about 5 wt % to about 20 wt %). Reference throughout the specification to “one embodiment”, “another embodiment”, “an embodiment”, and so forth means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the embodiment is included in at least one embodiment described herein, and might or might not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments. Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this invention belongs.
[0028] While the preferred embodiment to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described. | Stress enhanced transistor devices and methods of fabricating the same are provided. In one embodiment, a transistor device comprises: a gate conductor disposed above a semiconductor substrate between a pair of dielectric spacers, wherein the semiconductor substrate comprises a channel region underneath the gate conductor and recessed regions on opposite sides of the channel region, wherein the recessed regions undercut the dielectric spacers to form undercut areas of the channel region; and epitaxial source and drain regions disposed in the recessed regions of the semiconductor substrate and extending laterally underneath the dielectric spacers into the undercut areas of the channel region. | 7 |
BACKGROUND
[0001] The invention relates to a fabrication method for a printed circuit board (PCB), and more particularly to a method of plating a metal layer of the PCB.
[0002] PCBs, such as substrates for ball grid array (BGA) packages, generally have exposed pads or fingers for connection to an external device.
[0003] In FIG. 1 , a top view of an exemplary portion of a PCB for a BGA substrate is shown. Fingers 140 are disposed in a chip attachment area 120 . Trace lines 150 on a top surface respectively extend from fingers 140 to vias 160 and electrically connect to pads 130 on a bottom surface using trace lines on the bottom surface. A bus line 180 , disposed at an edge of the PCB, electrically connects to trace lines 150 , fingers 140 , and pads 130 using branch plating lines 181 . The pads 130 , fingers 140 , trace lines 150 , bus line 180 , and branch plating lines 181 are typically copper. The pads 130 and fingers 140 are typically exposed for electrical connection to external devices (not shown). The pads 130 and fingers 140 are usually plated with a Ni/Au layer (not shown) by electrical plating such that current flows to every pad 130 and finger 140 using bus line 180 and branch plating lines 181 to protect the exposed pads 130 and fingers 140 from oxidation.
[0004] The connections between respective trace lines 150 and bus lines 180 are cut step to separate an encapsulated package from the PCB. The branch lines 181 , however, remain in the package.
[0005] Due to the demand for small-aspect, light and powerful electronic products, PCB design rules demand layouts with increased density, resulting in increased overall density and reduced pitch in the remaining branch lines 181 , and increased distribution density of the vias 160 . The vias 160 suffer from the increased wiring density as follows:
[0006] Via size decreases with increased wiring density, resulting in difficulty drilling, electroplating through holes to form the vias, with increased aspect ratio of the through holes negatively affecting the product reliability, and decreased durability of the vias.
[0007] Moreover, crosstalk resulting from mutual inductance and capacitors between the branch lines 181 may not only negatively affect transmission of electrical signals and system stability, but also deviate character impedances of trace lines 150 , thereby further negatively affecting the electrical performance of an end product using the PCB.
SUMMARY
[0008] Thus, embodiments of the invention provide PCBs and methods for fabricating the same, capable of reducing density of remaining plating lines to improve electrical performance of end products using the PCB, maintaining via size when increasing wiring density of the PCB to simplify drilling and electroplating for via formation and improve via reliability, and electrically isolating the plating line from the trace line and pads when completing electroplating to prevent the plating line negatively affecting electrical performance of other parts of the wiring.
[0009] Embodiments of the invention provide a fabrication method for PCBs. First, a substrate, comprising a layout area and a periphery area on a surface, is provided. A patterned wiring layer, comprising a bus line in the periphery area, a via in the layout area, at least one pad in the layout area, a plating line electrically connecting the bus line and the via, and a trace line electrically connecting the via and the pad, is then formed overlying the substrate. A metal layer is further formed overlying the pad. Finally, the via is separated into a plurality of sub-vias electrically isolated from each other. The sub-vias connect to at least the plating line or the trace line.
[0010] Embodiments of the invention further provide a printed circuit board (PCB). The PCB comprises a substrate and a patterned wiring layer. The substrate comprises a layout area and a periphery on a surface. The patterned wiring layer overlies the substrate. The wiring layer further comprises a bus line, at least one pad, a separated via, a plating line and at least one trace line. The bus line is disposed in the periphery area. The at least one pad comprises a metal layer thereon and is disposed in the layout area. The separated via comprises a plurality of sub-vias electrically isolated from each other and is disposed in the layout area. The plating line electrically connects the bus line and the via. The at least one trace line electrically connects the sub-vias and the at least one pad.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Embodiments of the invention can be more fully understood by reading the subsequent detailed description in conjunction with the examples and references made to the accompanying drawings, wherein:
[0012] FIG. 1 is a top view of a conventional PCB.
[0013] FIGS. 2A, 2B , and 2 D through 2 I are top views of fabrication methods of PCBs of exemplary embodiments of the invention.
[0014] FIG. 2C is a cross-section of a via of PCBs of exemplary embodiments of the invention.
DETAILED DESCRIPTION
[0015] The following embodiments are intended to illustrate the invention more fully without limiting the scope of the claims, since numerous modifications and variations will be apparent to those skilled in this art.
[0016] FIGS. 2A through 2I show exemplary embodiments of PCBs of the invention and methods for fabricating the same.
[0017] As shown in FIG. 2A , a substrate 200 , such as a core substrate comprising fiber-reinforced or particle-reinforced materials such as epoxy resin, bismaleimide triazine-based (BT), Cyanate ester, or other materials, is provided. The substrate 200 may also be a core substrate plated with patterned wiring with an overlying dielectric layer. One surface of substrate 200 , such as that for connection to an external device, has a periphery 201 and layout area 202 .
[0018] FIGS. 2B through 2I illustrate an exemplary portion of the PCB of the invention. In practice, the quantity, shape, and size of the elements shown in the figures may be modified.
[0019] In FIG. 2B , a wiring layer 210 is formed overlying the surface of substrate 200 . A metal layer formed overlying substrate 200 , followed by patterning of the metal layer, forms wiring layer 210 . The metal layer is copper, tin, nickel, chrome, titanium, copper-chrome alloy, or tin-lead alloy. Alternatively, the wiring layer can be formed by physical vapor deposition such as sputtering or metal-organic chemical vapor deposition (MOCVD) directly in a predetermined pattern. In wiring layer 210 , a bus line 211 is disposed in the periphery 201 (shown in FIG. 2A ) of substrate 200 , a via 212 is disposed in the layout area 203 , a conductive finger 215 is disposed in the layout area 203 , a plating line 213 electrically connects the bus line 211 and the via 212 , and a trace line 214 electrically connects the via 212 and the conductive finger 215 .
[0020] An exemplary via 212 is shown in FIG. 2C . Formation of via 212 includes a through hole 220 formed in the substrate 200 by a method such as laser drilling or mechanical drilling, followed by conformal formation of a copper seed layer 222 overlying the substrate 200 and the through hole 220 utilizing electroless plating. A mask layer such as a resist layer or dry film, comprising an opening exposing the seed layer 222 on sidewalls of the through hole 222 , is formed overlying the substrate 200 by a method such as stencil printing, spin coating, or laminating. Next, a copper layer 228 is formed overlying the seed layer 222 by electroplating, providing electrical connection of the subsequently formed wiring layer and the underlying circuitry, followed by removal of the mask layer. Finally, the via 212 is filled with a dielectric plug 230 . Subsequently, the metal layer 228 overlying the substrate 200 is patterned to form a wiring layer.
[0021] In FIG. 2B , an anti-oxidation layer is formed overlying the conductive finger 215 by electroplating utilizing current through electrical connection of the plating line 213 , via 212 , and trace line 214 . Two exemplary methods for forming the anti-oxidation layer follow.
EXAMPLE 1 OF FORMATION OF THE ANTI-OXIDATION LAYER
[0022] FIGS. 2D through 2G show exemplary methods for forming the anti-oxidation layer for PCBs, following that shown in FIG. 2B . In FIG. 2D , a patterned solder mask 230 is formed overlying the substrate 200 (shown in FIG. 2A ). The solder mask 230 comprises an opening 231 exposing the bus line 211 and an opening 232 exposing the conductive finger 215 . The openings 231 and 232 are formed by a method such as photolithography or laser drilling.
[0023] In FIG. 2E , the substrate 200 is immersed in an electro-bath, followed by supply of current to exposed conductive finger 215 from bus line 211 via plating line 213 and via 212 sequentially. Thus, an anti-oxidation layer 250 , of gold, nickel, palladium, silver, tin, nickel/palladium, chrome/titanium, nickel/gold, palladium/gold, or nickel/palladium/gold, is plated overlying the bus line 211 exposed by the opening 231 and the conductive finger 215 exposed by the opening 232 .
[0024] In FIG. 2F , the solder mask 230 is shown transparently, revealing the underlying wiring layer 210 . A mechanical drill or laser drill at the solder mask side cuts the via 212 along line a-a to separate the via 212 into two electrically isolated sub-vias 212 a and form two isolation trenches 216 on the via 212 , exposing parts of sidewalls of the through hole and a bottom layer 234 . One sub-via 212 a connects to the plating line 213 , and the other connects to the trace line 214 .
[0025] In FIG. 2G , the solder mask 230 is shown transparently, revealing the underlying wiring layer 210 . The isolation trenches 216 and via 212 are filled with an insulating material 236 .
EXAMPLE 2 FOR FORMATION OF THE ANTI-OXIDATION LAYER
[0026] FIGS. 2D through 2G show another exemplary methods for forming the anti-oxidation layer for PCBs, following that shown in FIG. 2B . In FIG. 2D , a patterned resist layer 230 ′ is formed overlying the substrate 200 (shown in FIG. 2A ). The resist layer 230 ′ comprises an opening 231 ′ exposing the bus line 211 and an opening 232 ′ exposing the conductive finger 215 . The openings 231 and 232 are formed by a method such as photolithography or laser drilling.
[0027] In FIG. 2E , the substrate 200 is immersed in an electro-bath, followed by supply of current to exposed conductive finger 215 from bus line 211 via plating line 213 and via 212 sequentially. Thus, an anti-oxidation layer 250 , of gold, nickel, palladium, silver, tin, nickel/palladium, chrome/titanium, nickel/gold, palladium/gold, or nickel/palladium/gold, is plated overlying the bus line 211 exposed by the opening 231 ′ and the conductive finger 215 exposed by the opening 232 ′.
[0028] In FIG. 2F , the patterned resist layer 230 ′ is removed by a method such as etching, exposing the underlying wiring layer 210 . A mechanical drill or laser drill at the solder mask side cuts the via 212 along line a-a to separate the via 212 into two electrically isolated sub-vias 212 a and form two isolation trenches 216 on the via 212 , exposing parts of sidewalls of the through hole and a bottom layer 234 . One sub-via 212 a connects to the plating line 213 , and the other connects to the trace line 214 .
[0029] In FIG. 2G , the solder mask 230 is shown transparently, revealing the underlying wiring layer 210 . The isolation trenches 216 and via 212 are filled with an insulating material 236 , followed by forming a solder mask (not shown) overlying the substrate 200 , exposing the conductive finger 215 .
[0030] FIGS. 2H and 2I show an alternative embodiment, following that shown in FIG. 2A , of PCBs of the invention and methods for fabricating the same.
[0031] In FIG. 2H , a wiring layer 310 is formed overlying the surface of substrate 200 , comprising a metal layer formed overlying substrate 200 , followed by patterning of the metal layer. The metal layer is copper, tin, nickel, chrome, titanium, copper-chrome alloy, or tin-lead alloy. Alternatively, the wiring layer 310 can be formed by physical vapor deposition such as sputtering or metal-organic chemical vapor deposition (MOCVD) directly in a predetermined pattern. In wiring 310 , a bus line 311 is disposed in the periphery area 201 (shown in FIG. 2A ) of substrate 200 , a via 312 is disposed in the layout area 203 , three conductive fingers 315 are disposed in the layout area 203 , a plating line 313 electrically connects the bus line 311 and the via 312 , and three trace lines 314 electrically connect the via 212 and the respective conductive fingers 315 .
[0032] Formation of the via 312 is substantially the same as the description in FIG. 2C , and thus, is omitted herefrom. Further, an anti-oxidation layer 350 is formed respectively overlying the conductive fingers by electroplating utilizing electrical connection of the plating line 313 , via 312 , and trace lines 314 . Exemplary methods for forming the anti-oxidation layer 350 are substantially the same as the descriptions for FIGS. 2D through 2G , and thus, are omitted herefrom.
[0033] FIG. 2I shows separation of the via 312 of this embodiment. A mechanical drill or laser drill cuts the via 312 along lines b-b and c-c to separate the via 312 into four electrically isolated sub-vias 312 a and form four isolation trenches 316 on the via 312 , exposing parts of sidewalls of the through hole and a bottom layer 334 . One sub-via 312 a connects to the plating line 313 , and the others respectively connect to the trace lines 314 , followed by filling an insulating material 336 in the trenches 316 and the via 312 .
[0034] As described, the invention discloses the via 212 electrically connecting to the trace line 214 and the via 312 electrically connecting to the trace lines 314 . Thus, at least one plating line 213 is required to connect the via 212 and bus line 211 , and at least one plating line 313 is required to connect the via 312 and bus line 311 . Current may flow to finger 250 in the trace line 214 via the plating line 213 and the via 212 , and to fingers 350 in the corresponding trace lines 314 via the plating line 313 and the via 312 to respectively electroplate the anti-oxidation layers 250 and 350 overlying the conductive fingers 215 and 315 . Finally, only one plating line 213 / 313 remains, which does not negatively affect the electrical performance of end products utilizing the PCBs of the invention.
[0035] Further, the invention discloses the via 212 separated into two sub-vias 212 a and the via 312 separated into four sub-vias 312 a to replace the reduced via of the known art, increasing the wiring density of the PCBs, and electrically isolating the plating line 213 from the trace line 214 and the pad 215 , and the plating line 313 from the trace lines 314 and the pads 315 . The separation of the vias 212 and 312 simplifies the drilling and electroplating of the vias 212 and 312 , improving via reliability and simplifying the electrical isolation process for the plating line.
[0036] As shown in FIG. 2I , the PCB of an exemplary embodiment of the invention comprises a substrate 200 and a patterned wiring layer 310 overlying a surface of the substrate 200 . The substrate 200 comprises a layout area 203 and a periphery 201 on the surface. The wiring layer 310 is copper, tin, nickel, chrome, titanium, copper-chrome alloys, or tin-lead alloys.
[0037] The wiring layer 310 further comprises a bus line 311 , a plurality of conductive fingers 315 , a separated via 312 , a plating line 313 and at least one trace line 314 . The bus line 311 is disposed in the periphery area 203 . The conductive fingers 315 respectively comprise an anti-oxidation layer 350 thereon and are disposed in the layout area 203 . The anti-oxidation layer 350 is gold, nickel, palladium, silver, tin, nickel/palladium, chrome/titanium, nickel/gold, palladium/gold, or nickel/palladium/gold. The separated via 312 comprises a plurality of electrically isolated sub-vias 312 a and is disposed in the layout area 203 . The plating line 313 connects the bus line 311 and the sub-vias 312 a . One sub-via 312 a connects to the plating line 313 , and the others respectively connect to different trace lines 314 . The at least one trace line 314 electrically connects the sub-vias 312 a and the conductive fingers 315 .
[0038] The via 312 comprises isolation trenches 316 on either side of the sub-vias 312 a . The sub-vias 312 a connect to at least the plating line 313 or the at least one trace line 314 . The plating line 313 preferably connects the bus line 311 and one of the sub-vias 312 a . Further, the sub-vias 312 a and the isolation trenches 316 are filled with an isolating material 336 .
[0039] Thus, the invention discloses separation of the via into a plurality of sub-vias to replace the reduced via of the known art, increasing the wiring density of the PCBs and simplifying the drilling and electroplating of the vias to improve via reliability. Moreover, only one plating line remains, with no negative affect on the electrical performance of end products utilizing the PCBs of the invention. The invention improves via reliability with increased wiring density and electrical performance.
[0040] While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. It is therefore intended that the following claims be interpreted as covering all such alteration and modifications as fall within the true spirit and scope of the invention. | Printed circuit boards and methods for fabricating the same. A via in a printed circuit board electrically connects to trace lines of the PCB, such that only one plating line is required to electrically connect a plating bus and the plating through hole. Thus, in an electroplating step, current can flow to fingers in the trace lines to plate an anti-oxidation metal layer thereon. The via is separated into several sub-vias to electrically isolate the plating line from trace lines and fingers, each of which connects to the plating line or the trace lines. Finally, at least one plating line remains, thus avoiding negative impact on electrical performance of an electronic device that uses the printed circuit board. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to a warp knitting machine in which the knitting elements and each warp beam are driven by their own electric motors, powered from a common network.
Such a drive for a warp knitting machine is described in German Pat. No. 30 25 782. That patent publication points out that when a power failure occurs in the network, the main shaft of the machine and the parts connected with it come to a standstill only after a certain delay, because of their mass, while the drive of the warp beam or the drives of the warp beams are stopped relatively quickly. This means that all of the warp yarns of all of the warp beams can break. To eliminate this danger, the cited patent publication describes a switching mechanism in which the main shaft of the machine is equipped with an electrically controlled brake which moves from its disengaged position to its braking position under the influence of a stored braking force. This results in the main shaft coming to a stand-still in much less time, almost jerkily, so that breaking of the warp yarns is avoided. Because of the considerable masses involved with the main shaft, this almost jerky braking of the main shaft imparts great stresses upon the machine parts, and this, in turn, can lead to internal shifting in the machine and even to damage. The patent publication also discusses this stressing of the machine, specifically by indicating an additional switch to disengage the above-described brake in case of a normal shut-down process, so that the almost jerky stopping of the main shaft is avoided in this normal procedure. It is, however, impossible to eliminate the stress to the machine which results in case of network power failure.
It should also be noted here that U.S. Pat. No. 2,625,021 discloses an electrically engaged clutch in connection with a warp knitting machine wherein the force which drives the warp beam is derived from the main shaft. Here, the setting of a more or less powerful slaving force via the clutch ensures the maintenance of thread tension at its normal level by imparting more or less powerful driving force to the warp beam when yarn tension is altered.
SUMMARY OF THE INVENTION
It is an object of the instant invention to remove the danger of breakage to which the warp yarns are exposed when a power failure occurs in the network, without subjecting the machine to significant stresses. This is achieved according to the invention by installing an electrically engaged clutch connected to the drive between each warp beam and its electric motor, said clutch being connected to the power network and being engaged by the network current and disengaged when said network current fails.
This clutch is disengaged when a power failure occurs in the network. The interruption of the drive connection between the electric motor and the warp beam eliminates the danger of warp yarns breaking, since the warp beam or beams can continue rotating without difficulty as a result of the traction exerted on them by the knitting elements until said knitting elements are, in turn, stopped when the main shaft stops. In this case, the main shaft can slow down under the effect of its moment of inertia, so that said main shaft and the structural elements to which it is connected are not submitted to any significant stresses. This drive method has been proven through experience to be entirely without danger for the warp yarns because the warp beam is already rotating at this stage of the operation. The friction forces to which it is subjected are always kept as low as possible thanks to its bearing supports, so that the warp yarns still being pulled by the knitting elements can easily rotate the warp beam. This friction can also be entirely desirable, especially if the warp beam is out of balance, since it counters the tendency of said warp beam to continue its rotation because of this imbalance.
Another considerable advantage of interrupting the drive connection between the electric motor and the warp beam resides in the fact that knitting elements, which at first continue to operate when current ceases to flow, automatically bring about the necessary synchronization of the main shaft with the warp beam or beams because of the traction they exert upon the warp yarns and, through them, upon the warp beams, without any special means being required to achieve this. According to the state of the art discussed earlier, this synchronization is hindered in case of the almost jerky stopping of the main shaft, since it must be assumed that the drives of the warp beams stop immediately. For this reason, a preferred embodiment is referred to in German Pat. No. 30 25 782 in which the number of the main shaft's drift revolutions is limited to one or two.
In this manner, the high speed at which the main shaft is braked makes it possible to approach a synchronization of the main shaft with the warp beams, but this is achieved at the cost of subjecting the machine to stress because of the braking speed. By purposely allowing the main shaft to drift in case of a cessation of current flow by providing the further measure of interrupting the drive connection between the electric motor and the warp beam, with the resulting synchronization of the main shaft with the warp beam, the instant invention differentiates itself fundamentally from the principle disclosed in German Pat. No. 30 25 782.
Due to the fact that the warp beam of a warp knitting machine revolves very slowly, a step-down gear is built into the drive connection between the warp beam and its electric motor to adapt the different rotational speeds of the electric motor and motor and warp beam to each other. When an electric motor is now used as a drive at a relatively high speed, the step-down gear can bring about self-locking within the gearing, i.e. the gearing is unable to transmit torque in a direction opposite to the drive direction. This self-locking property prohibits any reverse driving. In such an embodiment, the clutch is installed in the power transmission area, between the warp beam and the self-locking zone. The knitting elements which continue to operate when a power failure occurs in the network continue exerting a pull upon the warp yarns and thereby continue rotating the warp beam without the self-locking feature taking effect, since the clutch separates the warp beam from the self-locking zone if it is disengaged.
Especially when elastic warp yarns are processed, it is possible for these warp yarns to continue exerting such pull upon the warp beam when the knitting elements stop moving that said warp beam continues to rotate for a while, so that the warp yarns finally hang down without tension. The moment of inertia of the warp beam also play a role in this case. Such a dangling of the warp yarns is undesirable because they can become tangled when the warp knitting machine starts up once more. In order to eliminate this danger in advance, it is possible to install a brake in the power transmis zone between the clutch and the warp beam, said brake being set so that in case of power failure the warp beam slows down while tolerable yarn tension is maintained. Since the brake is set to merely maintain a minimum of yarn tension, very little brake action is needed here, and therefore, the brake requires practically no additional energy consumption.
If the energy consumption caused by the brake is undesirable it can be eliminated by allowing the brake to engage only once the clutch has been disengaged.
The clutch can effectively be used as a brake by giving it such spring tension, acting in the direction of engagement, that the clutch acts as a brake when a power failure occurs. When the clutch is engaged under the influence of the network current flow, the brake does not even enter the picture since the clutch ensures power transmission without slippage in that case.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention is represented in the figures, in which:
FIG. 1 is a perspective view of the warp knitting machine of the invention, incorporating a warp beam and separate electric motor drives for the main shaft and for the warp beam; and
FIG. 2 is a detailed sectional view of the clutch of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The warp knitting machine shown in FIG. 1 consists of a machine frame 1, traversed by the main shaft 2, which drives the knitting elements (not shown). A warp beam 3 is supported by its axle 4 on the machine frame 1. The warp knitting machine can be equipped with several warp beams in a known manner. The warp yarns 5 are drawn off from the warp beam 3 and are guided to the knitting elements via yarn tensioning bar 6.
The main shaft 2 is driven via the two pulleys 7 and 8 and by the toothed belt 9 which runs around them. Pulley 8 is driven by the electric motor 10 which is the drive ensuring rotation of the main shaft 2.
The warp beam 3 is driven via the two pulleys 12, 11 about which toothed belt 13 runs. Pulley 12 is keyed on shaft 14 which extends into a clutch, represented schematically here by the two clutch disks 15 and 16, which face each other. When the two clutch disks 15 and 16 are pushed together, the clutch is engaged. In FIG. 1, the two clutch disks are shown as being apart to show that the clutch can assume a disengaged position in which said clutch interrupts the drive. The clutch disk 16 is keyed on shaft 17 which supports the worm gear 18. The worm gear 18 engages the endless screw 29, secured to the shaft of the electric motor 20 which is the drive motor of the warp beam 3.
In normal operation, the speeds of the two electric motors 10 and 20 are synchronized with each other through adjustment (in a known manner) so that the speed of the warp beam 3 is adjusted for the amount of warp yarn dictated by the operation of the knitting elements. Both of the electric motors 10 and 20 are connected to the same power network so that both stop in case of power failure. Because of the masses connected with the main shaft 2, the latter continues to rotate for a certain time span, whereby the knitting elements it drives, continue to draw the warp yarns 5 from the warp beam 3.
When current ceases to flow in the network, motor 20 stops earlier than motor 10, in particular because it is not connected with any great gyrating masses rotating at a high speed. To prevent the stopping of motor 20, occurring as it does earlier than the stopping of motor 10, from causing breakage of the warp yarns 5, a clutch consisting of clutch disks 15 and 16 is provided and is also connected to the power network as an electrically activated clutch. The clutch is fashioned so that it is engaged by the flow of network current and therefore disengages when a cessation of current flow occurs. When the current is on, the two clutch disks 15 and 16 are therefore pushed together so as to transfer torque from shaft 17 to shaft 14. In case of cessation of current flow, the clutch is disengaged so that shaft 14, belt pulleys 12 and 11 as well as the warp beam 3 can continue to rotate freely. At the same time, the continued pull exerted by the knitting elements upon the warp yarns 5 causes the warp beam to continue rotating, and to thus act to a certain extent as a reverse drive, slaving the clutch disk 15, thus rotated in relation to the stopped clutch disk 16, via belt pulleys 11 and 12 and toothed belt 13 as it slows down.
It should be pointed out here that design details of the clutch are shown in FIG. 2, which shall be discussed below.
The disengagement of the clutch consisting of clutch disks 15 and 16 in case of a cessation of current flow, thus makes it possible for the knitting elements, driven by the drifting main shaft 2, to draw off the warp yarns 5 from the warp beam 3 at a slowing pace without breakage of the warp yarns 5, since the pull exerted by said warp yarns 5 upon the warp beam 3 is entirely sufficient to cause its slowly drifting rotation. The required synchronization of the rotation of main shaft 2 with that of the warp beam 3 is obtained automatically by the pull exerted upon the warp yarns and the resulting slaving of warp beam 3, unhindered in its drifting rotation.
FIG. 2 shows an electrically activated clutch which can take the place of the clutch formed by clutch disks 15 and 16 of FIG. 1. According to FIG. 2, the worm gear 18 is keyed on shaft 21 (which corresponds to the shaft 17 of FIG. 1). The worm gear 18 is fixedly and non-slidably attached to shaft 21 by means of key 22. Worm gear 18 engages endless screw 19 which is driven by motor 10 as shown in FIG. 1. Furthermore, clutch disk 16 is seated on shaft 21 and is fixedly and non-slidably attached to shaft 21 by means of key 23. Opposite clutch disk 16 is clutch disk 15 which can be shifted in axial direction and which is equipped with the friction lining 24. When clutch disks 15 and 16 are pushed together with sufficient force, the lining 24 causes their mutual slaving. Clutch disk 15 is supported along shaft 21 on the bearings 25 which impart mobility to the coupling disk 15 in relation to shaft 21 so that the clutch disk 15 can be shifted in the axial direction with respect to the shaft 21 and can also be rotated with respect to said shaft 21. Pulley 12 is keyed on clutch disk 15 in fixed attachment to clutch disk 15 so that when clutch disk 15 rotates the pulley 12 is slaved and thus drives the toothed belt 13 in the manner shown in FIG. 1.
An electric magnet 26 with a magnetizing coil 27 is located within range of clutch disk 16, whereby the electric magnet 26 is held in its position by the bearing plate 28. A gap 29 is provided between the electric magnet 26 and the clutch disk 16 to ensure that free rotation of the clutch disk 16 in relation to electric magnet 26 is possible. This is a known design of an electrically activated clutch. When the magnetizing coil 27 is excited (connection to the power source) the magnetic field it generates pulls the clutch disk 15 against clutch disk 16, causing the clutch to be engaged. This is a process which is also known in electrically activated clutches. In case of cessation of current flow, however, clutch disk 15 is released (the effect of the pressure spring 30 shown in FIG. 2 shall be disregarded for the time being), so that the clutch disk 15 no longer presses against clutch disk 16, whereby the clutch is functionally disengaged. In this operation position, shaft 21 can stop rapidly while clutch disk 15 can rotate freely in relation to shaft 21. The warp beam 3 which drifts in this case and acts as a reverse drive according to FIG. 1, can thus drive pulley 12 and thereby clutch disk 15 in slow rotation until the warp beam 3 has drifted to a stop.
FIG. 2 furthermore shows pressure spring 30 which bears on one side against ring 31 which is fixedly seated on shaft 21 and bears on the other side against clutch disk 15. Pressure spring 30 is adjusted so that it pushes clutch disk 15 against clutch disk 16 with light pressure only. This weak pressure of pressure spring 30 causes weak friction to occur between friction lining 24 and clutch disk 16, acting here as a brake, in case that clutch 16 stops while clutch disk 15 continues to rotate. This friction brakes the rotation of clutch disk 15 so that a driven warp beam 3, which at first continues to rotate, is suitably braked and slowly stops. Prestressing of the pressure spring 30 is adjusted so that the braking action which it provokes does not expose the warp yarns 5 to excessive pull. To adjust the prestressing of the pressure spring 30, it is also possible to install ring 31 over spline 32 so that it is axially adjustable. Depending upon the axial position of ring 31, the degree of presetting of pressure spring 30 and thereby, the force with which a drifting warp beam 3 is braked will be more or less strong. In this design, the function of the clutch is thus combined with the function of the brake by utilizing the same construction elements. The brake therefore prevents the drifting warp beam 3 from "overrunning" the drifting main shaft 2.
In the embodiment shown in FIG. 2, the step-down ratio between endless screw 19 and shaft 21 is so great that the drive element constituted by endless screw 19 and worm gear 18 possesses a self-locking property which prevents rotation of the shaft 21 when the endless screw 19 comes to a stop. The self-locking zone lies in the engagement of worm gear 18 by endless screw 19. If the warp beam 3 could not be freed from the driving force of shaft 21 by such a self-locking effect, this would result, in case of cessation of current flow and continued draw-off of warp yarns 5, in the warp beam 3 being unable to follow this pull so that the warp yarns 5 would break. This breakage is prevented by consisting of clutch disks 15 and 16.
It will be understood, of course, that while the form of the invention herein shown and described constitutes a preferred embodiment of the invention, it is not intended to illustrate all possible form of the invention. It will also be understood that the words used are words of description rather than of limitation and that various changes may be made without departing from the spirit and scope of the invention herein disclosed. | This invention relates to a warp knitting machine in which the knitting elements and each of the warp beams are driven by separate electric motors, powered from a common electrical network. An electric clutch is included in the drive connection between each warp beam and its electric motor and said clutch is energized by the same electric network which powers the electric motors. The electric clutch is energized when electric current is supplied to it by the network and connects the warp beams with their own electric motors. Whenever the electric current in the network is interrupted, the electric clutch is disengaged. | 3 |
[0001] This application claims benefit of Provisional Application Ser. No. 61/701,387, filed Sep. 14, 2012 and entitled “Finger Armor”, and Provisional Application Ser. No. 61/770,228, filed Feb. 27, 2013 and entitled “Device for protecting hands in martial arts”, the disclosures of both applications being incorporated herein by this reference.
BACKGROUND OF THE INVENTION
[0002] Martial artists use board breaking as a method to demonstrate various attributes such as proper technique, power, targeting and speed among others. Board breaking is used in rank advancement testing, competitions, and even setting Guinness™ world records. Breaking boards requires one or more fellow students to hold the board (referred to as “holders”) for the student performing the technique (referred to as a “breaker”). While hand techniques are usually very accurate, foot techniques used in board breaking are usually not very accurate. High speed breaking techniques, particularly kicks, can cause noticeable injury to the target board holder's(s') hands and fingers due to poor targeting by the breaker. Once struck/injured, a holder is likely to “flinch” or move the board/target on subsequent attempts, increasing the difficulty of successfully breaking the board/target.
[0003] Prior art attempts at providing some hand protection have been generally unsuccessful, for example, benefitted only the holder, or compromising between benefitting the breaker and benefitting the holder to the point that neither attempt at protection has worked. A prior art attempt at providing hand protection is illustrated by the sheath ( 12 ) in U.S. Pat. No. 4,807,302 by Cannella. A prior art product very similar to the disclosure of Cannella, and marked in the past with the Cannella patent number, has been and is commercially available, but it does not include the spikes 14 shown in the Cannella drawings. Other prior art attempts at hand protection include the holders' wearing of padded gloves.
[0004] Increased Chance of Injury:
[0005] The inventors believe, in order to avoid or minimize the chance of injury, a holder should hold a board/target with the hand and fingers generally in the position shown by the bare-hand portrayal in FIG. 1A . This places the metacarpophalangeal joints (“knuckles” K) directly adjacent to (directly above in the drawing) the edge of the board B and at or very close to the central plane CP of the board. Further, the inventors prefer that the hand and forearm lie in positions wherein the heel H of the palm is slightly distanced from the board (see P 1 ) and closer to the outer perimeter edge E of the board, rather than being closer to the central region CB of the board, which is understood to be below FIG. 1A . Note the curved dashed line in FIG. 1A that indicates that many martial arts boards have a non-planar rear surface, due to the outer perimeter edges being the thickest portion of the board and the central region being of lesser thickness and/or having break joints. The front surface of martial arts boards are typically planar, represented by the front plane FP in FIG. 1A .
[0006] These preferred hand and forearm positions may be described as the hand/wrist being rotated into the position in FIG. 1A from the position of FIG. 1B , which for these figures is a counterclockwise rotation. Note that, in FIG. 1B , the knuckles K are behind the central plane and the rear surface of the board, and the heel H of the palm is pressed against the board and closer to the center region CB of the board.
[0007] The preferred position results in an angle between the main portion of the hand (and/or the palm) and the forearm is a large obtuse angle O 1 and small supplementary angle A 1 . The inventors prefer an angle O 1 of greater than or equal to 135 degrees and a corresponding supplementary angle A 1 of equal to or less than 45 degrees. Possible ranges for the obtuse angle O 1 may be, for example, 135-160 degrees, or especially about 135-155 degrees. Possible ranges for the acute angle A 1 may be, for example, 45-20 degrees, or especially 45-25 degrees.
[0008] The Cannella sheath CAN-S and said prior art commercial product COMM, on the other hand, are adapted to hold the fingers, hand, and wrist in positions substantially similar to those portrayed by the bare-hand holding the board in FIG. 1B . When the Cannella CAN-S and commercial product COMM are used, as shown in FIGS. 2A and 3A , respectively, the fingers, hand, and wrist positions stay similar to those in FIG. 1B . FIGS. 2A and 3A show that the fingers inside the Cannella/commercial-product, up to about the proximal inter-phalangeal joint (that is, the distal phalanx and the middle phalanx), lie parallel to and close to the front plane FP and the central plane CP of the board/target.
[0009] When inside the Canella sheath CAN-S, as shown by FIG. 2A , the fingers' distal phalanx and the middle phalanx are parallel to the board, distanced evenly all along their lengths from the front surface of the board by spikes (“ 14 ” in Cannella) and by the thickness of the underside (“ 18 ” in Cannella) of the sheath. Note, too, in FIG. 2A , that the metacarpophalangeal joints (knuckles K) lie rearward of the central plane CP of the board. The palm lies tight against the rear surface of the board (see P 2 ) and the wrist W is closer to the center of the board than in FIG. 1A . The angle O 2 of the forearm to the palm is smaller than angle O 1 , for example, less than 135 degrees, and more typically in the range of about 110-134 degrees. The corresponding supplementary angle A 2 in the Canella sheath, therefore, is greater than 45 degrees, and more typically in the range of about 70-46 degrees. Note that the board outer perimeter edge E region, which is typically the thickest region of a martial arts target board, is shown with front and rear surfaces parallel to each other, but the board may have a reduced thickness and/or curved rear surface nearer to the center of the board as shown by the curved line C.
[0010] The commercial product is likewise adapted so that the fingers, up to about the proximal inter-phalangeal joint (especially the distal phalanx and the middle phalanx), lie parallel to the front plane and the central plane of the board/target. In the commercial product COMM, as shown by FIG. 3A , the fingers' distal phalanx and middle phalanx are parallel to the board, distanced evenly from the front surface of the board, only by the thickness of the underside of the sheath. Note in FIG. 3A that the metacarpophalangeal joints (knuckles K) lie rearward of the central plane CP of the board. The palm lies tight against the rear surface of the board (see P 3 ) and the angle of the forearm to the palm O 3 and the supplementary angle A 3 are the same or nearly the same as O 2 and A 2 of the sheath of the Cannella patent, described above.
[0011] In summary, the surface that the user's fingers rest on, inside these prior devices, is parallel to the board, requiring the holder's fingers distal and middle phalanx to lie flat/parallel relative to the board's front and central planes, and forcing the heel of the holder's palm toward the board and further in toward the center of the target. These features of the prior art devices increases the likelihood of “jamming” the holder's wrist(s) as a result of a kick/strike.
[0012] Further, the Cannella sheath is described as “made of a tough, substantially nondeformable, abrasion and cutting resistant material, such as plastic or metal”. The prior art commercial product related to Cannella is advertised as being made of Lexan™ polycarbonate, which the inventors note is hard, rigid, completely-inflexible, and tends to become brittle over time making it more susceptible to breaking/shattering when struck. Also, as shown to best advantage in FIGS. 2B and 3B , both the Canella sheath and the commercial product comprise a flange FL (reference 28 in Cannella) that protrudes rearward from the sheath. This flange FL rests against the outer perimeter edge surface of the board to control and limit the position of the sheath on the board. This flange FL is believed by the inventors not only to limit the user's options for hand placement when holding the board, but also to increase the likelihood of breaker injury due to the introduction of rigid surfaces/edges into the target area.
[0013] Inadequate Gripping Surface:
[0014] Padded gloves commonly available in martial arts circles may protect the holder's fingers to some extent, and may provide a cushioned surface should the breaker hit the glove. However, even conventionally-padded, prior art martial arts gloves decrease the holder's grip, resulting in the target acting “slippery” and being difficult to hang on to. Gloves with increased padding would only interfere further with the holder's grip on the board. The result of padded gloves, therefore, is typically a reduced grip on the target, increasing the likelihood of dropping or prematurely releasing the board/target during the attempt and resulting in a missed attempt on the break.
[0015] Therefore, there is still a need for an improved device for finger protection in martial arts, and embodiments of the invention meet this need. Certain embodiments of the invention provide correct ergonomic positioning that is very different from the positioning encouraged by prior art sheaths. Also, certain embodiments of the invention provide the holder with multiple options for hand and protector placement on the board, while also providing a sure grip. Also, certain embodiments comprise firm, but non-injuring and slightly-compressible, elements and surfaces that provide a surprisingly effective balance of protecting/shielding the holder's hand/fingers and protecting the striker's foot and toes in the case of striking with the foot, or hands and fingers in the case of striking with the hand.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1A is a side view of a holder grasping a martial arts board with his/her bare hand, with the hand rotated counterclockwise to an ergonomically-beneficial position.
[0017] FIG. 1B is a side view of a holder grasping a martial arts board with his/her bare hand, with the hand rotated clockwise to a non-ergonomically-beneficial position.
[0018] FIG. 2A is a side view of a holder using a prior art sheath such as that disclosed in Canella, U.S. Pat. No. 4,807,302, to grasp a martial arts board, resulting in the hand being rotated clockwise in this figure.
[0019] FIG. 2B is a rear perspective view of the prior art sheath of FIG. 2A .
[0020] FIG. 3A is a side view of a holder using a prior art commercial sheath similar to that disclosed in Canella, U.S. Pat. No. 4,807,302, to grasp a martial arts board, resulting in the hand being rotated clockwise in this figure.
[0021] FIG. 3B is a rear perspective view of the prior art commercial sheath of FIG. 3A .
[0022] FIG. 4 is a side view of a holder using one embodiment of the invented protection device to hold a board.
[0023] FIG. 5A is a schematic front view of two of the protection device embodiments of FIG. 4 being used by a holder in right and left hands to grasp a martial arts board, wherein the devices and the holder's hands are at angles to the top edge of the board that is being grasped.
[0024] FIG. 5B is a schematic front view of two of the protection device embodiments of FIG. 4 being used by a holder in right and left hands to grasp a martial arts board, wherein the devices and the holder's hands are at the corners of the board at angles greater than in FIG. 5A to the top edge of the board.
[0025] FIG. 6A is a partially-cross-sectional view of the device of FIG. 4 on a martial arts board, showing an example angle A of the floor of the finger compartment relative to the surface of the board.
[0026] FIG. 6B shows the device and board of FIG. 6A in use by a holder's hand.
[0027] FIG. 7 is a rear perspective view of the device of FIG. 4 .
[0028] FIG. 8 is a rear view of the device of FIG. 4 .
[0029] FIG. 9 is a bottom view of the device of FIG. 4 .
[0030] FIG. 10 is a perspective distal end view of the device of FIG. 4 , that is, viewing the device as it is oriented in FIG. 11 from the right of FIG. 11 .
[0031] FIG. 11 is a side view of the device of FIG. 4 , with the device rotated to make the floor wall generally horizontal.
[0032] FIG. 12 is a top view of the device of FIG. 4 .
[0033] FIG. 13 is a rear view of the device of FIG. 4 illustrating force arrows so the viewed may note how the dividers of the finger compartment and the rearward extensions will transfer the force to the board (which would be below the device in this figure).
[0034] FIG. 14 is a cross-sectional view of the device of FIG. 4 , viewed along the line 14 - 14 in FIG. 13 .
[0035] FIG. 15 is a partial view of an alternative floor wall, specifically a section of a floor wall between two dividers, showing an alternative texture embodiment.
SUMMARY
[0036] The invention comprises a device for protecting the fingers, hand, and/or wrist of a person holding a board or other target that a martial artist attempts to hit or kick with a hand or foot. In this description and in the claims, the term “striker” is used as a broad term that may include both a person kicking a board and a person hitting with the hand or any body part. Said protection may be protection from direct impact, for example, kicking of the fingers, and/or from the force/shock that is transmitted rearward to the hand and wrists of the holder of the board/target.
[0037] The device comprises an enclosure for receiving and holding multiple of a board/target holder's fingers in a generally curled or other inwardly-slanted position, as the user grips/grasps the board/target between the device and the user's palm. The structure of the device, and especially a slanted floor of the enclosure, result in said curled or inwardly-slanted position for the fingers, which places the rest of the hand, the wrist, and forearm in ergonomic and safe positions. In certain embodiments, the device is made entirely or substantially of material(s) in a particular hardness range that protects the user's fingers but that also tends to prevent injury to the person hitting/kicking the board/target.
[0038] In certain embodiments, an interior space inside the device is adapted to receive the user's finger(s) so that the holder(s) may use two of the devices, one on each hand, to hold a board/target generally in front of or to the side of the holder(s) for presentation to the striker. The board is typically held generally vertical, for example for side-kicks, or at other angles, such as 5-45 degrees from vertical for other types of front or round kicks, or generally parallel to the floor (flat or almost flat) for ax kicks. Typically two holders are required or desired to hold a single board. Based on the orientation typically seen when the device is in use, structure behind the interior space rests on the board/target and structure in front of the interior space shield the fingers from direct impact. The rear portion of the device may comprise a rear wall, called in certain embodiments a “floor”, against which the fingers press, and one or more extension members/surfaces that extend out rearwardly from the floor wall to lie on a rear plane of the device. Said one or more extension members/surfaces is/are sized and shaped so that, when the extension members/surfaces is/are placed against the front surface of the board/target, the device is so oriented that the rear wall/floor is at an angle to the front surface of the board/target.
[0039] In certain embodiments, the device is adapted to be adjustable in position on the board/target, to give the user flexibility in grasping different portions of the board/target. Preferably, the device comprises no protrusions extending rearward of said rear plane, particularly no plate or protrusion(s) that extend(s) along, around or behind the outer perimeter edge of the board/target. Such plate(s) or protrusion(s) could interfere or limit the placement of the device relative to the board, and, therefore, the preferred device (missing such plate(s) and protrusion(s)) may be moved inward relative to the outer perimeter edge.
[0040] Objects of certain embodiments of the invention, therefore, comprise implementing a protective device, for a martial arts' board/target holder's hands, that provide both impact and ergonomic benefits for the holder(s). Another object of certain embodiments is that employing such a device should not dramatically increase the likelihood of injury to the breaker compared to the breaker hitting/kicking a board/target that is held with bare hands and/or soft/flexible gloves.
DETAILED DESCRIPTION
[0041] Referring to the Figures, there are shown examples of bare hands holding a martial arts board, and also two prior art devices being used in holding a martial arts board. Also shown in the Figures is one, but not the only, embodiment of the invented, improved device for finger and/or hand and wrist protection in martial arts and methods of using the embodiment. Martial arts boards, including rebreakable boards, are well-known in the art.
[0042] Device 10 is representative of one, but not the only, embodiment of the invented device for finger protection in martial arts. FIG. 4 (on the same page as FIGS. 1A and 1B ) and FIG. 6B show to best advantage examples of how the device 10 may be worn, and how the device 10 tends to cause the user's (holder's) hand to be rotated counterclockwise in FIG. 4 and clockwise in FIG. 6B , relative to the board B, compared to the un-ergonomic and possibly-injurious positions of FIGS. 1B , 2 A, and 3 A. One may see in FIGS. 4 and 6B that the distal portions of the fingers are curled/slanted, the knuckles are forward, and the wrist is straightened, compared to the prior art approaches.
[0043] As shown to best advantage in FIGS. 4 and 6A and B, device 10 is worn on the fingers of the holder's hand and is comprised of a enclosure 14 (or “finger compartment” or “pocket space”) and a rear portion 15 that extends rearward (to the right in FIG. 4 ) to rest on and grip the board. The enclosure 14 surrounds multiple sides of an interior space, and hence defines the interior space 16 into which the user slides his/her fingers. The main walls forming the enclosure 14 are a curved front wall 18 and a floor wall (“floor”) 20 . The front wall 18 curves from side- to-side in front of (or “over”) the interior space 16 and, hence, in front of the distal phalanx and the middle phalanx of the hand. The floor is a generally flat and planar wall that extends side to side behind (or “under”) the interior space 16 , and, hence, behind the distal phalanx and the middle phalanx.
[0044] As shown to best advantage in FIGS. 7-9 and 13 , one or more dividers 30 are provided in the interior space 16 , extending at least part of the way (and preferably all the way) between the closed end 32 and opening 34 of enclosure 14 , and extending from the inner surface of the front wall 18 to the inner surface of the floor 20 . Preferably three dividers are used, for creating four sub-compartments 36 , 37 , 38 , and 39 (see FIGS. 8 and 9 ) of the interior space 16 . These dividers 30 are walls that are transverse to the floor 20 , serving to separate the holder's fingers received in the interior space 16 and to provide surfaces against which the fingers may push or otherwise apply force during holding the target and in reaction to a strike. The dividers therefore may play roles in the generally- evenly-spaced-apart fingers applying rearward force to the device by means of force spread-out across the floor, and applying sideways force to the device by means of force on one or more of the dividers. In addition, having four fingers separated in four small sub-compartments 36 - 39 , helps in general with control of the device by the fingers/hand and in preventing the device from pivoting relative to the fingers or falling off the fingers. In addition, as emphasized schematically in FIG. 13 , the dividers 30 and the sidewalls 42 , 44 help spread-out the load of a strike, for example, transferring force from the top of the front wall 18 , to the sidewalls 42 , 44 and through the dividers 30 to the floor 20 , and then to the bottom ends of the sidewalls 42 , 44 and to the extensions 50 , thus shielding the fingers and helping to prevent collapse of the enclosure 14 .
[0045] The floor 20 of the enclosure 14 connects, or is integrally attached to, the side wall portions 42 , 44 of the front wall 18 and the distal portion 46 of the front wall. One may say the front wall 18 curves all the way to the floor 20 at two sides and at the distal end of the device, or one may say that the front wall 18 comprises sidewall portions 42 , 44 and distal wall portion 46 that connect to the floor 20 . The device's enclosure walls ( 18 , 42 , 44 , 46 , 20 ) are usually solid and continuous, but may optionally incorporate one or more openings for air ventilation. In FIG. 6A and 12 , one may see the portion referred to as the main portion 18 ′ or top portion of the front wall 18 . This main portion 18 ′ is a generally planar portion of the front wall 18 , typically being a plane MP that is at an angle of about 30-40 degrees from the rear plane RP, for example, and/or at an angle of about 10-25 degrees from the plane of the rear wall (floor 20 ), for example.
[0046] Extending rearward from the enclosure 14 is at least one rear portion of the device, which, in device 10 , takes the form of multiple protruding rearward extensions 50 . These extensions 50 are generally transverse to the plane of the floor 20 , so that they are generally parallel to the dividers 30 of the interior space. These extensions 50 each have a rear extremity that lies on the same plane, thus, defining a rear plane RP of the device (see FIGS. 8 and 11 ). The rear extremities of the extensions 50 , in this embodiment, are rear edges 52 that all lie on the rear plane. Extensions 50 are longer, or in other words extend farther from the floor 20 , at or near the proximal end of the device (opening 34 ), compared to their length at or near distal end of the device (closed end 32 ). The extensions 50 are generally triangular walls extending/protruding rearward from the floor of the enclosure. Thus, the extensions 50 hold the floor farther from the board B at the proximal/open end of the device than at the distal/closed end of the device, resulting in the floor 20 being at an angle A to said rear plane, as illustrated in FIG. 6A .
[0047] Thus, it may be said that, in certain embodiments, interior structure inside the device causes/urges the fingers to rest in said curled, inwardly-slanted, or other non-parallel position relative to the front plane and the central plane of the board/target. As shown in FIG. 6A , this may be done in certain embodiments by the surface against which the fingers rest being at an angle A to said rear plane of the rearmost extremity(ies), and hence at the same angle to the front surface of the board/target against which the rearmost extremity(ies) rest. In certain embodiments, angle A may be in the range of 5-45 degrees, for example, but the inventors have determined that angle A is more preferably between about 10-25 degrees, more preferably A is 16-20 degrees and especially-preferably angle A is about 18 degrees. With floor 20 being thus-angled or thus-slanted, the user can grasp the board/target securely between the device (with fingers inside) in front of the board/target, and the user's palm against or near the rear surface of the board/target, but the fingers are shielded, and the fingers, hand, wrist and forearm are in what the inventors refer to as “proper positions”, that is, ergonomic, comfortable, and safe positions. Due to the strength needed to safely and effectively hold the board/target and the force with which the striker may kick/hit the board/target, these proper positions, further described below, may be matters of slight changes in position of the fingers, hand, wrist and/or forearm and/or their angles to each other.
[0048] FIG. 6B illustrates the finger, hand, and wrist positions of the holder when using device 10 . This “proper holding position” comprises 1) the fingers being “curled” or otherwise slanting toward the board, which appears as slanting downward in this view; 2) the metacarpophalangeal joints (“knuckles” K) of the hand being generally aligned with (closely adjacent and generally centered over) the outer perimeter edge E and central plane of the board/target; and 3) the wrist angle IO (palm to forearm) being greater than or equal to 135 degrees, for example, about 135-160 degrees, or especially about 135-155 degrees, and corresponding supplementary angles IAbeing less than or equal to 45 degrees, or 45-20 degrees, or especially 45-25 degrees.
[0049] It will be understand that one, or more commonly two, holders cooperate to hold a single board/target. The two holders will each grasp opposite edges of the board in their two hands. The device 10 allows the holder's hands to cup and grip the board at any point on or near the board's edge including corners, and at various angles relative to the board edge, as shown in FIGS. 5A and 5B for one holder. The device 10 does not require seating of any flange or other limiting structure against the board's edge E and the device can be moved inward relative to the edge E, if desired. This flexibility in placement allows the holders the most comfortable and secure grip on the board.
[0050] Semi-Rigidity:
[0051] Certain embodiments of the device are made of a semi-rigid material that resists collapse/crush from the initial impact force of the strike, including hits, blows, or kicks, yet is somewhat pliable so the breaker's hand/foot will encounter a slightly-yielding surface and be less susceptible to injury. The inventors believe that too-rigid materials may injure the striker and/or may become brittle over time making it more likely to fracture and cause injury to the kicker/striker and/or the holder, while too-flexible materials may allow injury of the holder. The material employed preferably also incorporates a certain amount of “stickiness” to promote a measure of grip and skid resistance for both the holder's fingers/hand inside the device, as well as that portion of the device's surface that contacts the board. The material preferably also provides some level of elasticity to accommodate varying hand sizes. A variety of materials or mixes may create such properties, with the especially preferred material(s) exhibiting a durometer measurement from about 50 A to about 90 A on the Shore Hardness scale, and more preferably from 65 A to about 85 A. 85 A Shore Hardness is currently the especially-preferred hardness. These ranges of Shore Hardness Scale A, and particularly a hardness equal to, or about, 85 A Shore Hardness are particularly important in certain embodiments, to provide the desired balance between protection of the holder and protection of the kicker/striker. For example, 35 A Shore Hardness in many embodiments has been found by the inventors to be too flexible and soft, while 92 A Shore Hardness in many embodiments has been found by the inventors to be too rigid and hard. Examples of effective materials are thermoplastic elastomers, and especially thermoplastic vulcanizates (TPVs) such as Santoprene™, that are preferably in the 65-85 A Shore Hardness range. The overall outer shape of certain embodiments that use such semi-rigid material(s) as those described herein can be many different geometries, with the preferred embodiment using a rounded, domed, or “flattened dome”, such as device 10 , to minimize tearing or cutting injuries to the breaker.
[0052] Angled Ergonomic Base:
[0053] Certain embodiments of the device use what may be called “an angled base” to support proper hand/wrist position when holding the target, as this is particularly important at the time of impact of the kicker's/striker's foot/hand against the board. This angled base holds the device so that the rear wall/floor of the finger compartment/interior space of the device is at an angle A to the board/target. Given the geometry of a human hand, the angle A of the rear wall/floor encourages the holder to place the heels of their hands nearer to the outer perimeter of the board/target as opposed to the inner or more central region of the board/target. As discussed above, the heel of the user's hand, when using certain embodiments of the invention, may actually be rearwardly-distanced from the rear surface of the board, due to the preferred “rotation” of the hand, as discussed above.
[0054] The rear portion of the device, which in device 10 comprise rearward extensions 50 , may take various forms that rest on the board/target to position the device in front of the board/target and to place the rear wall/floor at the desired angle. The rear portion may be other arrangements and numbers of plates, protrusions, or other supporting structure, for example, a single or a plurality of solid or hollow structures having a rearward extremity(ies) that contact the board/target sufficiently to stabilize the device against the board/target. Those rear portion rearward extensions or other supporting structure(s) may be in the shape of triangular fins as in the preferred embodiment or can be in the shape of pyramids, pillars or other such geometric shapes such as honeycombed cells. The extension(s)/supporting-structure(s) may be symmetrical or asymmetrical, with the preferred embodiment using multiple triangular walls (hence, “tapered” from one end to the other) that are parallel to each other.
[0055] Load Transference:
[0056] The interior space of the device is preferably divided into multiple sections/portions. The device may use single or multiple dividers equally or unequally spaced across the compartment. Those dividers may be parallel with the device's sidewalls, or may employ a non-parallel orientation such as in a radiating fan shape. In the preferred configuration, the finger compartment is divided into four sections, with three dividers providing load support to transfer the breaker's force from the device's top/outer plate (the frontmost extremity of the front wall) to the rear wall/floor and then to the rear portion/extensions of the device that are in contact with the board. Such dividers also provide a gripping surface for the holder's fingers. The divider(s) may be curved at their proximal edges 31 , as in device 10 , to minimize the chance of pinching or scissoring the holder's fingers against the board surface.
[0057] It may be noted from the drawings, that the center divider 30 of device 10 is coplanar with the central extension 50 and that the sidewalls (sidewall portions 42 , 44 ) are coplanar with the outermost extensions 50 . These features may enhance load transference in certain embodiments. It may also be noted that the other dividers, that is, the dividers directly adjacent to center divider are parallel but not coplanar with any extensions. Thus, it may be said that some of the dividers 30 are co-planar with the extensions 50 while some are not. Alternatively, the dividers may be other shapes and arrangements in certain embodiments. Each divider may be solid, planar, and continuous, such as shown in device 10 , to maximize support and load transference, or alternatively may employ one or more holes, openings, ribs or reinforcements, for appearance and/or to enhance the divider's role in transferring the force through the device to the board and/or otherwise protecting the user's hand. It may also be notes that the extensions 50 may be other shapes than those drawn, for example, arches.
[0058] The device's floor 20 may be either smooth or feature raised protrusions or other texture to enhance grip and inhibit slip. As illustrated in FIG. 14 , certain embodiments use elongated ribs 60 that extend transversely to the dividers 30 , which ribs have been found to be excellent structures for the fingertips to engage/grip. Alternatively, ribs in a chevron or herringbone pattern, for example, may be excellent engagement/gripping structures. Other protrusions/texture may be used in certain embodiments, for example, geometric shapes such as hemispherical domes, protruding squares or protruding hexagonal piers 62 . Alternatively, the device may have texturing (like a roughened or bead-blasted surface, gunstock checkering or cross-hatching) on selected areas to improve the user's grip on the device, or more typically, the device's grip on the board. This texturing can also be added in other areas of the device for aesthetics and appearance or styling.
[0059] It should be noted that the terms “front” and “rear” are for convenience in describing various aspects of the protector device and are not necessarily intended to limit the use of the protector device to particular orientations.
[0060] Certain embodiments may be described as a protection device for use by a user grasping a martial arts board, the device comprising: an enclosure surrounding and defining an interior space, the enclosure having a front wall for receiving an impact from a martial arts striker (those impacting the board with hand, foot, or any body part) an opposing rear wall, and an open end for receiving distal portions of the fingers of the user in the interior space between the front wall and the rear wall so that the distal portions of the fingers push on the rear wall for grasping the board between the device and the palm of the user's hand; and the device further comprising at least one extension member extending from the enclosure and comprising a rearmost extremity for resting on a front surface of the martial arts board, said rearmost extremity being on, and defining, a rear plane parallel to the front surface of the board; wherein said rear wall is at an angle to said rear plane so that the fingers are at an angle to the front surface of the board. The at least one extension member may comprise a triangular wall perpendicular to the rear wall and having a rearmost edge that is the rearmost extremity on the rear plane. Or, the at least one extension member may comprise multiple, parallel triangular walls that are perpendicular to the rear wall and that each have a rearmost edge on the rear plane. The angle of the rear wall to the rear plane may be in the range of 5-45 degrees, for example, but more preferably is in the range of 16-20 degrees, and most preferably about 18 degrees for example, 17-19 degrees. The interior space is preferably divided into four sub-compartments by three dividing walls that are perpendicular to the rear wall, the four sub-compartments being for receiving four of said fingers. The front wall, the entire enclosure, or the entire protective device may be material characterized by having a Shore Hardness in the range of 65 A to 90 A, or more preferably about 85 A, for example. The front wall may have a planar main portion that is at an angle to the rear wall. The device may include no structure that extends rearward from said rear plane, for example, to enhance the options for placement on the board.
[0061] Certain embodiments may be described as a system for use in martial arts striking competition or practice, the system comprising a martial arts board having a front surface and a rear surface and an outer perimeter edge; and a finger protective device comprising: an enclosure surrounding and defining an interior space, the enclosure having a front wall for receiving an impact from a martial arts striker, an opposing rear wall, and an open end for receiving the user's fingers into the interior space; and at least one extension member extending rearward from the enclosure and comprising a rearmost extremity defining a rear plane, wherein the rearmost extremity is placed on the front surface of the board at or near the outer perimeter edge, with the rear plane being parallel to the front surface of the board, for the user to grasp the board between the device and the palm of the user's hand placed behind the board; wherein said rear wall is at an angle in the range of 5-45 degrees to said rear plane, so that the user's fingers resting on the rear wall are at an angle to the rear plane and to the front surface of the board; and wherein at least said enclosure is made of material having a Shore Hardness in the range of 65 A to 90 A. The angle of the rear wall to the rear plane may be in the range 16-20 degrees, or more preferably about 18 degrees, for example. The at least one extension member may comprise multiple, parallel triangular walls that are perpendicular to the rear wall and that each have a rearmost edge on the rear plane. The interior space may be divided into four sub-compartments by three dividing walls that are perpendicular to the rear wall, the four sub-compartments being for receiving four of said fingers. In certain embodiments, the front wall, the entire enclosure, or the entire protective device may be made from material characterized by having a Shore Hardness in the range of about 65 A to 90 A, for example, or more preferably about 85 A. The front wall may have a planar main portion that is at an angle to the rear wall. In certain embodiments, the device comprises no structure that extends rearward from said rear plane, to enhance the options for placement of the device on the board.
[0062] Certain embodiments may be described as a finger protector for holding a martial arts board, the protector being adapted for receiving distal portions of fingers of a user, and the protector comprising a front wall for receiving an impact from a striker of the board, a rear wall for being pressed-on by the fingers or fingertips of said fingers, and a rear portion for resting on the martial arts board, wherein the rear wall is at an angle, to the rearmost plane of the rear portion and also to the front surface of the board, in the range of 5-45 degrees, to cause the user's hand to rotate forward relative to the board when grasping the board between the device and the user's palm, for placing the user's hand and wrist in an improved ergonomic position for increased safety. The finger protector may be made of material characterized by having a Shore Hardness in the range of 65 A to 90 A, for example, or most preferably about 85 A. In certain embodiments, the device comprises no structure that extends rearward from said rear plane, to enhance the options for placement of the device on the board.
[0063] Although this invention has been described above with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to these disclosed particulars, but extends instead to all equivalents within the scope of the following claims. | A protection device for a holder of a martial arts board/target provides protection from direct impact and/or from the force/shock that is transmitted rearward to the hand and wrists of the holder of the board/target. The device receives the board/target holder's fingers, and a slanted floor inside the device urges the fingers into a generally curled or other inwardly-slanted position, and urges the rest of the hand, the wrist, and forearm into ergonomic and safer positions. The device is preferably made of material(s) in a particular hardness range that protects the user's fingers but that also prevents injury to the striker who is hitting/kicking the board/target. There are preferably no flanges or stops that limit placement of the device to particular places on the board, but rather the holder determines and controls the placement. | 8 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a steering column for a motor vehicle, which comprises a jacket unit supporting a steering shaft rotatably about its longitudinal axis and a retaining part, which the jacket unit is secured non displaceably up to a limit value of a force acting onto the jacket unit parallel to the longitudinal axis of the steering shaft in the direction toward the front of the motor vehicle. If the limit value is exceeded, the jacket unit is displaceable parallel to the longitudinal axis in the direction toward the motor vehicle front. The jacket unit is connected with the retaining part, for one, across an energy absorption connection, which comprises at least one bending wire or strip that, upon a displacement of the jacket unit with respect to the retaining part parallel to the longitudinal direction toward the motor vehicle front, is deformed, and is connected, for another, across a break-away connection which, up to the limit value of the force, is closed and blocks a displacement of the jacket unit with respect to the retaining part and which is released if the limit value of the force is exceeded. The invention further relates to a method for the production of such a steering column.
[0002] Steering columns for motor vehicles are most often implemented such that they are adjustable so that the position of the steering wheel can be adapted to the seating position of the driver. Such adjustable steering columns are known in various embodiment forms. Apart from adjustable steering columns which are only adjustable in the length or height or inclination direction, steering columns are also known which are adjustable in the length as well as also the height or inclination direction.
[0003] As a safety measure in the event of a vehicle crash, it is known and conventional to realize in steering columns for motor vehicles the steering shaft together with a jacket unit, rotatably supporting the steering shaft, in a section adjoining the steering wheel-side end such that it is displaceable in the longitudinal direction of the steering column (=parallel to the longitudinal axis of the steering shaft) with the absorption of energy. A conventional implementation form provides for this purpose that a bracket unit, with respect to which in the opened state of the clamping mechanism the jacket unit is displaceable for setting the position of the steering column, is so connected with a mounting part attached on the vehicle chassis that the jacket unit with the absorption of energy is dislocatable with respect to the mounting part. Such a construction is shown, for example, in U.S. Pat. No. 5,517,877 A.
[0004] DE 28 21 707 A1 discloses a non-adjustable steering column in which the jacket tube rotatably supporting the steering shaft includes bilaterally projecting fins which had been connected on the chassis by securement blocks and bolts penetrating therethrough. In the event of a crash, the fins can become detached from the securement blocks, whereby a dislocation of the jacket tube is enabled. Between the securement blocks and the fins, U-shaped bending strips are herein provided on which deformation work is carried out during the dislocation of the jacket tube. The bending strips are enclosed in chambers of the fins and are in contact on opposing side walls of the chambers such that the rolling radius of the particular bending strip during its deformation is limited and predetermined.
[0005] An adjustable steering column comprising a jacket unit rotatably supporting the steering shaft and a bracket unit, with respect to which the jacket unit in the opened state of a securement device is displaceable for setting the position of the steering column at least in the longitudinal direction of the steering column, is disclosed in EP 0 598 857 B1. In the event of a crash, the jacket unit can be dislocated with respect to the bracket unit or with respect to a clamp bolt of the securement device in the longitudinal direction of the steering column. For the energy absorption, bending strips or bending wires are provided that are entrained with the jacket unit and placed about the clamp bolt, which strips or wires are deformed. One disadvantage of this solution is that the possible displacement path or the characteristic of the energy absorption in this device depends on the particular positioning length of the steering column.
[0006] Further, U.S. Pat. No. 5,961,146 A describes a steering column which in normal operation is only adjustable in the height direction. In a manner similar to that described above, a bending wire is provided curved in the shape of a U about the clamp bolt of the securement device, which in the event of a crash is entrained by the jacket unit dislocating with respect to the clamp bolt in the longitudinal direction of the steering column, whereby bending work is performed.
[0007] In the steering column disclosed in WO 2007/048153 A2, in the closed state of the securement device a retaining part is prevented by a securement part of the securement device from being displaced with respect to this securement part referred to the direction parallel to the steering shaft. The jacket unit can become dislocated in the longitudinal direction of the steering column with respect to the retaining part with the absorption of energy. For the energy absorption, a bolt is disposed on the retaining part which projects into an elongated hole of an energy absorption part disposed on the jacket unit and which, during its shift in the event of a crash, widens this elongated hole. To attain defined energy absorption, the material properties of the energy absorption part in the proximity of the elongated hole must be precisely defined such that they are reproducible.
[0008] Similar steering columns are also disclosed in EP 0 849 141 A1 and EP 1 464 560 A2. The retaining parts are guided by guide parts in the manner of a carriage such that they are displaceable in the longitudinal direction of the steering column. They are held under frictional closure with respect to the guide parts or plastically deform them with the consumption of energy. In the case of a frictionally engaged mounting, the clamping force of the securement device must be taken into account when considering the magnitude of the energy absorption. In a plastic deformation of the guide parts, their material properties must be implemented in a precisely defined reproducible manner.
[0009] A steering column of the above type is disclosed in DE 10 2008 034 807 B3. The retaining part is connected with the jacket unit, for one, across a bending wire or strip and, for another, across a pin forming a break-away connection between the retaining part and the jacket unit. If, in the event of a crash, a force, acting onto the steering wheel-side end of the steering shaft parallel to the longitudinal axis of the steering shaft in the direction towards the vehicle front, exceeds a limit value, the pin is shorn off and the break-away connection is consequently released. The jacket unit can then become dislocated with respect to the retaining part parallel to the longitudinal axis of the steering shaft in the direction toward the vehicle front, wherein the bending wire or strip is deformed and thereby energy is absorbed. The retaining part is herein hindered from being displaced in the direction parallel to the longitudinal axis of the steering shaft through its engagement with its securement part of the securement device. In the opened state of the securement device, the securement part is raised from the retaining part and the jacket unit, together with the retaining part, can be displaced parallel to the longitudinal axis of the steering shaft in order to carry out a length positioning of the steering column. Further, in the opened state of the securement device, a height or inclination adjustment of the steering column is feasible.
[0010] One disadvantage in this prior known steering column includes that during the opening of the break-away connection a force peak (=break-away peak) occurs, e.g. the limit value of the force acting parallel to the longitudinal axis of the steering shaft, starting at which the break-away connection is released and an energy absorbing displacement of the jacket unit with respect to the retaining part sets in, is relatively high. After the break-away connection has been released, the force counteracting a displacement of the jacket unit with respect to the retaining part is less.
SUMMARY OF THE INVENTION
[0011] The invention addresses the problem of at least decreasing this force peak (=break-away peak), and to do so in a simple and cost-effective yet functionally advantageous implementation.
[0012] This is attained according to the invention through a steering column with the features described below or, respectively, through a method for the production of a steering column with the features described below. Advantageous further developments are described in the dependent claims.
[0013] In the steering column of the invention an elastic prestress is exerted onto the at least one bending wire or strip. The jacket unit is thereby prestressed with respect to the retaining part in the displacement direction parallel to the longitudinal axis of the steering shaft in the direction toward the vehicle front. This prestress acts on the break-away connection between the jacket unit and the retaining part. The force required in the event of a crash to release the break-away connection is thereby decreased since the elastic reset force of the at least one bending wire or strip is added to the force exerted, in particular through the secondary collision of the driver with the steering wheel, parallel to the longitudinal axis of the steering shaft in the direction toward the vehicle front. The force peak during the breaking away of the jacket unit from the retaining part (=break-away peak) can thereby be decreased or entirely avoided. Nevertheless, in normal driving operation (thus when no vehicle crash occurs), an adequately stable connection is provided between the retaining part and the jacket unit, through which a shaking between the jacket unit and the retaining part and vibrations through intrinsic resonances can be avoided, and this can be achieved with a very simple implementation.
[0014] The steering column is preferably implemented such that it is adjustable in length. An openable and closable securement device is herein provided, in the opened state of which the jacket unit is displaceable with respect to a bracket unit supporting the jacket unit parallel to the longitudinal axis of the steering shaft and which, in its closed state, applies a securement force for the securement of the jacket unit with respect to the bracket unit against a displacement parallel to the longitudinal axis of the steering shaft. In the mounted state of the steering column the bracket unit is herein firmly secured on the vehicle, at least in normal operation, thus without a crash having occurred, e.g. up to a maximum force acting in the direction of the longitudinal axis of the steering shaft.
[0015] An advantageous embodiment of the invention provides that the retaining part is formed by a part of the securement device. The retaining part in the closed state of the securement device is herein in engagement with a securement part which is secured in position with respect to the bracket unit such that it is nondisplaceable in the direction of the longitudinal axis of the steering shaft. Through this engagement between the securement part and the retaining part, at least a portion of the securement force is applied securing, in the closed state of the securement device, the jacket unit against a displacement parallel to the longitudinal axis of the steering shaft. In the opened state of the securement device, the retaining part and the securement part are out of engagement. However, the energy absorption device for enabling the energy absorbing dislocation of the jacket unit in the event of a crash is integrated into the securement device. In this embodiment of the invention, the vehicle-stationary mounting of the bracket unit can be provided. A further energy absorbing dislocateability between the bracket unit and a mounting part, displaceably supporting this bracket unit parallel to the longitudinal axis of the steering shaft and mounted stationarily on the vehicle, can consequently be omitted.
[0016] Since in this embodiment of the invention the securement part, referred to in the direction of the longitudinal axis of the steering shaft, is nondisplaceable with respect to the bracket unit. The retaining part, during the displacement of the jacket unit with respect to the bracket unit, in the opened state of the securement device moves simultaneously with the jacket unit. The securement part and the retaining part thus come in different length settings of the steering column in different positions into mutual contact when the securement device is closed. In the closed state of the securement device, the displacement of the retaining part with respect to the securement part (in the direction parallel to the longitudinal axis of the steering shaft) is counteracted by securement elements cooperating, preferably under form closure, advantageously through cooperating toothings. The securement of the jacket unit in the closed state of the securement device against a displacement in the length displacement direction, consequently, takes place at least also via the cooperation of the securement part with the retaining part. Additionally, for example, securement elements acting under frictional closure can be provided for the securement of the jacket unit against a displacement in the length displacement direction in the closed state of the securement device.
[0017] The height or inclination of the steering column is especially preferably also settable in the opened state of the securement device.
[0018] In the event of a crash, after the break-away connection has been released during the dislocation of the jacket unit with respect to the retaining part (which is held nondisplaceably with respect to the securement unit in the direction parallel to the longitudinal axis of the steering shaft), at least a section of the at least one bending wire or strip is entrained by the jacket unit. The deformation of the bending wire or strip takes place by the bending of the bending wire or strip or comprises at least one such. The bending wire or strip preferably comprises two legs connected via a recurvature, wherein the two legs form an angle in particular in the range of 150° to 220°, preferably an angle of 180°, such that a U-shaped development of the bending wire or strip results.
[0019] An advantageous development provides that the bending wire or strip is at least partially enclosed in a housing which preferably is formed by a portion of the jacket unit. For this purpose, a rail U-shaped in cross section is secured in position on a jacket tube rotatably supporting the steering shaft. A development of the housing or a portion thereof on the, respectively of the, bracket unit is also conceivable and feasible.
[0020] The break-away connection between the retaining part and the jacket unit can be formed, for example, by a pin connecting these two parts, which, in the event of a crash, is sheared off if the limit value of the force acting upon the steering shaft and thereover onto the jacket unit parallel to the longitudinal axis of the steering shaft in the direction toward the vehicle front is exceeded. Other types of form closure connections, which, in the event of a crash, are released through material reforming, material shearing or fracture, are also conceivable and feasible. A break-away connection can, for example, also be attained through a frictional closure connection which, if the limit value of the force is exceeded, enables a dislocation of the jacket unit with respect to the retaining part and only acts over a small first segment of the displacement path. Consequently, as a break-away connection any connection between the jacket unit and the retaining part should be considered which, after a displacement over a short displacement path between the jacket and the retaining part (parallel to the longitudinal axis), which is preferably less than two centimeters, counteracts a further displacement between the jacket unit and the retaining part with no force or only a significantly lower than initial force, preferably less than one tenth of the initial force.
[0021] Accordingly, a solder connection or welded connection or adhesive connection is suitable as the break-away connection if it is laid out such that it is released when the desired force is exceeded.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Further advantages and details of the invention will be explained in the following in conjunction with the enclosed drawings, in which:
[0023] FIG. 1 is a side view of a steering column according to a first embodiment of the invention;
[0024] FIG. 2 is a section view along line BB of FIG. 1 ;
[0025] FIG. 3 is a section view along line AA of FIG. 1 ;
[0026] FIG. 4 is an oblique view of the steering column of FIG. 1 ;
[0027] FIG. 5 is an oblique view of the jacket unit, of the section of the steering shaft rotatably supported thereby and the retaining part;
[0028] FIG. 6 is a section view corresponding to line CC of FIG. 2 , wherein, however, are omitted the bracket unit, the intermediate unit and the securement device, apart from the securement part in engagement with the retaining part (shown in section);
[0029] FIG. 7 a is a section view along line EE of FIG. 2 during the assembly of the steering column, the parts listed in FIG. 6 being again omitted;
[0030] FIG. 7 b is a section view analogous to FIG. 7 a in the completed state of the steering column;
[0031] FIG. 8 is a section view analogous to FIGS. 7 a and 7 b after a vehicle crash;
[0032] FIG. 9 is an exploded view depicting the jacket unit, of the retaining part and the connection parts connecting these according to a second embodiment of the invention;
[0033] FIG. 10 is an oblique view onto the back side, not visible in FIG. 9 , of the retaining part;
[0034] FIG. 11 a is a view onto the back side, not visible in FIG. 9 , of the rail of the jacket unit attached on the jacket tube in the state connected with the retaining part, in a state during the assembly of the steering column;
[0035] FIG. 11 b is a view corresponding to FIG. 11 a after a further assembly step;
[0036] FIG. 11 c is a view corresponding to FIG. 11 a in the completed state of the steering column.
DETAILED DESCRIPTION OF THE INVENTION
[0037] A first embodiment of the invention is depicted in FIGS. 1 to 8 . The steering column comprises a jacket unit 2 which bearing supports a steering shaft 1 rotatably about the longitudinal axis 4 of the steering shaft 1 , which comprises a steering wheel-side end 3 serving for the connection of a steering wheel, not shown in the Figures. The jacket unit 2 is connected with a retaining part 5 across a break-away connection and energy absorption connection, which will be more precisely described later. Up to a limit value of a force acting between the jacket unit and the retaining part 5 parallel to the longitudinal axis 4 , the retaining part 5 is connected with the jacket unit 2 such that it is nondisplaceable relative to the direction of the longitudinal axis 4 . The limit value can herein be identical or different for the two directions parallel to the longitudinal axis 4 and be set during the construction of the system.
[0038] A force F (or the corresponding force component parallel to the longitudinal axis 4 ), exerted in the event of a crash through the secondary collision of the driver onto the jacket unit 2 , is directed toward the vehicle front, as is illustrated in FIG. 1 , and accordingly is absorbed through a counter-force on the bracket unit 6 .
[0039] A bracket unit 6 supporting the jacket unit 2 in the operating state of the steering column is rigidly connected with the chassis of the motor vehicle. In the opened state of a securement device 7 the steering column can be adjusted in length and in height or inclination. The jacket unit 2 is herein displaceable with respect to the bracket unit 6 parallel to the longitudinal axis 4 (=length adjustment direction 8 ) and into a height or inclination adjustment direction 9 , at right angles thereto, with respect to the bracket unit 6 . In the closed state of the securement device 7 a securement force, for the securement of the jacket unit 2 relative to a displacement taking place parallel to the longitudinal axis 4 with respect to the bracket unit 6 , is applied, wherein the securement force is, at least relative to a displacement parallel to the longitudinal axis 4 in the direction toward the vehicle front, higher than the limit value of the force up to which the jacket unit 2 is held nondisplaceably with respect to the retaining part 5 . Further, by the securement device 7 , a securement force for the securement of the jacket unit 2 is applied against a displacement with respect to the bracket unit 6 in the height or inclination adjustment direction 9 .
[0040] In the depicted embodiment, the jacket unit 2 is located between side jaws 10 , 11 of the bracket unit 6 . Between the side jaws 10 , 11 of the bracket unit 6 and the jacket unit 2 are located side flanks 12 , 13 of an intermediate unit 14 which encompasses the jacket unit 2 at least over a large portion of its circumference. In the opened state of the securement device 7 the intermediate unit 14 is displaceable with respect to the bracket unit 6 in the height or inclination adjustment direction 9 . For this purpose, it is swivellable about a swivel axis 15 with respect to the bracket unit 6 . The intermediate unit 14 is connected with the bracket unit 6 nondisplaceably, relative to the direction of the longitudinal axis 4 , for example (also) via the development of this swivel axis 15 . The jacket unit 2 in the opened state of the securement device 7 is displaceable with respect to the intermediate unit 14 , displaceably guiding the jacket unit 2 , parallel to the longitudinal axis 4 and, in the closed state of the securement device 7 , is held nondisplaceably with respect to the intermediate unit 14 through the securement force applied by the securement device 7 in the direction of the longitudinal axis 4 .
[0041] The securement device 7 comprises a clamp bolt 16 extending at right angles to the longitudinal axis 4 which penetrates through openings 17 , 18 (cf. FIG. 2 ) in the side jaws 10 , 11 , which are implemented as elongated holes extending in the direction of the height or inclination adjustment 9 and in which the clamp bolt 16 shifts during the height or inclination adjustment of the steering column. The clamp bolt 16 is held by the margins of these openings 17 , 18 nondisplaceably, relative to the direction of the longitudinal axis 4 , with respect to the bracket unit 6 . The clamp bolt 16 , further, penetrates openings in the side flanks 12 , 13 of the intermediate unit 11 whose diameter, apart from a sliding clearance, correspond to that of the clamp bolt 16 .
[0042] On the clamp bolt 16 securement parts 19 , 20 are disposed on both sides of the side jaws 10 , 11 of bracket unit 6 , through which parts penetrates the clamp bolt 16 through openings and which are axially displaceable in the direction of the axis of the clamp bolt 16 . The one securement part 19 includes a section in which it is penetrated by clamp bolt 16 and a section 22 connected therewith across a connection section 21 , in which section 22 the part 19 cooperates, as will be described below, with the retaining part 5 . The securement part 20 and the securement part 19 , in the proximity of its section penetrated by clamp bolt 16 , in the closed state of the securement device are pressed onto the side jaws 10 , 11 of the bracket unit 6 in order to secure in position the adjustment of the steering column in the height or inclination adjustment direction. This securement in position can take place through frictional closure. Elements cooperating under form closure, for example toothings, can also be provided.
[0043] For tightening the securement parts 19 , 20 with the side jaws 10 , 11 and securement part 19 with the retaining part 5 , the securement device 7 can be implemented in the conventional manner. For example, a clamping lever 23 serving for opening and closing the securement device 7 is connected with a cam disk 24 , which it entrains upon a turning about the axis of the clamp bolt 16 and which cooperates with a link disk. The link disk is here implemented as integral with the securement part 19 , but a separate link disk could also be provided. Configurations with rolling bodies or other implementations of clamping mechanisms are also applicable.
[0044] The section 22 of the securement part 19 penetrates an opening in the side jaw 10 (the side jaw 10 could also terminate above the section 22 of the securement part 19 ) and an opening in side flank 12 of the intermediate unit 14 . In the closed state of the securement device, section 22 is pressed with a toothing 25 disposed thereon onto a toothing 26 of the retaining part 5 . Depending on the length positioning of the steering column, the toothings 25 , 26 come into mutual contact in different positions.
[0045] Section 22 of securement part 19 , which in its entirety is located on one side of clamp bolt 16 , is held nondisplaceably against a shift with respect to the bracket unit 6 in a direction parallel to the longitudinal axis 4 by the margins of the penetrated opening in side jaw 10 and/or by the margins of the penetrated opening in side flank 12 of the intermediate unit 14 .
[0046] Through the cooperating toothings 25 , 26 the retaining part 5 in the closed state of the securement device 7 is secured in position against a displacement with respect to securement part 19 in the direction of the longitudinal axis 4 . If, during the closing of the securement device 7 , these two toothings come into mutual contact in a tooth-on-tooth position, at least after a minimal initial shift (which is less than the tooth spacing of the toothing) a further shifting of the retaining part 5 with respect to the securement part 19 is blocked.
[0047] Other form-closure connections between the securement part 19 and the retaining part 5 are also feasible, for example via bolts engaging into holes.
[0048] In the opened state of the securement device 7 the securement part 19 is retracted from the retaining part 5 and these two parts are brought out of engagement, wherein the jacket unit 2 , together with the retaining part 5 , is displaceable in the length adjustment direction 8 .
[0049] Apart from the type of implementation of the connection between the jacket unit 2 and the retaining part 5 , which will be described more precisely in the following, the elements of the steering column described above can be implemented in a manner known from prior art, in particular according to DE 10 2008 034 807 B3 cited in the introduction to the description.
[0050] The retaining part 5 is guided displaceably with respect to the jacket unit 2 parallel to the longitudinal axis 4 and is connected with the jacket unit 2 , for one, across a break-away connection and, for another, across an energy absorption connection. The break-away connection can be realized, for example, via a shear bolt 27 . In the depicted embodiment example, the shear bolt 27 is set, on the one hand, into an opening 28 in the retaining part 5 , for example into an opening 29 (cf. FIG. 3 ). The jacket unit 2 comprises in this embodiment example a jacket tube 30 and a rail 31 with U-shaped cross section rigidly connected therewith, for example by welding, and extending in the direction of the longitudinal axis 4 . The opening 29 is here implemented in the rail 31 .
[0051] For developing the energy absorption connection serves a bending wire or strip 32 , which is connected, on the one hand, with the retaining part 5 , on the other hand, with the jacket unit 2 . In the depicted embodiment, the bending wire or strip 32 is developed in the shape of a U, wherein the one U-leg is connected with the retaining part 5 and the other U-leg with the jacket unit 2 , specifically with the rail 31 . The connections of the U-legs are each such that they act in both directions parallel to the longitudinal axis 4 , preferably under form closure. The two U-legs preferably extend, at least substantially, parallel to the longitudinal axis 4 .
[0052] To connect the one U-leg with the retaining part 5 , this part can comprise, for example, a pin 33 projecting through a slot 34 extending parallel to the longitudinal axis 4 in the rail 31 and engaging into an eyelet 35 in the bending wire or strip 32 . The connection of the other U-leg with the jacket unit 2 can be developed, for example, by placing the end of the U-leg in contact on a stop 36 of the rail and through extensions 37 of the rail engaging into indentations in the U-leg.
[0053] In the embodiment, the bending wire or strip 32 is enclosed in an inner chamber of a housing formed by the rail 31 and the section of the jacket tube 30 terminating it. In this housing, the bending of the bending wire or strip 32 takes place freely, thus not about a pin.
[0054] During assembly of the steering column, the bending wire or strip is elastically deformed, e.g. it is deformed with respect to a neutral position which it assumes without external forces, wherein it exerts a reset force in the direction of the neutral position. For this purpose the bending wire or strip 32 is comprised of an adequately elastic material, for example a spring-elastic steel. Through this elastic prestress of the bending wire or strip 32 , the jacket unit 2 is prestressed with respect to the retaining part 5 relative to a displacement parallel to the longitudinal axis 4 in the direction toward the motor vehicle front.
[0055] The implementation of this prestress is depicted schematically in FIGS. 7 a and 7 b . In FIG. 7 a , the bending wire or strip has its non-prestressed neutral position which it assumes without action of an external force, wherein it is connected with the jacket unit 2 and the retaining part 5 . As indicated in FIG. 7 a , in this production step the opening 28 in the retaining part 5 (shown above the longitudinal axis 4 ) and the opening 29 in rail 31 (shown beneath the longitudinal axis 4 ) are offset with respect to one another in the direction of the longitudinal axis 4 .
[0056] The retaining part 5 is subsequently displaced (toward the left in FIG. 7 b ) with respect to the jacket unit 2 parallel to the longitudinal axis 4 by a distance d in the direction toward the vehicle front, wherein the pin 33 elastically prestresses the bending wire or strip. In this prestressed position according to FIG. 7 b , the opening 28 in the retaining part 5 (shown above the longitudinal axis 4 ) and the opening 29 in the rail 31 (shown beneath the longitudinal axis 4 ) overlap one another and the shear bolt 27 is now inserted (illustrated by the arrow in FIG. 7 b ) whereby the break-way connection is implemented.
[0057] If in the event of a crash at least a force acting parallel to the longitudinal axis 4 in the direction toward the vehicle front is exerted onto the steering wheel-side end 3 of the steering shaft 1 , in particular through the secondary collision of the driver, this force is transmitted from the steering shaft 1 onto the jacket unit 2 and is added to the prestress force exerted by bending wire or strip 32 , and, if the sum of these forces exceeds a limit value, the break-away connection is released through the shearing-off or breaking-off of the shear bolt 27 . Therewith, the dislocation of the jacket unit 2 parallel to the longitudinal axis 4 in the direction toward the vehicle front can commence, thus into the direction away from the steering wheel-side end 3 of the steering shaft 1 , wherein the jacket unit 2 is dislocated with respect to the retaining part firmly secured by the securement part 19 . After a first partial segment of this displacement path, which is preferably smaller than one tenth of the entire displacement path between the jacket unit 2 and the retaining part 5 , the bending wire or strip 32 starts to counteract the further dislocation with a force as soon as the neutral position of the bending wire or strip 32 has been reached or has been exceeded. During the further dislocation, the bending wire or strip 32 is deformed with the absorption of energy, wherein this deformation, after a further segment of the displacement path which is preferably smaller than a tenth of the entire displacement path, transitions into a plastic deformation. The state after the vehicle crash in shown in FIG. 8 .
[0058] For the layout of the energy absorption, in particular with respect to magnitude and course, the cross section and the cross section course of the bending strip 32 can be dimensioned appropriately. Further, essential for the energy absorption behavior are the strength of the connection between the rail 31 with the jacket unit 2 and the metal sheet thickness of the rail 31 as well as the course of the width of the slot 34 in the rail 31 . Additionally, the radius of curvature of the rail 31 in the direction of the tabs, with which the rail 31 is secured on the jacket unit 2 , is a parameter affecting the determination of the energy absorption behavior.
[0059] The securement device can hold the jacket unit 2 , even additionally to the mounting through the engagement between the securement part 19 and the retaining part 5 , for example under frictional closure, against a displacement parallel to the longitudinal axis 4 , for example, so that during the closing of the securement device 7 , the intermediate unit 14 is tightened against the jacket unit 2 . Such an additional holding force exerted by the securement device 7 directly onto the jacket unit 2 is taken into account in the limit value of that force above which, in the event of a crash, a dislocation of the jacket unit 2 with respect to the bracket unit 6 occurs.
[0060] A second embodiment form of the invention is depicted in FIGS. 9 to 11 . The distinction from the previously described embodiment lies in the energy absorption connection between the jacket unit 2 and the retaining part 5 . The break-away connection is implemented by a shear bolt 27 as in the previously described embodiments.
[0061] The one U-leg of the bending wire or strip 32 is secured with the rail 31 against a displacement in both directions parallel to the longitudinal axis 4 through prominences 38 of the bending wire or strip 32 , which engage into a cutout 39 of the rail 31 . However, only one prominence 38 engaging into a cutout 39 could also be provided. The other U-leg includes at the end side a bend-off with a thickened end 40 . This is retained in an interspace between projections 41 , 42 disposed on the retaining part 5 , which penetrate the slot 34 in the rail 31 . This leg of the bending wire or strip is thereby held nondisplaceably in both directions of the longitudinal axis 4 with respect to the retaining part 5 .
[0062] During the assembly, the unstressed bending wire or strip 32 is inserted and connected with both of its legs with the retaining part 5 and the rail 31 . The retaining part 5 is subsequently first displaced parallel to the longitudinal axis 4 by a distance c in the direction away from the vehicle front, thus in the direction toward the steering wheel-side end 3 of the steering shaft 1 (toward the left in FIG. 11 b ), see the position evident in FIG. 11 b in comparison to FIG. 11 a . During this displacement, a plastic deformation of the bending wire or strip 32 occurs. Manufacturing tolerances can thereby be compensated such that in this manner a defined starting state is attained. Subsequently, there results a displacement of the retaining part 5 by a distance d parallel to the longitudinal axis 4 in the direction toward the vehicle front, thus away from the steering wheel-side end 3 of the steering shaft 1 (toward the right in FIG. 11 c ), wherein the bending wire or strip 32 is elastically prestressed, see FIG. 11 c in comparison to FIG. 11 b . In this position, the openings 28 , 29 in the retaining part 5 and in the rail 31 overlap and the shear bolt 27 is inserted, which is illustrated by the arrow in FIG. 11 c.
[0063] The described plastic deformation before the elastic prestress could also be carried out in the case of the first described embodiment.
[0064] In addition to the already listed advantages, the solution according to the invention has an advantageous effect on the noise behavior of the steering column. Through the prestress a dampening effect is achieved.
[0065] The break-away connection between the retaining part 5 and the jacket unit 2 could also be implemented in a manner other than in the first and second embodiment, e.g., a nose tapering the slot 34 could also be provided, over which the pin 33 or the projection 41 would need to drive for the release of the break-away connection. The break-away connection secures the jacket unit 2 with respect to the retaining part 5 and in normal operation thus prevents shaking of the jacket unit 4 with respect to the retaining part 5 .
[0066] An implementation with more than one bending wire or strip 32 is also conceivable and feasible. One of the bending wires or strips or more than one of the bending wires or strips could here be elastically prestressed in the described manner. For example, on both sides of the jacket unit 2 retaining parts 5 could be provided which cooperate with securement parts, for example in the manner described in connection with the securement part 19 . Both retaining parts 5 could herein be connected with the jacket unit 5 across an energy absorption connection comprising at least one bending wire or strip 32 and across a break-away connection. A connection of only one of the retaining parts with the jacket unit through an energy absorption connection or through a break-away connection is also feasible.
[0067] Although the implementation with side jaws 10 , 11 of the bracket unit 6 disposed on both sides of the jacket unit 2 is preferred, against which, in the closed state of the securement device 7 , parts of the securement device are tightened, implementations are also conceivable and feasible in which the bracket unit comprises only one side jaw located on one side of the jacket unit 2 .
[0068] A steering column according to the invention could, for example, also be implemented such that it is adjustable only in the length adjustment direction 8 . In such an embodiment, the intermediate unit 14 could be omitted and the opening 17 , 18 through which penetrates clamp bolt 16 could be implemented in the shape of a circle in each side jaw 10 , 11 of the bracket unit.
[0069] A steering column adjustable in the length adjustment direction 8 as well as also in the height or inclination adjustment direction 9 can also be implemented without an intermediate unit 14 . Herein in the jacket unit 2 elongated holes could be provided, penetrated by clamp bolt 16 , which extend in the length adjustment direction 8 of the steering column. For example, for this purpose on the jacket tube 30 at least one upwardly or downwardly projecting part could be disposed in which these elongated holes are disposed.
[0070] The jacket unit 2 can also, at least over a portion of its longitudinal extent, be implemented such that it is circumferentially open.
[0071] If, through a frictional closure connection a sufficiently high desired securement force in the direction of the length adjustment 8 between the retaining part 5 and a securement part 19 is attainable, a frictional closure engagement between these two parts could also be provided. To increase the securement force could herein also be provided additional cooperating friction faces, for example in the form of cooperating lamellae. Such cooperating lamellae could also be provided for the additional securement in the height or inclination adjustment direction 9 .
[0072] As is known, the bracket unit 6 could also be connected, dislocatably in the direction parallel to the longitudinal axis 4 in the event of a crash under energy absorption, with a mounting part connected stationarily on the vehicle.
[0073] For the case that an energy absorption is required in a direction that does not coincide with the longitudinal direction of the steering column (=direction of the longitudinal axis 4 ), the device according to the invention can also be oriented in this direction. The prestress would in that case be introduced in this direction into the one or the several bending wires or strips 32 . According to the illustrated examples, the rail 31 would be accordingly secured on the jacket unit oriented in this direction.
LEGENDS TO THE REFERENCE NUMBERS
[0000]
1 Steering shaft
2 Jacket unit
3 Steering wheel-side end
4 Longitudinal axis
5 Retaining part
6 Bracket unit
7 Securement device
8 Length adjustment direction
9 Height or inclination adjustment direction
10 Side jaw
11 Side jaw
12 Side flank
13 Side flank
14 Intermediate unit
15 Swivel axis
16 Clamp bolt
17 Opening
18 Opening
19 Securement part
20 Securement part
21 Connection section
22 Section
23 Clamping lever
24 Cam disk
25 Toothing
26 Toothing
27 Shear bolt
28 Opening
29 Opening
30 Jacket tube
31 Rail
32 Bending wire or strip
33 Pin
34 Slot
35 Eyelet
36 Stop
37 Extension
38 Prominence
39 Cutout
40 End
41 Projection
42 Projection | A steering column for a motor vehicle includes a casing unit, which rotatably supports a steering shaft about the longitudinal axis thereof, and a retaining part. The casing unit is held in a fixed manner relative to said retaining part up to a threshold value of a force acting on the casing unit in a parallel manner to the longitudinal axis of the steering shaft in the direction of the front of the vehicle. When the threshold value is exceeded, the casing unit is movably held in a parallel manner to the longitudinal axis in the direction of the front of the vehicle. The casing unit is connected to the retaining part via an energy-absorbing connection, which a bending wire or strip that is deformed when the casing unit is moved relative to the retaining part parallel to the longitudinal axis in the direction of the front of the vehicle, and via a breakaway connection closed up to a threshold value of the force and blocks a movement of the casing unit relative to the retaining part and which opens when the threshold value of the force is exceeded. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to building construction components and, more particularly, to devices for stiffening the webs of metal joists to provide reinforcement and prevent crippling of the joist web.
[0003] 2. Description of the Invention Background
[0004] Traditionally, the material of choice for new residential and commercial building framing construction has been wood. However, over the years, the rising costs of lumber and labor required to install wood framing components have placed the dream of owning a newly constructed home out of the economic reach of many families. Likewise such increasing costs have contributed to the slowing of the development and advancement of urban renewal plans in many cities. Other problems such as the susceptibility to fire and insect damage, rotting, etc. are commonly associated with wood building products.
[0005] In view of the foregoing problems and shortcomings of wood construction, steel is rapidly gaining acceptance among homebuilders and homeowners alike due to its cost effectiveness, dimensional stability, noncombustibility, insect resistance, durability, high strength-to-weight ratio and recycleability. These advantages have long been recognized by the commercial construction industry wherein steel has been the material of choice for several decades.
[0006] Regardless of whether a building comprises a multistory commercial structure or a single story residence, the floor of a structure is commonly formed from a series of support members that span the distance between support structures or support walls. These support members are known in the industry as floor joists and commonly have a web portion and an upper flange and a lower flange. Short “returns” or bends are provided on the ends of the upper and lower flanges. Such floors are generally constructed with steel joists having depths that range from 8 to 14 inches (203 to 356 mm) with a steel thickness from 43 mil to 97 mil (1.1 to 2.5 mm).
[0007] The ends of the joists are coupled to C-shaped tracks referred to as rim joists that are either supported on a wall or other structure by one of their flanges or have their webs attached to the wall or structure. The joists are commonly attached to the joist rims by conventional L-shaped clips or by tabs that are integrally formed in the web of the rim joist. Web stiffeners (sometimes also called bearing stiffeners or transverse stiffeners) are used to strengthen the web of the joist member by increasing its web crippling strength and preventing the joist from crumpling due to applied loads.
[0008] FIG. 1 illustrates a prior web stiffener 10 that has a web portion 12 and two outwardly protruding flange portions 14 . FIG. 2 illustrates the use of one conventional web stiffener 10 in connection with a conventional rim joist 20 and a conventional joist 30 . In practice, it is usually desirable for the web stiffener 10 to extend across the depth of the web 32 of the joist 30 . Such stiffeners 10 can be installed on either side of the web 32 of the joist 30 (either on the outside of the joist web 32 — FIG. 1 or on the inside of the joist web 32 — FIG. 3 ). When installed on the inside (between the lower flange 34 and the upper flange 36 of the joist 30 ), the web stiffener 10 is installed by sliding it in from the end of the joist 30 . Such installation method can be cumbersome and time consuming. Moreover, the web stiffener 10 must be properly sized relative to the joist 30 to enable it to be installed between the joist flanges 34 , 36 . Consequently, such one-piece web stiffeners 10 are often installed on the outside of the joist 30 ( FIG. 3 ). Such installation method is not always available and the web stiffener 10 lends no support to the upper flange 36 of the joist 30 .
[0009] In an effort to address such installation shortcomings when installing one-piece web stiffeners on the inside of the joist, two piece web stiffeners were developed. FIG. 4 illustrates a prior two-piece web stiffener 40 . When using such web stiffener 40 , the stiffener 40 is inserted into position between the flanges 24 and 26 of the joist 20 and then one piece 42 of the stiffener is moved relative to the other piece 44 of the stiffener 40 until at least piece 42 abuts the lower flange 24 and the other piece 44 abuts the upper flange 26 . Screws 38 are then installed through slots 46 in the pieces 42 , 44 to retain the pieces 42 , 44 in position. Such two-piece embodiment, while effective, is more difficult to manufacture and requires extra screws to install.
[0010] Thus, as can be appreciated from the forgoing discussion, there is a need for a simple one-piece web stiffener that can be easily and quickly installed on the inside of a floor joist between the upper and lower flanges, after the joist has already been installed, which eliminates the traditional requirement of pre-installed stiffeners.
SUMMARY
[0011] In accordance with one embodiment of the present invention, there is provided a web stiffener that comprises a substantially C-shaped member that has a web portion. In one embodiment, the web portion has a top edge and a bottom edge and first and second lateral sides that extend between the top edge and the bottom edge. A first flange protrudes outward from the first lateral side of the web portion and extends between the top edge and the bottom edge. A first portion of the top edge that intersects the first flange extends at a first substantially acute angle relative to a remaining portion of the top edge. A second flange protrudes from the second lateral side of the web portion and extends between the top edge and the bottom edge. A second portion of the bottom edge that intersects the second flange extends at a second substantially acute angle relative to a remaining portion of the bottom edge.
[0012] Another embodiment of the subject invention comprises a support wall and a rim joist that is attached to the support wall. At least one joist is attached to the rim joist. Each joist has a joist web and upper and lower joist flanges protruding therefrom. At least one web stiffener is oriented adjacent to the joist web of a corresponding joist. The web stiffener comprises a web portion that has a top edge and a bottom edge and first and second lateral sides that extend between the top edge and the bottom edge. A first flange protrudes outward from the first lateral side of the web portion and extends between the top edge and the bottom edge. A first portion of the top edge that intersects the first flange extends at a first substantially acute angle relative to a remaining portion of the top edge. A second flange protrudes from the second lateral side of the web portion and extends between the top edge and the bottom edge. A second portion of the bottom edge that intersects the second flange extends at a second substantially acute angle relative to a remaining portion of the bottom edge.
[0013] Another embodiment of the present invention comprises a floor structure that includes a support wall and a first joist that has a first joist end that is supported on the support wall. The first joist has a first joist web and upper and lower first joist flanges protruding therefrom. A second joist that has a second joist end is also supported on the support wall adjacent to the first joist end. The second joist has a second joist web and upper and lower second joist flanges. At least one web stiffener is oriented adjacent to one of the first and second joist webs and is attached thereto. The web stiffener comprises a web portion that has a top edge and a bottom edge and first and second lateral sides extending between the top edge and the bottom edge. A first flange protrudes outward from the first lateral side of the web portion and extends between the top edge and the bottom edge. A first portion of the top edge that intersects the first flange extends at a first substantially acute angle relative to a remaining portion of the top edge. A second flange protrudes from the second lateral side of the web portion and extends between the top edge and the bottom edge. A second portion of the bottom edge that intersects the second flange extends at a second substantially acute angle relative to a remaining portion of the bottom edge.
[0014] Another embodiment of the present invention comprises a web stiffener that has a web. The web has a top edge and a bottom edge. The top edge has a non-radiused portion and a radiused portion wherein the radiused portion forms an upper corner portion of the web. The bottom edge has a non-radiused portion and a radiused portion wherein the radiused portion of the lower edge forms a lower corner portion that is diagonally opposite to the upper corner portion. A first flange protrudes from a side of the web and extends from the non-radiused portion of the bottom edge to the radiused portion of the top edge. A second flange protrudes from another side of the web and extends from the non-radiused portion of the top edge to the radiused portion of the bottom edge.
[0015] Another embodiment of the present invention comprises a web stiffener that has a web. The web has a top edge and a bottom edge and a first lateral side edge that extends between the top edge and the bottom edge. A portion of the first lateral side edge is substantially perpendicular to the top edge and another portion of the first lateral side is not substantially perpendicular to the top edge. The web further has a second lateral side edge that extends between the top and bottom edges such that a portion of the second lateral side edge is substantially perpendicular to the bottom edge and another portion of the second lateral side is not substantially perpendicular to the bottom edge. A first flange protrudes outward from a portion of the first lateral side edge that is substantially perpendicular to the bottom edge of the web. A second flange protrudes outward from a portion of the second lateral side edge that is substantially perpendicular to the top edge of the web.
[0016] Another embodiment of the present invention comprises a web stiffener that has a web. The web has first and second lateral side edges and a top edge that extends in a radius between the first and second lateral sides and a bottom edge that extends in a radius between the first and second lateral sides. A first flange protrudes from the first lateral side and a second flange protrudes from the second lateral side.
[0017] Another embodiment of the present invention comprises a web stiffener that has a web having a first edge and a second edge and a pair of lateral side edges. One side edge extends between the first edge and the second edge such that a portion of the side edge is substantially perpendicular to the second edge and another portion of the side edge is not substantially perpendicular to the first edge. Another side edge extends between the first and second edges and a portion of the another side edge is substantially perpendicular to the first edge and another portion of the another side edge is not substantially perpendicular to the second edge. A first flange protrudes outward from a portion of the first lateral side edge that is substantially perpendicular to the second edge of the web. A second flange protrudes outward from the portion of the second lateral side edge that is substantially perpendicular to the first edge and wherein another portion of the other side edge extends in a radius from the second flange to the second edge of the web.
[0018] Another embodiment of the present invention comprises a web stiffener that includes a web. The web has a first lateral side edge and a second lateral side edge and top and bottom edges that extend between the first and second lateral side edges. The top edge has a non-radiused top edge portion disposed between a first radiused top edge portion and a second radiused top edge portion. The bottom edge has a non-radiused portion disposed between a first radiused bottom edge portion and a second radiused bottom edge portion. A first flange protrudes from the first lateral side edge and a second flange protrudes from the second lateral side edge.
[0019] Another embodiment of the present invention comprises a method for reinforcing a joist that has a web and an upper and a lower flange protruding from the web. In one embodiment, the method includes inserting a web stiffener that has a web and a top edge and a bottom edge and a pair of flanges that protrude from the web between the flanges of the joist such that the web of the web stiffener is adjacent to the web of the joist. The method also includes rotating the web stiffener such that at least a portion of the top edge of the web stiffener is closely adjacent to or in abutting contact with the upper flange of the joist and at least a portion of the bottom edge of the web stiffener is closely adjacent to or in abutting contact with the lower flange of the joist. The method also includes fastening the web of the web stiffener to the web of the joist.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In the accompanying Figures, there are shown present embodiments of the invention wherein like reference numerals are employed to designate like parts and wherein:
[0021] FIG. 1 is a perspective view of a prior one-piece web stiffener;
[0022] FIG. 2 is a perspective view of a portion of a conventional joist attached to a portion of a conventional rim joist and utilizing a prior web stiffener attached to an inside surface of the joist web;
[0023] FIG. 3 is a perspective view of a portion of a conventional joist attached to a portion of a conventional rim joist and utilizing a prior web stiffener attached to an outside surface of the joist web;
[0024] FIG. 4 is a perspective view of a prior two-piece web stiffener;
[0025] FIG. 5 is a perspective view of a web stiffener embodiment of the present invention;
[0026] FIG. 6 is a partial elevational view illustrating an initial position of a web stiffener embodiment of the present invention prior to be inserted between the upper and lower returns of a joist;
[0027] FIG. 7 is an end view of the web stiffener as positioned in FIG. 6 relative to the joist and prior to insertion between the upper and lower flanges of the joist;
[0028] FIG. 8 is another partial elevational view of the joist and rim joist assembly with the web stiffener installed in its final position;
[0029] FIG. 9 is an end view of the joist and rim joist assembly and web stiffener of FIG. 8 ;
[0030] FIG. 10 is a partial perspective view of the assemblies of FIGS. 8 and 9 ;
[0031] FIG. 11 is a perspective view of an embodiment of a web stiffener of the present invention used to reinforce the web of a joist that spans a wall assembly;
[0032] FIG. 12 is a perspective view of an embodiment of a web stiffener of the present invention used to reinforce the web of a joist that overlaps and is attached to a second joist to form a continuous joist assembly that spans a wall assembly;
[0033] FIG. 13 is a front elevational view of another web stiffener embodiment of the present invention;
[0034] FIG. 14 is a top view of the web stiffener of FIG. 13 ;
[0035] FIG. 15 is a front elevational view of another web stiffener embodiment of the present invention;
[0036] FIG. 16 is a top view of the web stiffener of FIG. 15 ;
[0037] FIG. 17 is a front elevational view of another web stiffener embodiment of the present invention;
[0038] FIG. 18 is a top view of the web stiffener of FIG. 17 ; and
[0039] FIG. 19 is a front elevational view of another web stiffener embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Referring now to the drawings for the purposes of illustrating the present embodiments of the invention only and not for the purposes of limiting the same, FIG. 5 illustrates one embodiment of a web stiffener 100 of the present invention that is particularly well-suited for use in connection with a joist arrangement 200 of the type depicted in FIGS. 6-10 . As can be seen in FIGS. 6-10 , the joist arrangement 200 includes a rim joist 210 that has a web 212 and an upper flange 214 and a lower flange 216 . The lower flange 216 may be supported on and attached to a top track 222 of a wall assembly 220 . See FIGS. 6, 8 and 10 . The reader will appreciate that rim joist 210 may be supported on and/or otherwise attached to a variety of different walls and support structures without departing from the spirit and scope of the present invention.
[0041] An end of a conventional floor joist 230 is supported between the upper and lower flanges 214 , 216 of the rim joist 210 and is attached thereto by L-shaped clip angles or tabs that are integrally formed in the web. The floor joist 230 has a web portion 232 and an upper flange 234 and a lower flange 236 . The floor joist 230 is sized such that the end thereof may fit between the upper and lower flanges of the rim joist 210 . An upper return portion 238 is formed on the end of the upper flange 234 and a lower return 240 is formed on the end of the lower flange 236 .
[0042] As can be seen in FIG. 5 , the web stiffener 100 of this embodiment is substantially C-shaped and has a web portion 102 that has a top edge 104 , a bottom edge 106 , a first lateral side edge 108 , and a second lateral side edge 110 . In one embodiment, for example, the web stiffener 100 may be fabricated from 12 gage (97 mil) 50 ksi, G60 galvanized steel. A first flange 112 protrudes outwardly from the first lateral side 108 at a first flange angle and a second flange 114 protrudes outwardly from the second lateral side 110 at a second flange angle. In one embodiment, the first flange 112 is substantially parallel with the second flange 114 and the first and second flange angles are approximately ninety degrees.
[0043] The first flange 112 protrudes outward from the first lateral side 108 of the web portion 102 and extends between the top edge 104 of the web portion 102 and the bottom edge 106 of the web portion. To facilitate easy insertion of the web stiffener 100 between the upper and lower flanges 234 , 236 of the joist 230 , a first portion 120 of the top edge 104 that intersects the first flange 112 extends at a first substantially acute angle “A” relative to a remaining portion 122 of the top edge 104 . The first portion may extend from a point “B” that is centrally located along the top edge 104 . Likewise, a second portion 130 of the bottom edge 106 that intersects the second flange 114 extends at a second substantially acute angle “C” relative to a remaining portion 132 of the bottom edge 106 . The second portion may extend from a point “D” that is centrally located along the bottom edge 106 . In one embodiment, the first acute angle “A” and the second acute angle “B” are each approximately 20 degrees. However, other angle arrangements could be employed.
[0044] Also in the embodiment depicted in FIG. 5 , the first flange 112 and the second flange 114 protrude from the web portion 102 a distance “E”. In one embodiment, distance “E” may be approximately 1.25 inches. The distance “H” is sized such that the when the web stiffener 100 is positioned as shown in FIGS. 8 and 10 , the portion 122 of the top edge 104 is closely adjacent to (for example, within approximately ⅛ inch (3.2 mm)) or abuts the bottom surface of the top flange 234 of the joist 230 and the portion 132 of the bottom edge 106 is closely adjacent to (for example, within approximately ⅛ inch (3.2 mm)) or abuts the upper surface of the bottom flange 236 of the joist 230 . The width “W” could conceivably be a variety of different lengths. See FIG. 5 . The chart provided below provides examples of web stiffener loads for different sizes of joists and stiffeners that have a width “W” of 3.5 inches and 6 inches.
Joist Size Gage 3.5″ Web Stiffener 6″ Web Stiffener (In.) (mils) Fy (ksi) Cond. 1 Cond. 2 Cond. 3 Cond. 1 Cond. 2 Cond. 3 8 16 (43) 33 5.3 5.8 5.6 5.9 6.4 6.2 16 (54) 33 5.4 6.1 5.9 6.0 6.8 6.5 50 5.6 6.6 6.3 6.2 7.3 6.9 14 (68) 33 5.6 6.7 6.3 6.2 7.4 7.0 50 5.8 7.5 6.9 6.4 8.3 7.6 12 (97) 33 6.0 8.4 7.5 6.7 9.3 8.3 50 6.5 10.1 8.7 7.2 11.1 9.6 10 16 (54) 33 5.4 6.0 5.9 6.0 6.7 6.5 50 5.5 6.4 6.2 6.1 7.1 6.8 14 (68) 33 5.6 6.6 6.3 6.1 7.3 6.9 50 5.7 7.3 6.8 6.3 8.1 7.5 12 (97) 33 6.0 8.2 7.4 6.6 9.1 6.2 50 6.4 9.8 8.5 7.1 10.8 9.4 12 16 (54) 33 5.4 5.9 5.8 6.0 6.6 6.4 50 5.5 6.3 6.1 6.0 7.0 6.8 14 (68) 33 5.5 6.5 6.2 6.1 7.2 6.9 50 5.7 7.1 6.7 6.3 7.9 7.4 12 (97) 33 5.9 8.0 7.3 6.5 8.9 8.1 50 6.3 9.5 8.4 6.9 10.5 9.3 14 14 (68) 33 5.5 6.4 6.1 6.1 7.0 6.8 50 5.6 6.9 6.6 6.2 7.0 7.3 12 (97) 33 5.8 7.9 7.2 6.5 6.7 8.0 50 6.2 9.2 6.3 6.8 10.2 9.1 Notes: 1) 3.5″ web stiffeners can be used with bearing widths of 3.5″-5.5″. 6″ web stiffeners can be used with bearing widths 6″ and greater. 2) Attach the web stiffener to the joist web with at least (3) #10-16 screws. Drive screws through the top, bottom, and middle pre-punched holes. 3) Web stiffeners are 12 gage (97 mil), 50 ksi with 1.25″ flanges.
[0045] To facilitate attachment of the web stiffener 100 to the web 232 of the joist 230 , one or more fastener holes 150 are provided through the web portion 102 . Appropriately sized fasteners 152 such as no. 10-16 screws may be inserted through the fastener holes 150 to affix the stiffener 100 to the joist web 232 . In one embodiment, the lowermost hole 150 may be approximately 1.0 inch from the bottom edge 106 (distance “F”). The uppermost hole 150 may also be approximately 1.0 inch from the top edge 104 . The holes 150 may be equally spaced across the height “H” of the web 102 . For example, for an embodiment that has a height “H” of 14 inches, a total of seven holes 150 that are 5/32 inches in diameter and spaced at 2.0 inches on center may be employed. The lower most hole 150 may be 1.0 inch from the bottom edge 104 and the uppermost hole 150 maybe 1.0 inch from the upper edge 106 .
[0046] FIGS. 6-10 illustrate one method for quickly and easily installing the web stiffener 100 without having to slide it in from a free end of the joist 230 . As can be seen in FIG. 6 , the web stiffener 100 is initially rotated such that the upper edge portion 120 is parallel with the lower edge of the upper flange 238 of joist 230 and the lower edge portion 130 is parallel with the upper edge of the lower flange portion 240 of the joist 230 such that the web stiffener 100 may be inserted between the upper and lower flanges 238 , 240 in the direction represented by arrows “G” ( FIGS. 7 ). After the web stiffener 100 has been inserted between the upper flange 238 and lower flange 240 and the web 102 is adjacent to the web 232 of the joist 230 , it is rotated (arrow “I” in FIG. 6 ) to the position illustrated in FIGS. 8 and 9 . When in the position illustrated in FIGS. 8 and 9 , there may be a small amount of space or “play” between the web stiffener 100 and the upper flange 234 and lower flange 236 of the joist 230 . For example, in one embodiment, there may be approximately ¼ inch (6.4 mm) of “play” between the web stiffener 100 and the upper flange 234 and the lower flange 236 . However, other amounts of play could be provided. Installation screws 152 or other suitable fasteners may then be installed through the holes 150 to affix the web stiffener 100 to the web 232 of the joist 230 . In alternative embodiments, the web stiffener 100 may be welded to the joist 230 or attached with other fasteners such as bolts, rivets, adhesive, etc.
[0047] FIG. 11 illustrates the use of a web stiffener 100 to reinforce the web 232 of a joist 230 that spans a wall assembly 220 that comprises a plurality of metal wall studs 224 that are attached to an upper track 222 and a bottom track (not shown). As can be seen in that Figure, the web stiffener 100 is substantially axially aligned with the underlying stud 224 such that the load from the stud 224 is axially transferred to the web stiffener 100 . The web stiffener 100 may be installed and attached to the web 232 of the joist 230 in the manner described above.
[0048] FIG. 12 illustrates the use of a web stiffener 100 to reinforce the ends of two overlapping joists 230 that span a wall assembly 220 that comprises a plurality of metal wall studs 224 that are attached to an upper track 222 and a bottom track (not shown). As can be seen in that Figure, the web stiffener 100 is substantially aligned with the underlying stud 224 such that the load from the stud 224 is axially transferred to the web stiffener 100 . The web stiffener 100 may be installed and attached to the web 232 of one of the joists 230 in the manner described above.
[0049] FIGS. 13 and 14 illustrate another web stiffener embodiment of the present invention. As can be seen in FIG. 13 , the web stiffener 300 of this embodiment has a web portion 302 that has a top edge 310 , a bottom edge 320 , a first lateral side edge 330 , and a second lateral side edge 340 . In one embodiment, for example, the web stiffener 300 may be fabricated from 12 gage (97 mil) 50 ksi, G60 galvanized steel. The top edge 310 of this embodiment has a radiused portion 312 and a non-radiused portion 314 . The radiused portion 312 forms an upper corner portion generally designated as 316 . Likewise, the bottom edge 320 has a radiused portion 322 and a non-radiused portion 324 . The radiused portion 322 forms a lower corner portion, generally designated as 326 , that is diagonally opposite from the upper corner portion 316 as shown in FIG. 13 . In one embodiment, the radiused portions 312 , 322 may each have a radius “R” of approximately 1.75 inches from the central axis of the web 302 . However, other radiuses “R” and other arcuate edges may be employed. The length of edge portions 314 , 324 , may be approximately W/2.
[0050] In this embodiment, a first flange 350 protrudes outwardly from the first lateral side edge 330 at a first flange angle and a second flange 360 protrudes outwardly from the second lateral side edge 340 at a second flange angle. In one embodiment, the first flange 350 is substantially parallel with the second flange 360 and the first and second flange angles are approximately ninety degrees.
[0051] The first flange 350 protrudes outward from the first lateral side edge 330 of the web portion 302 and extends from the non-radiused portion 324 of the bottom edge 320 to the radiused portion 312 of the top edge 310 . Likewise, the second flange 360 protrudes outward from the second lateral side edge 340 of the web portion 302 and extends from the non-radiused portion 314 of the top edge 310 to the radiused portion 322 of the bottom edge 320 .
[0052] Also in the embodiment depicted in FIGS. 13 and 14 , the first flange 350 and the second flange 360 protrude from the web portion 302 a distance “E”. In one embodiment, distance “E” may be approximately 1.25 inches. The web stiffener 300 is installed in the manner described above with respect to web stiffener 100 . That is, the web stiffener 300 is oriented in a position to enable it to be inserted between the upper flange 234 (and upper return 238 ) and the lower flange 236 (and lower return 240 ) of the joist 230 . After the web stiffener 300 has been inserted into position between the upper flange 234 and the lower flange 236 such that the web 302 is adjacent to the web 232 of the joist, it is rotated such that the portion 314 of the top edge 310 is closely adjacent (for example, within approximately ⅛ inch (3.2 mm)) or such that it abuts the lower surface of the upper flange 234 and the portion 324 of the bottom edge 320 is closely adjacent to (for example, within approximately ⅛ inch (3.2 mm )) or such that it abuts the upper surface of the lower flange 236 . Distance “H” is sized such that the web stiffener 300 may be inserted between the upper flange 234 and 236 of the joist 230 and then rotated to the above-described position. The width “W” could conceivably be a variety of different lengths. For example, 3.5″, 6.0″, etc. See FIG. 14 .
[0053] After the stiffener 300 has been rotated into position, installation screws (not shown) or other suitable fasteners may then be installed through the holes 380 in the web 302 to affix the web stiffener 300 to the web 232 of the joist 230 . In alternative embodiments, the web stiffener 300 may be welded to the joist 230 or attached with other fasteners such as bolts, rivets, adhesive, etc.
[0054] FIGS. 15 and 16 illustrate another web stiffener embodiment of the present invention. As can be seen in FIG. 15 , the web stiffener 400 of this embodiment has a web portion 402 that has a first edge 410 , a second edge 420 , a first lateral side edge 430 , and a second lateral side edge 440 . In one embodiment, for example, the web stiffener 400 may be fabricated from 12 gage (97 mil) 50 ksi, G60 galvanized steel. The first edge 410 of this embodiment has a radiused portion 412 and a non-radiused portion 414 . The radiused portion 412 forms a first corner portion generally designated as 416 . In one embodiment, the radiused portion 412 may have a radius “R” of approximately 1.75 inches. However, other radiuses “R” and other arcuate edges may be employed. Edge portion 414 may have a length of W/2.
[0055] In this embodiment, a first flange 450 protrudes outwardly from the first lateral side edge 430 at a first flange angle and a second flange 460 protrudes outwardly from the second lateral side edge 440 at a second flange angle. In one embodiment, the first flange 450 is substantially parallel with the second flange 460 and the first and second flange angles are approximately ninety degrees. Other flange angles could be employed.
[0056] The second edge 420 has a straight portion 422 and an angled portion 424 . The angled portion 424 extends at a substantially acute angle “C” relative to the straight portion 422 of the second edge 420 . The angled portion 424 may extend from a point “D” that is centrally located along the second edge 420 . In one embodiment, the angle “C” is approximately 20 degrees. However, other angle arrangements could be employed.
[0057] The first flange 450 protrudes outward from the first lateral side edge 430 of the web portion 402 and extends from the radiused portion 412 of the first edge 410 to the straight portion 422 of the second edge 420 . The second flange 460 protrudes from the second lateral side edge 440 of the web portion 402 and extends from the non-radiused portion 414 of the first edge 410 to the angled portion 424 of the second edge 420 . Also in the embodiment depicted in FIGS. 15 and 16 , the first flange 450 and the second flange 460 protrude from the web portion 402 a distance “E”. In one embodiment, distance “E” may be approximately 1.25 inches.
[0058] The web stiffener 400 is installed in the manner described above with respect to web stiffener 100 . That is, the web stiffener 400 is oriented in a position to enable it to be inserted between the upper flange 234 (and upper return 238 ) and the lower flange 236 (and lower return 240 ) of the joist 230 . After the web stiffener 400 has been inserted into position between the upper flange 234 and the lower flange 236 , it is rotated such that the portion 414 of the top edge 410 is closely adjacent (for example, within approximately ⅛ inch (3.2 mm)) or such that it abuts the lower surface of the upper flange 234 and the portion 324 of the bottom edge 422 is closely adjacent to (for example, within approximately ⅛ inch (3.2 mm)) or such that it abuts the upper surface of the lower flange 236 . Distance “H” is sized such that the web stiffener 400 may be inserted between the upper flange 234 and 236 of the joist 230 and then rotated to the above-described position. The width “W” could conceivably be a variety of different lengths. For example, W may be 3.5″, 6.0″, etc. See FIG. 16 .
[0059] After the stiffener 400 has been rotated into position, installation screws (not shown) or other suitable fasteners may then be installed through the holes 480 in the web 402 to affix the web stiffener 400 to the web 232 of the joist 230 . In alternative embodiments, the web stiffener 400 may be welded to the joist 230 or attached with other fasteners such as bolts, rivets, adhesive, etc.
[0060] FIGS. 17 and 18 illustrate yet another web stiffener embodiment of the present invention. As can be seen in FIG. 17 , the web stiffener 500 of this embodiment has a web portion 502 that has an upper edge 510 , a lower edge 520 , a first lateral side edge 530 , and a second lateral side edge 540 . In one embodiment, for example, the web stiffener 500 may be fabricated from 12 gage (97 mil) 50 ksi, G60 galvanized steel. The upper edge 510 and lower edge 520 are radiused as shown. In one embodiment, the radius “R” may be approximately W/2.
[0061] In this embodiment, a first flange 550 protrudes outwardly from the first lateral side edge 530 at a first flange angle and a second flange 560 protrudes outwardly from the second lateral side edge 540 at a second flange angle. In one embodiment, the first flange 550 is substantially parallel with the second flange 560 and the first and second flange angles are approximately ninety degrees. Other flange angles could be employed. The first flange 450 protrudes outward from the first lateral side edge 530 of the web portion 502 and extends between the upper radiused end 510 and the lower radiused end 520 . The second flange 460 protrudes from the second lateral side edge 540 of the web portion 502 and extends between upper end 410 and the lower end 420 .
[0062] Also in the embodiment depicted in FIGS. 17 and 18 , the first flange 550 and the second flange 560 protrude from the web portion 502 a distance “E”. In one embodiment, distance “E” may be approximately 1.25 inches. The distance “H” is sized such that the when the web stiffener is installed as described above, it is closely adjacent to or in abutting contact with the bottom surface of the top flange 234 of the joist 230 and the upper surface of the bottom flange 236 of the joist 230 . The width “W” could conceivably be a variety of different lengths.
[0063] The web stiffener 500 is installed in the manner described above with respect to web stiffener 100 . That is, the web stiffener 500 is oriented in a position to enable it to be inserted between the upper flange 234 (and upper return 238 ) and the lower flange 236 (and lower return 240 ) of the joist 230 . After the web stiffener 500 has been inserted into position between the upper flange 234 and the lower flange 236 , it is rotated such that a portion of the top edge 510 is closely adjacent (for example, within approximately ⅛ inch (3.2 mm)) or such that it abuts the lower surface of the upper flange 234 and a portion of the bottom edge 520 is closely adjacent to (for example, within approximately ⅛ inch (3.2 mm )) or such that it abuts the upper surface of the lower flange 236 . Distance “H” is sized such that the web stiffener 500 may be inserted between the upper flange 234 and 236 of the joist 230 and then rotated to the above-described position.
[0064] After the stiffener 500 has been rotated into position, installation screws (not shown) or other suitable fasteners may then be installed through the holes 588 in the web 502 to affix the web stiffener 500 to the web 232 of the joist 230 . In alternative embodiments, the web stiffener 500 may be welded to the joist 230 or attached with other fasteners such as bolts, rivets, adhesive, etc.
[0065] FIG. 19 depicts another web stiffener embodiment of the present invention. In this embodiment, the web stiffener 600 is essentially identical in construction as web stiffener 500 described above. However, in this embodiment, a non-radiused top edge portion 580 is formed on the top edge 510 as shown. Thus, in this embodiment, the top edge 510 has a non-radiused top portion 580 that is centrally disposed between a first radiused top edge portion 582 and a second radiused top edge portion 584 . Radiused top edge portion 582 extends from the first lateral side edge 530 to the non-radiused top portion 580 and the radiused top edge portion 584 extends from the second lateral side edge 540 to the non-radiused top edge portion 580 . Also in this embodiment, a non-radiused bottom edge portion 590 may be formed on the bottom edge 520 . Thus, the bottom edge 520 has a non-radiused bottom portion 590 that is centrally disposed between a first radiused bottom edge portion 592 and a second radiused bottom edge portion 594 . The first radiused bottom edge portion 592 extends from the first lateral side edge 530 to the non-radiused bottom edge portion 590 and the second radiused bottom edge portion 594 extends from the second lateral side edge 540 to the non-radiused bottom edge portion 590 as shown. In one embodiment wherein, for example “W” is approximately 3.5 inches, the upper non-radiused portion 580 may have a length “L” of approximately 1.25 inches. The lower non-radiused portion 590 may have a similar length. This embodiment may be installed in the manner described above.
[0066] In particular, the web stiffener 600 is oriented in a position to enable it to be inserted between the upper flange 234 (and upper return 238 ) and the lower flange 236 (and lower return 240 ) of the joist 230 . After the web stiffener 600 has been inserted into position between the upper flange 234 and the lower flange 236 , it is rotated such that the portion 580 of the top edge 510 is closely adjacent (for example, within approximately ⅛ inch (3.2 mm)) or such that it abuts the lower surface of the upper flange 234 and the portion 590 of the bottom edge 520 is closely adjacent to (for example, within approximately ⅛ inch (3.2 mm)) or such that it abuts the upper surface of the lower flange 236 . Distance “H” is sized such that the web stiffener 600 may be inserted between the upper flange 234 and 236 of the joist 230 and then rotated to the above-described position.
[0067] After the stiffener 600 has been rotated into position, installation screws (not shown) or other suitable fasteners may then be installed through the holes 588 in the web 502 to affix the web stiffener 600 to the web 232 of the joist 230 . In alternative embodiments, the web stiffener 600 may be welded to the joist 230 or attached with other fasteners such as bolts, rivets, adhesive, etc.
[0068] The various web stiffener embodiments of the present invention may be used to prevent joist web crippling, while serving to pass loads from above to walls or bearings below. The unique design of the web stiffeners of the present invention allows the web stiffeners to be easily rotated in place between the flanges while providing a minimal amount of play therebetween without having to slide the web stiffener in from a free end of the joist and without having to use a two piece web stiffener.
[0069] The invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. The embodiments are therefore to be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such equivalents, variations and changes which fall within the spirit and scope of the present invention as defined in the claims be embraced thereby. | A one piece web stiffener that may be easily and quickly installed between the upper and lower flanges of a joist without having to slide the web stiffener in from and end of the joist is disclosed. One embodiment of the web stiffener includes a web and a pair of protruding flanges. Opposing upper and lower corners are provided at angles to enable the web stiffener to be inserted between returns formed on the upper and lower flanges of the joist and then rotated to fit relatively tightly between the upper and lower flanges of the joist. In other embodiments, one corner is radiused and an opposing corner is angled. Other embodiments include radiuses on two diagonal corners or radiused ends to enable the web stiffeners to be inserted between the upper and lower flanges of a joist and then rotated into a final web stiffening position wherein it can be attached to the joist web. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a temperature-sensitive actuator comprised of a thermo-element that advances and retracts a piston in response to changes in temperature and a PTC heater for selectively heating the temperature-sensitive part of the thermo-element.
[0003] 2. Description of the Background Art
[0004] This type of temperature-sensitive actuator is used in a driven member of an electronic valve control device or the like of a carburetor adapted to an ordinary engine, as a temperature-sensitive actuator for controlling the operation of a choke or a throttle that opens and closes the intake of the carburetor.
[0005] Conventionally, this type of temperature-sensitive actuator has a thermo-element with thermo wax enclosed in its temperature-sensitive part, and is constructed of a piston that advances and retreats axially in response to expansion and contraction of the thermo wax with changes in temperature and a PTC heater that heats the temperature-sensitive part with a given electric current (see for example, Utility Model Application Publication No. H05-8158).
[0006] In addition, this type of temperature-sensitive actuator is configured so that it is possible to control the change in the volume of the thermo wax attendant upon changes in temperature with the PTC heater, thereby moving the piston only the required lift amount, operating at a given timing with only the necessary energizing to move the piston, and operating independently even when power supply is stopped, to move the appropriate moving member.
[0007] However, with a temperature-sensitive actuator having the configuration described above, there is a risk that contact between the thermo-element temperature—sensitive part (i.e., the case) and the PTC heater becomes a point-contact. Such point-contact arises, for example, in a case in which the actuator is tilted during assembly, or the contact surface is not flat but uneven, or the degree of flatness increases due to deformation (bending, etc.) of the PTC heater occurring during formation or warping of the PTC heater due to machining.
[0008] Further, with the above-described temperature-sensitive part of the thermo-element, in order to prevent differences between products from arising due to tiny differences in mounting or the amount of wax sealed within occurring during production, it is common to carry out an adjustment step whereby the bottom of the thermo-element case is dented and deformed. However, depending on the degree of adjustment a variety of things occur in the resulting adjustment mark. With the deformation stemming from this adjustment mark, the degree of flatness of the machining, warping, shape and the like, there is a risk that the contact between the thermo-element temperature-sensitive part and the PTC heater becomes a point-contact.
[0009] Occurrence of the point-contact condition described above leads to such inconveniences as lack of adequate energization, as a result of which the PTC heater cannot exert its maximum heat-generating potential; heat cannot be propagated smoothly from the PTC heater, leading to an inability to attain stable PTC heater output; and variations arise between individual actuators. There is thus a need for some countermeasure capable of solving these sorts of problems.
SUMMARY OF THE INVENTION
[0010] The present invention is conceived in light of the circumstances described above and has as its object to provide a thermostat device configured to be able to energize the PTC heater and propagate heat from the PTC heater for the thermo-element temperature-sensitive in the required state inexpensively and reliably.
[0011] To achieve this object, the present invention (according to claim 1 ) provides a temperature-sensitive actuator comprising a thermo-element having a thermal expansion unit sealed within a temperature-sensitive part of the thermo-element; a PTC heater that selectively heats the temperature-sensitive part of the thermo-element; and a contact member inserted between the temperature-sensitive part of the thermo-element and the PTC heater.
[0012] The present invention (according to claim 2 ) provides a temperature-sensitive actuator according to claim 1 , wherein the contact member has a shape such that a portion of a side of the contact member that contacts the thermo-element lacks a contacting part.
[0013] The present invention (according to claim 3 ) provides a temperature-sensitive actuator according to either claim 1 or claim 2 , further comprising a pair of electrical terminals provided at an actuator mount for the temperature-sensitive actuator and configured to fixedly hold the temperature-sensitive actuator on both sides of the temperature-sensitive actuator along a central axis of the temperature-sensitive actuator, wherein the temperature-sensitive actuator is configured to be fixedly held at the actuator mount side by being engaged and held at two places in the axial direction of the temperature-sensitive actuator by the pair of electrical terminals.
EFFECT OF THE INVENTION
[0014] As described above, the temperature-sensitive actuator according to the present invention is configured so as to interpose a contact member between the thermo-element and the PTC heater, and thus is able to secure a sufficient contact area, eliminate variations in heat transmission and heater output (energization amount) between individual products, and achieve stability.
[0015] That is, with the conventional structure, the contact between the thermo-element and the PTC heater is a point-contact, so that energizing is not sufficiently carried out, the amount of energization is small, and the amount of heat generated is reduced, such that the PTC heater cannot exert its heat-generating capability to maximum effect, or the transmission of heat from the PTC heater is not conducted smoothly, leading to an inability to achieve stable PTC heater output. However, with the present invention, the contact member can provide sufficient contact area for energizing and heat transmission between the thermo-element and the PTC heater, and moreover serves the function of holding and storing heat generated between the thereto-element and the PTC heater, thereby enabling the heat to be conducted to the thermo-element case efficiently.
[0016] In addition, the contact member according to the present invention, because it is heated by the heat generated by the PTC heater, enables the FTC heater to continue to generate heat efficiently. As a result, although it takes longer for the thermo-element to begin to operate than it would without a contact member, once the temperature of the contact member rises and the contact member retains a certain amount of heat, the amount of heat that the thermo-element receives also increases, resulting in faster lift and better responsiveness, and further, the PTC heater output is stable, so that it is possible for the thermo-element to operate in the required state.
[0017] In addition, according to the present invention, the contact member is formed so as to not have, at a portion of a side of the contact member that contacts the thermo-element, a portion that contacts the thermo-element (for example, the contact member has an annular shape). Accordingly, the contact area between the bottom of the thermo-element case and the contact member and the contact area between the PTC heater and the contact member is constant, and it is possible to keep the amount of heat transmitted to the thermo-element and the amount of heat generated by the PTC heater constant regardless of the size of the adjustment mark added to the thermo-element temperature-sensitive part during manufacture. As a result, variations between products in the amount of lift described above disappear.
[0018] In particular, by making the hole in the annular contact member larger than the adjustment mark in the bottom of the case of the thermo-element temperature-sensitive part, and further by providing a gap so that there is no overlapping of the adjustment mark, it is possible to keep the contact area between bottom surface of the thermo-element case and the contact member and the contact area between the contact member and the PTC heater constant regardless of the size of the adjustment mark in the bottom of the thermo-element case, and thus it is possible to keep the amount of heat transmitted to the thermo-element and the amount of heat generated by the PTC heater constant regardless of the size of the adjustment mark in the bottom of the thermo-element case, increasing the amount of heat that the thermo-element absorbs, resulting in faster lift and improved responsiveness, thereby eliminating the variation in lift amount between products described above.
[0019] Further, the present invention also has a good effect on the manufacturing process as well, insofar as there is no longer any need to adjust the output of the FTC heater in order to minimize variation in the amount of lift described above.
[0020] That is, with the method of direct contact between the thermo-element and the PTC heater as in the conventional structure, there arise variations in the contact area between the thermo-element and the PTC heater attributable to differences in the size of the above-described adjustment mark that in turn affect the amount of heat generated and the transmission of heat, thus causing variations in the amount of lift to occur. Even assuming an annular PTC heater were to be manufactured, its machining would be difficult and consequently it would be costly. However, providing an annular contact member allows the actuator to be manufactured inexpensively. It should be noted that it is possible to select the shape of the contact member from among a variety of different shapes, including round, square, or the like, provided only that the contact member is the same size as or larger than the above-described adjustment mark, and does not overlap the adjustment mark.
[0021] In addition, in the present invention, the mount for mounting and fixing the temperature-sensitive actuator in place is provided with electrical terminals that serve to engage and hold the temperature-sensitive actuator and also function as electrode terminals, thereby facilitating fixing and attachment of the temperature-sensitive actuator to the mount as well as eliminating the need for attachment parts and screws or the like, thus eliminating the need for tightening screws.
[0022] In particular, with the conventional structure, in order to hold the thermo-element and the PTC heater the thermo-element and the PTC heater are inserted in the actuator case, capped, and screwed together to form the thermo-element/PTC heater assembly, which assembly is then further screwed together and fixed in place. By contrast, the present invention is configured to provide the housing mount with electrode terminals on which the thermo-element is mounted, thereby providing greater freedom of layout design.
[0023] Further, according to the present invention, in the mounting of the temperature-sensitive actuator onto the housing or other such mount of the device that is the drive source of the temperature-sensitive actuator, it is possible to fix the temperature-sensitive actuator fully in place simply by pressing the actuator into the electrical terminals that act as fixing jigs, thus eliminating the need for the screws, bolts, nuts, and other such fixing means required conventionally, thereby facilitating assembly. Moreover, since there is no need to insert terminal fittings in the body of the actuator, this arrangement has the additional advantage that it is possible to minimize both cost and the number of parts.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0024] FIG. 1 is a schematic cross-sectional view of the entirety of one embodiment of a temperature-sensitive actuator according to the present invention;
[0025] FIG. 2 is a schematic perspective view of the exterior of the temperature-sensitive actuator according to the present invention;
[0026] FIG. 3 is a graph illustrating operating characteristics of a temperature-sensitive actuator with and without the contact member that is the distinctive feature of the present invention;
[0027] FIGS. 4A and 4B are partial enlarged cross-sectional views of variations of the contact member that is the distinctive feature of the present invention; and
[0028] FIG. 5 is a schematic exploded perspective view of another embodiment of a temperature-sensitive actuator according to the present invention, illustrating a state in which the temperature-sensitive actuator is mounted on an actuator mount.
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIG. 1 and FIG. 2 show one embodiment of a temperature-sensitive actuator according to the present invention.
[0030] In these drawings, the temperature-sensitive actuator indicated in its entirety by reference numeral 10 is comprised of a temperature-sensitive part 13 , itself comprised of a thermal expansion unit such as wax 12 sealed inside a substantially cylindrical case 11 , and a moving part 16 , itself comprised of a piston 14 that advances and retreats along the axis of the temperature-sensitive actuator 10 with expansion and contraction of the wax 12 within the temperature-sensitive part 13 and a guide tube 15 fixedly mounted on the tip of the case 11 so as to slidably hold the piston 14 , thus forming a thermo-element.
[0031] Reference numeral 18 in the drawings indicates a diaphragm provided between the wax 12 of the temperature-sensitive part 13 and the piston 14 . The diaphragm 14 is movable with expansion and contraction of the wax 12 , and that movement is transmitted to the piston 14 via a sealed medium and an auxiliary piston, such that the piston 14 advances and retreats axially. The piston 14 is configured so that, through a spring 36 that gives the temperature-sensitive actuator 10 an elastic holding capability, the piston 14 can move as the wax 12 contracts via a cap-shaped tubular body 35 .
[0032] Further, a PTC heater 20 is installed in a lower end of the case 11 , at a bottom side of the case 11 that constitutes the thermo-element temperature-sensitive part 13 (in this case, below a dividing wall 17 formed inside the case 11 ), thus forming a heater holder 21 .
[0033] Here, reference numeral 22 in the drawing indicates a terminal base fitted into the lower end of the case 11 , 23 indicates a terminal held within the terminal base 22 , and 24 indicates an electrically conductive spring interposed between an inner end of the terminal 23 and the PTC terminal 20 that also functions as a lead wire.
[0034] The conductive spring 24 presses against the PTC heater 20 and at the same time also absorbs vibration, thereby also functioning to prevent the PTC heater 20 from being destroyed by these vibrations. Further, because the PTC heater 20 is biased by the conductive spring 24 , if, for example, the PTC heater 20 or the like is assembled tilted during assembly, or the contact surface of the PTC heater 20 or the like is not flat but uneven, or further, if the PTC heater 20 is deformed (bent) during formation, the dividing wall 17 of the case 11 is deformed by an adjustment mark, or the degree of flatness increases due to undulation from machining, good contact area of the PTC heater 20 for the dividing wall 17 that divides the thermo-element temperature-sensitive part 13 can still be obtained.
[0035] In addition, a pair of electrode terminal jigs 31 , 32 are preset onto the outside the case 11 as well as the lower end of the terminal 23 . Lead wires 33 , 34 leading from the jigs 31 , 32 are connected to a controller, not shown, by which it is possible to selectively energize the PTC heater 20 to obtain reciprocal movement of the piston as the temperature-sensitive actuator 10 .
[0036] It is to be noted that reference numeral 35 in FIG. 1 indicates the cap-shaped tubular body fitted onto the guide tube 15 of the temperature-sensitive actuator 10 . Reference numeral 36 indicates the spring, which, as described above, acts to elastically hold the temperature-sensitive actuator on a mount on the main device side and to push the lifted piston 14 back when the wax 12 contracts.
[0037] In addition, the temperature-sensitive actuator 10 described above is made of metal material having good thermal conductivity, the wax or other thermal expansion unit 12 is made of material that changes volume as the temperature changes, and the other parts have structures that are known conventionally, and detailed discussion thereof is omitted.
[0038] According to the present invention, in the temperature-sensitive actuator 10 configured as described above, the provision of the contact member 40 so as to be interposed between the thermo-element temperature-sensitive part 13 and the PTC heater 20 is the distinctive feature.
[0039] A copper material or the like having good thermal conductivity may be used as the contact member 40 . Of course, the contact member 40 is not limited to such material, and anything having the proper volume, shape, and composition may be used as the contact member 40 .
[0040] In addition, the contact member 40 also has the function of connecting the PTC heater 20 to the terminal jig 31 and the lead wire 33 via the case 11 .
[0041] The contact member 40 configured as described above secures a sufficient contact area for energizing and transmitting heat between the thermo-element temperature-sensitive part 13 and the PTC heater 20 and putting thermal conductivity performance into the required state, thereby enabling the thermo-element temperature-sensitive part 13 to be controlled and heated to the required state.
[0042] In addition, the contact member 40 serves to hold and store the heat generated between the thermo-element temperature-sensitive part 13 and the PTC heater 20 , thereby enabling transmission of heat from the thermo-element temperature-sensitive part 13 to the case 11 to be conducted efficiently.
[0043] Further, since the contact member 40 is heated by the heat generated by the PTC heater 20 , the PTC heater can continue to generate heat efficiently to replace that which is absorbed by the contact member 40 , thereby enabling the PTC heater 20 output to be stabilized.
[0044] Then, using the contact member 40 described above, the heat from the PTC heater 20 is conducted to the contact member 40 and then to the thermo-element temperature-sensitive part 13 via the contact member 40 .
[0045] If the PTC heater 20 does not conduct heat to the surrounding members, for example to the element case 11 , the heat remains trapped in the PTC heater itself, its temperature rises, and its internal resistance increases, thus decreasing its heat-generating capability, whereby it cannot continue to generate heat efficiently. However, the contact member 40 , which continuously absorbs the heat generated by the PTC heater 20 , is disposed between the PTC heater 20 and the thermo-element temperature-sensitive part 13 , thereby enabling the PTC heater 20 to continue to generate heat efficiently. Therefore, the PTC heater 20 can continue to output stably.
[0046] The temperature-sensitive actuator 10 having the configuration described above, because it is configured to interpose the contact member 40 between the thermo-element temperature-sensitive part 13 and the PTC heater 20 , can provide sufficient contact area to eliminate any discrepancies in heat transmission and heater output (amount of heat generated) from one product to the next and stabilize them.
[0047] Put differently, with the conventional structure, the contact between the thermo-element (temperature-sensitive part 13 ) and the PTC heater 20 is a point-contact, leading to insufficient energizing and a consequent inability of the PTC heater to exert its heat-generating capability to maximum effect, or cases in which transmission of heat from the PTC heater is not conducted smoothly, leading to an inability to obtain stable PTC heater output. However, in the present invention, the contact member 40 can provide sufficient contact area for energizing and heat transmission between the thermo-element temperature-sensitive part 13 and the PTC heater 20 , and moreover, serves the function of holding and storing heat generated between the thermo-element temperature-sensitive part 13 and the PTC heater 20 , thereby enabling the heat to be conducted to the thermo-element case 11 efficiently.
[0048] In addition, the contact member 40 described above, because it is heated by the heat generated by the PTC heater 20 , enables the PTC heater 20 to continue to generate heat efficiently. As a result, although the thermo-element takes longer to operate longer at the beginning of energizing than it would without a contact member, heat can continue to be conducted to the temperature-sensitive part 13 for a certain period of time even after energizing is stopped, thus minimizing power consumption and also achieving energy savings. Moreover, once the temperature of the contact member 40 rises and the contact member 40 holds a certain amount of heat, the PTC heater 20 output stabilizes, allowing the thermo-element to be operated continuously in the required state.
[0049] A graph of the operating characteristics of the temperature-sensitive actuator 10 according to the present invention described above is shown in FIG. 3 .
[0050] In FIG. 3 , compared to a conventional example (without a contact member) indicated by a broken line, the present invention (with the contact member 40 ) indicated by a solid line has superior rise characteristics during operation. For example, the time until the rise reaches a point at which the lift amount after initial energizing reaches 4.5 mm is ½ that of the conventional example. In addition, in the case of the present invention, it is also confirmed that the lift amount also increases by 10%.
[0051] Then, as is clear from the graph shown in FIG. 3 , use of the contact member 40 enables the performance of the temperature-sensitive actuator 10 to be improved. Moreover, such performance improvement is obtained as a result of the heat retention and heat storage effects produced by the contact member 40 , and its effect in actual use is clear. In other words, this effect is due to the smooth transfer of heat by the contact member 40 and the consequent ability of the PTC heater 20 to maintain a stable high output.
[0052] FIGS. 4A and 4B show other embodiments of the temperature-sensitive actuator according to the present invention.
[0053] As shown in these drawings, the contact member 40 is depicted as formed so as to not have, in a side of the contact member 40 that contacts the thermo-element, a portion, and in particular a central portion, that contacts the thermo-element; for example, the contact member 40 has an annular shape with an empty space (or a depression) in the middle.
[0054] More specifically, with the temperature-sensitive actuator 10 , it is known that tiny differences in the mounting of the thermo-element temperature-sensitive part 13 or the amount of wax 12 sealed therewithin during manufacture produces differences (variations) between individual products. As a result, conventionally, in order to minimize such variation a dent is made in the bottom of the thermo-element case 11 after assembly as an indispensible step in the manufacturing process. Typically, by forcibly pushing in the chamber into which the wax 12 is put inside the thermo-element case 11 , the projecting length of the piston 14 is forcibly adjusted, thereby adjusting the lift amount of the thermo-element to a reference value.
[0055] As a result, however, an adjustment mark 43 is formed in the bottom surface of the thermo-element case (the dividing wall 17 ). The size of the adjustment mark 43 varies depending on the extent of the adjustment.
[0056] By contrast, because the present invention forms the contact member in an annular shape, regardless of the existence of the adjustment mark 43 described above the contact area between the bottom of the thermo-element case 11 (the dividing wall 17 ) and the contact member 40 and the contact area between the contact member 40 and the PTC heater 20 is kept constant, and it is possible to keep the amount of heat transmitted to the thermo-element and the amount of energizing of the PTC heater constant regardless of the size of the adjustment mark added to the thermo-element temperature-sensitive part during manufacture. As a result, the temperature-sensitive actuator 10 eliminates the variation in lift amount between products described above.
[0057] In particular, by making the hole in the annular contact member 40 larger than the adjustment mark 43 in the bottom of the case (the dividing wall) of the thermo-element temperature-sensitive part 13 , and further by providing a gap so that there is no overlapping of the adjustment mark 43 , it is possible to keep the contact area between the bottom surface of the thermo-element case 11 (the dividing wall 17 ) and the contact member 40 and the contact area between the contact member 40 and the PTC heater 20 constant regardless of the size of the adjustment mark 43 in the bottom of the case 11 of the thermo-element, and thus it is possible to keep the amount of heat transmitted to the thermo-element and the amount of energizing of the PTC heater 20 constant regardless of the size of the adjustment mark 43 in the bottom of the case 11 of the thermo-element, thereby eliminating the variation in lift amount between products described above.
[0058] FIG. 5 shows yet another embodiment of the present invention.
[0059] That is, with the temperature-sensitive actuator 10 in the embodiments described above, as shown for example in FIG. 2 , the electrode terminal jigs 31 , 32 with lead wires 33 , 34 attached are fitted onto the outside of the case 11 , and the whole assembly is configured so as to be mounted and fixed on a predetermined place on a mount on a main unit. Instead, as shown in FIG. 4 , the present embodiment utilizes electrical terminals 51 , 52 provided on the mount 50 side in place of the electrode terminal jigs 31 , 32 described above, configured to engage and fixedly mount the temperature-sensitive actuator thereon.
[0060] More specifically, in the present embodiment, on the mount 50 for mounting and fixing the temperature-sensitive actuator 10 , the body of the temperature-sensitive actuator (as shown in FIG. 5 ) provides the electrical terminals 51 , 52 that serve to engage and hold the temperature-sensitive actuator 10 and also function as electrode terminals, which makes fixedly mounting the temperature-sensitive actuator 10 on the mount 50 easy and also provides greater freedom of layout design.
[0061] The electrical terminal 51 may be composed of a spring retention tab that sandwiches the central axis of the temperature-sensitive actuator 10 and presses against the temperature-sensitive actuator 10 from both sides, for example. Similarly, the electrical terminal 52 may be composed of a spring engagement tab that elastically contacts the terminal 23 exposed at the end of the heater holder 21 of the temperature-sensitive actuator 10 . The temperature-sensitive actuator 10 is engaged and held in place by these electrical terminals 51 , 52 .
[0062] It is to be noted that, in the configuration shown in FIG. 5 , a portion of intermediate diameter of the temperature-sensitive actuator 10 (indicated by reference character A in FIG. 5 ) is sandwiched by the pair of spring retention tabs that constitute the electrical terminal 51 and fixedly mounted in place. By fixedly mounting the temperature-sensitive actuator 10 at the portion of intermediate diameter A in this way, the electrical terminal 51 is engaged by a large-diameter portion of the temperature-sensitive actuator 10 (indicated by reference character B in FIG. 5 ) and the temperature-sensitive actuator 10 is held between the electrical terminal 51 and the electrical terminal 52 , thereby restricting movement of the temperature-sensitive actuator in the axial direction (the direction in which the piston 14 advances and retreats).
[0063] Of course, the present arrangement is not limited to that which is described above, and alternatively, it is possible to arrange matters so that either the large-diameter portion B or a small-diameter portion (that portion of the guide tube 15 which is indicated by reference character C in FIG. 5 ) is sandwiched by the spring retention tabs that constitute the electrical terminal 51 to fixedly mount the temperature-sensitive actuator 10 in place. For example, when the small-diameter portion C of the temperature-sensitive actuator 10 is sandwiched by the electrical terminal 51 and fixedly mounted in place, an axial length of the cap-shaped tubular body 35 and the spring 36 that constitute a return spring mechanism fitted onto the guide tube 15 that is this small-diameter portion C may be shortened, and a portion pressed onto the electrical terminal 51 held and secured.
[0064] With the conventional structure, in order to hold the thermo-element temperature-sensitive part 13 and the PTC heater 20 , the thermo-element and the PTC heater 20 are put into the actuator case 11 , capped, and screwed together to form the thermo-element and PTC heater 20 assembly, which assembly is then screwed together and fixedly mounted in place. However, with the present invention it is possible to solve such problems at a stroke.
[0065] That is, with the configuration described above, in the mounting of the temperature-sensitive actuator onto the housing or other such mount of the device that is the drive source of the temperature-sensitive actuator, it is possible to fix the temperature-sensitive actuator fully in place simply by pressing the actuator into the electrical terminals 51 , 52 that act as fixing jigs, thus eliminating the need for the screws, bolts, nuts, and other such fixing means, thereby facilitating assembly. Moreover, since there is no need to press terminal fittings into the body of the actuator, it is possible to minimize both cost and the number of parts.
[0066] The present invention is not limited to the embodiments described above, and it is possible to vary and change the shapes, structures, and so forth of the various parts that comprise the temperature-sensitive actuator 10 as needed.
[0067] For example, as described in JP-2006-57497-A, by using the temperature-sensitive actuator 10 described above in place of a power motor as a motorized actuator for controlling the operation of a choke or a throttle that opens and closes the intake mainly in a driven member of an electronic valve control device or the like of a carburetor adapted to an ordinary engine, it is possible to obtain the effect of the present invention.
[0068] In particular, using the temperature-sensitive actuator 10 utilizing a thermo-element in place of a power motor as a drive source for a variety of electrical devices as described above provides such advantages as allowing the overall apparatus to be made smaller and more compact as well as saving energy by using the battery less often.
[0069] Of course, the present invention is not limited to use in the devices described above, and is effective when used in any field in which the motorized actuator 10 outputs a required lift amount when energized. | Disclosed is a temperature-sensitive actuator which is configured in such a manner that heat from a PTC heater for the temperature-sensitive part of a thermoelement can be received appropriately and reliably in a required state. Specifically disclosed is a temperature-sensitive actuator ( 10 ) which is configured to sense the temperature although a piston ( 14 ) is operated forcibly by generating heat from a PTC heater ( 20 ) and warming the temperature-sensitive part ( 13 ) of a wax thermoelement, wherein a contact member ( 40 ) is interposed between the temperature-sensitive part of a thermoelement and the PTC heater. Consequently, variation in the amount of heat which is received at the temperature-sensitive part of a thermoelement from the PTC heater is limited, and the stabilized output (lift) of the thermoelement can be ensured. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to virtual machines, and more particularly to security control in virtual machines.
BACKGROUND
[0002] It becomes very difficult to apply information security to a whole system because the software ecosystem is becoming more and more complex. Indeed, nowadays it is rare to build a machine software stack only by using in-house software; it is common to combine open sources software, commercial software and in-house solutions, all with very different know-how and skills about secure development and design. As a consequence, a single failure in the design, development, deployment and maintenance activities may introduce a security breach. Additionally, software vulnerabilities are more on more highlighted at the application level, on the client side (Flash plug-in, Acrobat Reader, Internet Browsers, Smartphones Apps), as well as on the server side (machine virtualization, application servers (PHP, Java, .Net), Web middleware, Databases).
[0003] For a long time, Discretionary Access Control (DAC) has been used. This approach is user or role based, that is why if root/admin access is gained by an attacker, the overall access control becomes useless. To cope up with this problem, Mandatory Access Control (MAC) has been designed. Mandatory Access Control is a security approach to enforce operating system authorization by forcing access request checking. This is done in regards to a security policy independent from system users.
[0004] One MAC implementation, SElinux, can be applied at system level to enforce Security Policies, regardless the user identity. Even an illegitimate “root” can be blocked by MAC. Windows Vista and Seven now include MAC by default, and administration tasks must be explicitly defined or approved.
[0005] However, this type of access control is not efficient for ensuring security into virtual machines, for example Java Virtual Machines (JVM). Indeed, the JVM process is like a black box to the system that is why it is often impossible for the system to distinguish between malicious and legitimate activities in the JVM. Java Authentication and Authorization Service (JAAS) is classically used for ensuring security in the JVM, but this security mechanism is not mandatory and is only a perimeter protection between the JVM and the system.
SUMMARY
[0006] It is an object of the invention to describe a security model to provide Mandatory Access Control model which applies to a virtual machine.
[0007] To this end, the invention provides a method for ensuring Mandatory Access Control in a virtual machine adapted for running object oriented programs and based on strongly typed language, by means of a mandatory access control module, said method comprising:
configuring the mandatory access control module with an access policy; upon event reception indicating a method invocation or an access request to a variable member, adding an access control label to the object calling the method or requesting the access, named “caller”, and the object called by the method or whose access is requested, named “callee”, according to the caller and callee language types; making a decision of blocking the execution of the method or the access to the variable member, named “negative decision”, or a decision of letting the virtual machine run the method or access the variable member, named “positive decision”, according to said access control labels, the instance numbers of the caller and the callee, and the access policy; transmitting said decision to the virtual machine to block or grant the corresponding access attempt.
[0012] According to not limited embodiments, the method can comprise one or more of the following additional characteristics:
the step of configuring the mandatory access control module is realized upon reception of an event indicating a launch or an initialization (VM_start, VM_init) of the virtual machine. events are standardized instrumentation oriented events which activate callback functions. an event reception directly modifies the virtual machine internals. the step of configuring the mandatory access control module comprises loading a label policy file defining correspondences between language types and access control labels, and the step of adding a label is realized by means of said label policy file. the step of adding an access control label comprises using an external database comprising correspondences between object instances and access control labels. the step of making a decision is realized by cooperation between the mandatory access control module and an external decision engine. the method comprises a step of recording in an external database:
information about the invocated method; information about the caller and the caller, for example their language types and their access control labels, their instances numbers; the decision made.
the method comprises a step of raising an exception by the virtual machine in case of negative decision, for blocking the execution of the requested method or the access to the variable member.
[0024] In addition, there is provided a mandatory access control module for ensuring Mandatory Access Control in a virtual machine adapted for running object oriented programs and bases on strongly typed language, comprising:
a reference monitor, which is the mandatory path for methods invocation and variable member access, adapted for transmitting a decision to the virtual machine of blocking the execution of said method or said access to the variable member, named “negative decision”, or a decision of letting the virtual machine run said method or access said variable member, named “positive decision”; a labeling engine adapted for adding an access control label to the object calling the method or requesting the access, named “caller”, and the object called by the method or whose access is requested, named “callee”, according to the caller and callee language types; a decision engine adapted for making said decision, according to said labels, the instance numbers of the caller and the callee, and the access policy.
[0028] According to a not limited embodiment, the mandatory access control module can comprise one or more of the following additional characteristics:
the mandatory access control module is a module partially external to the virtual machine, named instrumentation module, adapted for communicating with the virtual machine via standard protocols and a standard instrumentation interface. the labeling engine is adapted for communicating with the virtual machine for requiring the caller and callee language types. the label engine is adapted for communicating with an external database comprising correspondences between object instances and access control labels. the decision engine is adapted for communicating with an external decision engine, and waiting for an external decision from the decision engine to make a positive or a negative decision. the mandatory access control module comprises a trace engine adapted for recording information about the invocated method, for example language types and access control labels of the caller and the callee, their instances numbers, and the decision made, in an external database.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Some embodiments of apparatus and/or methods in accordance with embodiments of the present invention are now described, by way of example only, and with reference to the accompanying drawings, in which:
[0035] FIG. 1 shows a flowchart which schematically illustrates a method according to a non limited embodiment of the invention;
[0036] FIG. 2 schematically illustrates a mandatory access control module according to a non limited embodiment of the invention;
DESCRIPTION OF EMBODIMENTS
[0037] In the following description, well-known functions or constructions by the man skilled in the art are not described in detail since they would obscure the invention in unnecessary detail.
[0038] FIG. 1 shows a flowchart illustrating a method 100 according to a not limited embodiment of the invention. This method 100 aims at ensuring Mandatory Access Control in a virtual machine adapted for running object oriented programs and based on strongly typed language. More particularly, the method 100 aims at blocking the execution of a method from a first object by said virtual machine, or an access to a variable member from a second object, different from the previous one, if policy is not respected.
[0039] This principle can be applied to any virtual machine VM based system, for example Java Virtual Machine (JVM), Dalvik, Python or PHP, provided that a reference monitor can be implemented, the related language is objet oriented, and methods invocation or field member accesses can be intercepted and blocked.
[0040] As represented in FIG. 2 , the method 100 is performed by a mandatory access control module Instr_module which is, in this not limited embodiment, a module partially external to the virtual machine VM. Using an external module avoids modifying the virtual machine VM. In this configuration, a standardized interface Instr_Interf between the virtual machine VM and the mandatory access control module Instr_module is used. The control module Instr_module needs to take out a subscription to some events, at least events indicating a launch VM_start or an initialization VM_init of the virtual machine VM, and events indicating a method invocation Meth_entry or an access request to a variable member.
[0041] It is to be noted that in another not detailed embodiment, the mandatory access control module is completely included in the virtual machine VM. Including the control module into the virtual machine permits to improve performances and reduces response time.
[0042] In the detailed embodiment, the control module Instr_module comprises several modules communicating between each other, whose functionalities are explained further:
a reference monitor Ref_mon; a policy loader module Pol_load; a labeling engine Lab_eng; a decision engine Dec_eng; a trace engine Tr_eng.
[0048] The method 100 comprises:
In a step 1 , once the virtual machine VM is ready to execute a user's program, it raises a launch event VM_start or an initialization event VM_init, which triggers the configuration of the control module Instr_module. More precisely, an access policy file Acc_rul_file defining an access policy Acc_pol, and a label policy file Lab_pol_file defining a labeling policy Lab_pol, are loaded by a policy loader module Pol_load. The notions of access policy Acc_pol et label policy Lab_pol are explained further. In a step 2 , upon an event indicating a method invocation Meth_entry or an access request to a variable member, the reference monitor Ref_mon is invoked. FIGS. 1 and 2 deal with the case of a method Meth invocated by an object named caller CalR, and calling an object named callee CalE.
[0051] The reference monitor Ref_mon is a mandatory path when a method is invocated of when an access to a variable member is requested: this is necessary to implement mandatory access control within the virtual machine VM. The reference monitor Ref_mon identifies the caller CalR and the callee CalE to deduce security contexts from their type signatures and the requested permission.
[0052] It is to be noted that the reference monitor Ref_mon as defined by James P. Anderson is a validation mechanism which mediates access requests between entities to enforce an access control policy. By definition, a reference monitor is mandatory, tamperproof, and small enough to be formally proven.
In a step 3 , the labeling engine Lab_eng is initiated. The labeling engine Lab_eng aims at adding access control labels LabE and LabR on the callee CalE and the caller CalR. A label is a unique security identifier which points out a set of entities with the same security requirements. A labeling mechanism associates an entity to a predefined label. Labelization is carried out according to the labeling policy Lab_pol. For example, the labeling policy can be based on the language's inheritance principles. This means that the security label of a given class is inherited from its super-class one by default.
[0054] In this not limited embodiment, the labeling engine Lab_eng first asks an external database Lab_cache, said database comprising correspondences between object instances and access control labels, if labels of the caller CalR and the callee CalE are known. This step is optional but improves performance if the caller CalR and the CalE have previously been involved in a method invocation. If the external database Lab_cache does not have stored the desired labels, the labeling engine Lab_eng adds control label LabE and LabR to the caller CalR and the CalE according to their types Typ_CalR, Typ_CalE. Indeed, the label policy Lab_Pol defines correspondences between language types with access control labels. Then, the labeling engine Lab_eng stores correspondences in the external database Lab_cache.
In a step 4 , the decision engine Dec_eng is initiated to make a decision Dec of blocking the execution of the method Meth, named “negative decision”, or a decision of letting the virtual machine VM run the method Meth, named “positive decision”, according to said access control labels LabE and LabR, the instance numbers of the caller Inst_Num_CalR and the callee Inst_Num_CalE, the access policy Acc_pol, and the access permissions (read/write, for example).
[0056] In this not limited embodiment, an external decision engine Ext_dec_eng is connected to the decision engine Dec_Eng: the decision engine Dec_Eng relies on this third party access control engine Ext_dec_eng for a complementary decision. In this case, a local decision Loc_Dec is sent to the external decision engine Ext_dec_Eng, which makes an external decision Ext_Dec according to the local decision Loc_Dec. An external decision engine is particularly important for avoiding transitive information flows aiming at getting around the access policy. In other words, the external decision engine Ext_dec_eng controls indirect access violations. This is possible thanks to the cooperation between the decision engine Dec_Eng and the external decision engine Ext_dec_eng.
[0057] The following use case illustrates this situation. This use case involves two Java objects, Admin and User, and a confidential data “secret”. The aim is to ensure Admin's object confidentiality regarding User's object, thanks to the labeling policy. Access control policy Acc_pol allows method invocation from Main to Admin and User. As a consequence, without an external decision engine Ext_dec_Eng, direct information flow from Admin to Main and from Main to User are allowed, but not from Admin to User directly. Indeed, method invocation between Admin and User is denied by default by the access policy Acc_pol. The external decision engine Ext_dec_eng permits to avoid User getting the secret via Main, by monitoring all information flows between instances of objects.
In a step 5 , if the decision Dec is positive, that is to say the decision engine Dec_eng grants the method Meth invocation according to the access policy Acc_pol, the reference monitor Ref_mon is requested to leave the virtual machine VM to run the invocated method Meth. On the contrary, if the decision Dec is negative, that is to say the decision engine Dec_Eng does not grant the method invocation, the reference monitor Ref_mon is requested to raise a virtual machine exception to block the method Meth invocation.
[0059] It is to be noted that, in case of an access request to a variable member instead of a method invocation, a positive decision means that access is granted, and a negative decision means that access is refused.
[0060] It is to be noted that, in a not limited embodiment of the invention, the information about the invocated method Meth, the information about the caller CalR and the caller CalE, for example their language types Typ_CalE, Typ_CalR, and their access control labels LabE and LabR, their instances numbers Inst_Num, and the decisions made Loc_Dec, Ext_Dec, are recorded by the trace engine Tr_eng in an external database Tr_database. More particularly, the tracing engine Tr_eng checks from policy if the method Meth has to be logged or not. If yes, extracted information are formatted as an access request and a trace log is created.
[0061] A first implementation, named SEJava, of this MAC model dedicated to a Java Virtual Machine has been tested. SEJava controls every information flow between two Java objects (class or class instance) by mediating each method invocation and field access. Security contexts are based on Java objects and labeling mechanism relies on Java objects type signature (see Java specifications from Oracle for details about Java's type signatures). SEJava has been implemented on the OpenJDK's Java Virtual Machine using JVMTI specifications, that is to say without patching the JVM internals. JVMTI is a standard Java API form Oracle enabling to instrument a compatible virtual machine and which is mainly used for profiling purposes. The JVMTI has been tuned to be used as an Anderson's reference monitor in order to invoke SEJava's engine for all method invocations. This engine checks if the method invocation satisfies the SEJava security policy. The use of a standard instrumentation interface (here JVMTI) eases the implementation of the reference monitor within the virtual machine.
[0062] In contrast with JAAS that controls mainly the flows between the methods and the external resources (for example files), SEJava enables to:
Control the flows between all the Java objects; May learn the required security policy during a “learning” phase, before the “access control enforcing” phase; Connect SEJava with an external reference monitor, for example PIGA. PIGA is detailed in:
J. Briffaut, “Formalisation et garantie de propriétés de sécurité système: application à la détection d′intrusions”, thèse de doctorat d'informatique, soutenue le 13 décembre 2007, LIFO Université d'Orléans, France.
J. Briffaut, C. Toinard, M. Peres, “A dynamic End-to-End Security for Coordinating Multiple Protections within a Linux Desktop”, workshop on Collaboration and Security (Colsec 2010), in the proceedings of the 2010 International Symposium on Collaborative Technologies and Systems (CTS 2010), USA.
[0068] On a real product, the Security modeling will be assisted, based on runtime observations of the software. The default and initial labeling will be based the leaves of the Java types hierarchy of the application. Each type will be assigned its unique Security context, allow observing the information flow between all instances of objects of different types. This is already the case in the current SEJava implementation.
[0069] The result will be displayed to the people responsible for creating the Security model for this application. The user can choose to join or split existing security context. He will also choose what are allowed and forbidden information, thus creating Access Control rules.
[0070] A second implementation, named SEDalvik, has been tested. The only difference in this implementation, based on the same security model as described above, is that it has been written as integrated into the virtual machine interpreter and debugger. It was possible because the language used, Java (the security model) is the same, even if the VM bytecode is different.
[0071] To conclude, the method provides an efficient isolation mechanism for the Java application. Indeed, most advanced security features available for virtual machines are globally based on data tainting, virtual machine deep inspection of interpreter state of virtual machine program analysis. But most of them are not able to perform real-time virtual machine program enforcement with dynamic policy.
[0072] Additionally, current security features for virtual machines impose developers and/or administrators to provide a specific security policy for each program to run. The method 100 enables to compute dynamically the security contexts and the required rules. First, the security contexts are derived from the class naming convention, that is to say signatures. Secondly, the reference monitor Ref_mon audits all the method calls. Thus, the method 100 enables to transform all the denied calls into SEJava rules.
[0073] Is it important to notice that:
Having the source code of the application is not required; It is not required to modify the source code to observe information flows, The virtual machine does not requires modifications (depending on JVMTI support) thus the proposed method and its implementation is applicable to pre-existing applications or software products.
[0077] There are three enhancements regarding existing solution:
The control of the information flow is carried out between all Java objects; the solution does not require any code preprocessing, analysis, or any instrumentation; defined policy is fully applicable to new programs and/or can be directly learned. | A method and system for authenticating a user to provide access to a secure application configured on a mobile device are disclosed. The method includes receiving an input from the user. The input is associated with a plurality of parameters. The method includes extracting a biometric pattern based on the input. The biometric pattern may be generated from the plurality of parameters associated with the input. The method may include comparing the biometric pattern with a plurality of reference patterns. The plurality of reference patterns are pre-defined by an owner of the mobile device. Furthermore, the method may include authenticating the user when the biometric pattern matches a reference pattern associated with the secure application from the plurality of reference patterns. Moreover, the method includes allowing the user to access the secure application, based on the authentication. | 6 |
This application claims the benefit of U.S. provisional application No. 60/401,457 filed on Aug. 5, 2002 incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The field of the invention is electronic file searching.
BACKGROUND OF THE INVENTION
Pattern matching may be defined as an activity which involves searching or scanning any type of data which can be stored or transmitted in digital format. A common type of pattern matching is searching for text in a file. Construction of a “machine” for pattern matching can be relatively intuitive. For example, given the pattern, “abc”, we would look at every character in the file, initially expecting an ‘a’. If found, we would then examine the next character, expecting a ‘b’. If a ‘b’ was found, we would then expect a ‘c’. If, at any point, we do not find what we expect, we return to the expectation of an ‘a’.
We have just begun to describe a finite state automaton—which generally comprises the following five components:
1. a finite alphabet (e.g. the ascii characters); 2. a finite set of patterns (e.g. “abc”, . . . ); 3. a finite set of states (e.g. one for each of ‘a’, ‘b’, and ‘c’.); For each pattern, we may also define a final (“accepting”) state, which we enter upon having matched that pattern (e.g. “abc”); 4. one designated initial state; and 5. a move function that defines how the automaton changes state as it processes an input stream (described above.)
Parallelism in Pattern Matching
The notion of parallelism in pattern matching has to do with subpatterns, in particular, subpatterns of the type in which one or more consecutive elements, starting with the first element, occur (in sequence) in a second pattern. There are typically two ways in which this can manifest:
Case 1. The first N elements of Pattern 1 are also the first N elements of pattern 2 , (N>=1). For example, “air”, “airplane”. Case 2. The subpattern consisting of the first N elements of pattern 1 appears in pattern 2 , but does not include the first element of pattern 2 . For example, “eel” and “feeler”.
Finite state automata (fsa or state machines) are typically represented as directed graphs (also called state transition diagrams). This type of diagram preferably has a root node, which represents the initial state, and edges (or transitions) connecting the nodes, and labeled with the input which will trigger each transition.
An existing pattern matching algorithm is that developed by Aho & Corasik and later improved upon by Commentz-Walter. The Commentz-Walter method is commonly known as fgrep. Fgrep uses hashing to skip over areas in the text where no matches are possible. All commonly implemented methods of pattern matching use either the original Aho & Corasik implementation of the finite state automaton or the fgrep method of partial FSA implementation.
There is a need, however, to simplify the FSA, making it so fast that it is as good as hashing or other skipping methods in the regions without matches, yet faster than Aho & Corasik where matches are found.
SUMMARY OF THE INVENTION
The present invention provides systems and methods for creating a finite state automata (FSA) that matches patterns in parallel including the steps of creating states of the automata from a set of patterns to be matched and passing over the patterns a second time adding transitions to the states to match all the possible patterns that can start within the pattern.
Another aspect is directed toward a FSA that uses array-based transitions. The system includes an alphabet of size N in which each state is represented by an object containing an array of N pointers to possible successive states and wherein the numeric value of each member of the alphabet is then used as an offset into the array to point to the next state for the input.
Yet a further aspect is directed toward creating a case-insensitive FSA by making each pattern all one case and after having created the FSA, adding corresponding transitions on each alphabetic character so that the case of characters in the input stream will have no effect on the performance of the FSA.
Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a FSA shown as a directed graph.
FIG. 2 is partially built FSA.
FIG. 3 is diagram demonstrating steps of the FSA.
FIG. 4 is a state transition diagram for a completed FSA.
DETAILED DESCRIPTION
Referring first to FIG. 1 , a state transition diagram 100 for a partially constructed FSA for matching “free” and “eel” is generally comprised of circles 110 – 180 which represent the states of the machine, with the double circles ( 150 and 180 ) representing final (or accepting) states. Implicit in these diagrams is that, for any state, for any input other than those shown, there is a transition to the initial state.
The arrows between the circles represent the transitions or edges, and, in this document the numbers in the circles simply represent the order of creation. Since a state can have at most one transition for a given input, the set of all possible transitions of a particular FSA can be described as a set of ordered pairs of the type{input, state}.
Definitions
For the Remainder of this Document, we will use the Following Conventions:
∃ is equivalent to “there exists”.
| is equivalent to “such that”.
is equivalent to “element of”.
The ‘.’ operator is used to indicate an attribute (data or function) of an object.
a i means “the ith element of A”. e.g. “∃ t(a i , s′)|t(a i , s′) s.T” means, “there exists a t(a i ,s) such that t (a i , s) is a member of s.T”.
is the assignment operator, meaning “becomes”.
= is the equivalence operator.
null represents the empty state (or “no state”).
Ellipsis “ . . . ” indicate zero or more unspecified parameters.
Exemplary pseudocode is one-based, i.e. “for i 1 until length (p)” means for each i starting with the first element up to the length of p. (This convention differs from languages such as C++, C, and Java, which are all zero based).
F denotes FSA. S denotes the set of all states in machine. s 0 is a special identifier for the initial state of machine, which is equivalent to s o . Σ denotes the alphabet i.e. the finite set of all possible inputs to machine. We define a transition t (a, s), as an ordered pair|a Σ and s S. Each sate s of S has a (possibly empty) set of transitions, denoted by “s.T”.
Note that the action of any machine, upon matching a pattern will be application-specific. e.g. A text search engine might simply list the number of occurrences of each pattern. A virus detection engine might create another thread or process to quarantine or remove the file being searched, etc. We will, therefore only refer to two unspecified functions, setAction and doAction , which are simply placeholders for specific functions which define and invoke the action to be taken.
The move function may be defined as a member of the class state. For any input a in A, if s is the current state, we call s.move(a) to determine the next state:
function move (a i ) begin if ∃ t(a i , s′) | t(a i , s′) T return s′; else return null; endif end
Array-Based Implementation
For alphabets of up to 256 elements, we may implement each state's set of transitions as an array (a fixed block of contiguous memory) of length the size of the alphabet. (128 for ascii, 256 for binary searches). This array may contain pointers to states, and initially will typically contain all zeros (null pointers) if we are building a non-deterministic FSA. (When building a deterministic FSA, we will create the initial state first, and initialize its array, and the arrays of all subsequently created states to the address of the initial state). This strategy allows us the fastest possible state lookup, simply using the numeric value of the input character as an offset into the current state's array to determine the next state.
The following two examples depict the implementation of our array based approach to transitions:
function move (a i )
function move (a i )
begin
begin
return Array [a i & 127];
return Array [a i ];
end
end
7 bit (ascii) move ( )
8 - bit (binary) move ( )
We define a second member function of state, addTransition , as follows: Using our system, one has the option of creating a non-deterministic FSA and then converting it to a deterministic FSA, if so desired, or simply building a deterministic FSA from the beginning. In the following pseudocode, there will be minor differences, depending upon which type of FSA we are building. We use the following conventions to indicate which type we are creating:
Text in italics is specific to non-deterministic FSA only.
Underlined Text Indicates Pseudocode Specific to Deterministic FSA Only.
Where there is a pair of lines of the above format, one would be used, depending upon the type of FSA.
function addTransition (a, s2) begin if Array [a] = null if Array [a] = s0 Array [a] s2; endif end
Note: addTransition ensures that there can be only one transition from state s on input a. Once entered that transition will not change.
Constructing the Machine
1. Creating the Graph
We may now define the following functions for building our FSA from a set of patterns, P. Generally, we first define a function, CreateGraph, which, for each pattern, P, in our set of patterns, calls the following function, createGraph (P).
function createGraph (p)
begin
if s0 = null
s0 new state;
endif
state currentState s0;
state nextState null;
for i 1 until length (p)
nextState currentState.move (p i );
if nextState = s0
if nextState = null
nextState new state;
currentState.addTransition (p i nextState);
endif
currentState nextState;
endfor
currentState.setAction(...);
end
2. Completing the Graph
If we consider the two necessary and sufficient conditions for a pattern matching FSA, we will find that having called CreateGraph, we have created an FSA which will satisfy case 1, above. We will see that we have already created enough states to satisfy both case1 and case 2, above. All that remains is to add any missing transitions. That is to say, whenever a pattern (or any first portion of a pattern) appears as a subpattern of another, we add the appropriate transitions to the states that match the containing pattern so that the subpattern will not be missed. Since the patterns to be matched, in combination with the transitions of the initial state, typically contain all the information needed to determine any necessary additional transitions, the most direct approach to completing graph is to pass each pattern through our partially constructed machine as follows:
We define a second function, Complete Graph , which, in turn calls completeGraph (P) for each of patterns. In completeGraph, we make a second pass over P, starting with its transition out of the initial state to the next state, which expects p 2 , the second element of P. We then move to the second state, as dictated by p 2 . At this point we check for a transition out of state 0 on element p 2 . If found, we add all transitions in that state to our current state, and enqueue that state to be examined in the next iteration. We also check each of the previous states in our queue, if any, to see if there is a move from that state on p 2 . If so, we add the edges from the state moved to, and enqueue that state. We repeat this process until reaching the end of our pattern.
function completeGraph (pattern P)
begin
queue parallelMatches;
state currentState s0.move (p 1 );
state temp null;
for i 2 until length (p)
currentState currentState.move (p i );
int qlen parallelMatches.cardinality ( );
for j 0 until qlen
temp parallelMatches.removeLast ( );
temp tmp.move (p i );
if temp ≠ null
if temp ≠ s0
parallelMatches.insertFirst (tmp);
currentState.addEdges (tmp);
if tmp.isAccepting( )
currentState.setAction(...);
endif
endif
endfor
temp s0.move(p i );
if temp ≠ null
if temp ≠ s0
currentState.addEdges (tmp);
parallelMatches.insertFirst (tmp);
endif
endfor
end
The following function of state, addEdges is called by completeGraph .
function addEdges (state destination) begin for i 1 until length (Alphabet) state tmp source.move (a i ); if tmp ≠ null if temp ≠ s0 addTransition (a i , tmp); endif endfor end
Note that transitions will be added only if there is a null (non-deterministic FSA) or s 0 (deterministic FSA) transition on the given character.
Completed Non-Deterministic FSA
Note that states are generally created in the createGraph function, and these states may be all that are needed. We have now a fully functional FSA with the minimal number of states and transitions. In fact, for a nondeterministic FSA, we may have transitions on only a few of the 128 (or 256) possible elements of our alphabet. Therefore, we may make multiple (two, to be exact) transitions on many inputs. This characteristic is precisely what makes it nondeterministic. A non-determinisitic FSA is capable of quite efficiently matching any number of patterns in parallel using the function, nfaSearch , or may be converted to a deterministic FSA, as will be shown later. A separate search function, dfaSearch , makes at most one move per input, as will also be shown later.
Case Insensitivity in Text Searches
In text searches, it is often desirable to make the search case insensitive. We use the following mechanism to attain this end with no loss in efficiency. First, all patterns are converted to lower case before being added to the machine. Then, after running createGraph and completeGraph on all patterns, we call makeCaseInsensitive on machine, which for each state, for each transition on the set of characters a–z, adds a similar transition to the corresponding upper case character.
Running a Non-Deterministic Automaton
By calling nfaSearch on an input stream, we can match every occurrence of all patterns entered by using the functions above, making, at most, 2 transitions on any given input:
nfaSearch (input stream t) begin for i 1 until length(t) if currentState ≠ null currentState currentState.move (t i ); if currentState ≠ null if currentState.isAccepting ( ) = true currentState.doAction (...); endif else currentState s0.move (t i ); endif else currentState s0.move (t i ); endif endfor end
Completing a Deterministic Automaton
If we have followed the steps above, (following the pseudocode specific to creating a deterministic FSA), then all that remains is the following:
completeDfa ( )
begin
for each state s | s S
for each a | a Σ
state tmp s.move(a);
if tmp = s0
tmp = s0.move (a);
if tmp ≠ s0
s.addTransition (a, tmp);
endif
endif
endfor
endfor
end
Having built a deterministic FSA, we now have, for each state in our machine, one transition on each member of the alphabet. The number of states remains unchanged, but the total number of transitions changes to the number of states multiplied by the size of the alphabet —128 for purely ascii searches, 256 for searches on all 8 bit entities.
Making a Non-Deterministic FSA Deterministic
To make a machine deterministic, we simply iterate through all states, and for all possible inputs for which a state has no transition, if there is a non-null transition from the initial state on that input, we add that transition to the current state. If not, we add a transition on that input to the initial state:
makeDeterministic ( )
begin
for each state s | s S
for each a | a Σ
state tmp s.move(a);
if tmp = null
tmp = s0.move (a);
if tmp ≠ null
s.addTransition (a, tmp);
else
s.addTransition (a, s0);
endif
endif
endfor
endfor
end
Having built a deterministic FSA, we now have, for each state in our machine, transitions on every member of the alphabet. The number of states remains unchanged, but the total number of transitions changes to the number of states multiplied by the size of the alphabet—128 for purely ascii searches, 256 for searches on all 8 bit entities. (If our alphabet were larger, for example 64 kilobytes for 2-byte elements, we would probably use a non-deterministic machine on current hardware.)
We now define a search function for our deterministic FSA. Here is the pseudocode:
dfaSearch (input stream t)
begin
for i 1 until length(t)
currentState currentState.move (t i );
if currentState.isAccepting ( ) = true
currentState.doAction (...)
endif
endfor
end
(Note: currentState will be set to s 0 before the first call to dfaSearch .)
The search function for our deterministic machine will make exactly one move for each element in the input stream.
Any pattern used to build a finite automaton using CreateGraph and CompleteGraph will be likely be matched if it occurs in an input stream.
Proof by mathematical induction:
Given a pattern P of length n occurring in input stream I:
1. p 0 will be matched, since:
a. If the current state is s 0 , by createGraph (P), a transition t (p 0 , sp 0 ) was placed in s 0 . b. If the current state is s≠s 0 , by completeGraph (P), s must either have a transition t (p 0 , sp 0 ), in which case it is matched, or not, in which case the state will become s 0 (in a dfa) and the transition from s 0 will be made.
2. For any p k |k<n−1, if is p k is matched, p k+1 will be matched, since: By createGraph and completeGraph, the current state, s k , reached by recognition of p k , must have a transition, t(p k+1 ,s k+1 ) which will match p k+1 .
A Specialized Approach for Smaller Alphabets
For certain applications, the alphabet can be quite small. For example, a DNA molecule can be thought of as a string over an alphabet of four characters {A, T, C, G} (nucleotides). For RNA the characters are {A, C, G, U}. By masking off the 5 high order bits, we get the following:
(In the syntax of C and C++, the “&” operator is used for masking off unwanted bits, in that only the bits that are common to the numbers on either side of the & are looked at. The binary notation for 7 is 00000111).
a & 0x07=1 c & 0x07=3 g & 0×07=7 t & 0x07=4 A & 0x07=1 C & 0x07=3 G & 0x07=7 T & 0x07=4 (For RNA searches): u & 0x07=5
U & 0x07=5
If we use only the three low-order bits, we can now reduce the size of each state's Array to 8, or 1/16 th the size required for a full ascii search. We then change our move and
addTransition functions to ignore the 5 high-order bits, and the resulting FSA is much more compact, giving the ability to search for many more patterns in parallel with much less performance degradation due to memory usage. As a side effect, we also get built-in case insensitivity.
function move (a i )
begin
return Array [a i & 7];
end
function addTransition (a, s2)
begin
int index a & 7;
ifArray [index]= null
if Array [index] = s0
Array [index] s2;
endif
end
Extending Our Specialized Approach to Full Ascii Searches by Adding a Hash Function
A commonly used method of indexing databases is the hash function. A hash function reduces a string of characters to a numeric value.
If we use a machine, such as the one described above, which examines a subset of low orders bits of each input on an alphabet which includes all ascii characters, we will get “false” matches, eg each character in “abcdefghij” has the same 5 low order bits as the corresponding elements of “qrstuvwxyz”. (The values are 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, respectively). If, however, we apply a hashing function to the two strings, we get values 306089158 for “abcdefghij”, and 1270619813 for “qrstuvwxyz”.
Using our hash function, which can be case insensitive if we so desire, we can now derive a numeric value of each of our patterns, and store it in the accepting state for that pattern. When our machine has a match based upon the low-order bits, the hash function is then applied to the characters in the input stream which caused the “partial” match, to determine whether it has an exact match.
This solution has the advantage of smaller arrays, requiring substantially less time to create the FSA, the ability to do case-insensitive searches with no performance hit, and very little decrease in search speed compared to our version using arrays of 128 or 256 elements.
Creating a 3-by-5 Card Prototype Using Our System
Let us begin by building a simple pattern-matching FSA using 3″ by 5″ note cards. (Paper of any size would do.)
Our goal is to number cards as they are used to create states (we start with 0), and on the cards add whatever transitions are needed. The transitions determine what the next state should be for a given input. If a card represents an accepting state (one which denotes a match) we will place an asterisk followed by the pattern matched.
Creating the Graph
The first step in creating our machine is to define a set of patterns, which we wish to match. We will use the patterns, “free” and “eel”, for simplicity. First, we create an initial state (state 0 ). We add the patterns one by one, adding a transition consisting of the first character of our first pattern followed by the state to which to move. We continue until we have reached the end of the pattern, marking the final state as accepting, with no transitions. After entering the first pattern, we use existing states where appropriate, creating new states only when needed, and marking the final state as accepting for each pattern. The cards are numbered for convenience, by order of creation. The functionality of the machine does not depend on their numbers, but helps us to differentiate them in the diagrams.
The Move Function
Referring to FIG. 2 , a FSA machine 200 for “free” and “eel” generally comprises states 0 – 7 ( 210 – 280 ) and functions as follows: Start by placing a coin on state 0 ( 210 ), indicating that it is the current state. Then scan a stream of text; and for each character, if there is a transition out of state 0 ( 210 ) on that character, move coin to the state indicated by that transition. Continue in this way until reaching the end of the input stream. Whenever there is no transition out of a state on a character, we may make two moves—first we move the coin to state 0 ( 210 ) and, if there is a transition out of state 0 ( 210 ) on that character, move again.
Clearly, either of patterns will be recognized if they begin with machine in state 0 ( 210 ). Consider, however, the input stream, “freel or eeel”. It contains two instances of “eel”, but neither will be recogized, because the machine will not be in state 0 ( 210 ) when the first ‘e’ of “eel” is encountered. It is now time to apply second method, completing the graph.
Completing the Graph
In the following we will refer to the state moved to on the first character of a string as the “first state” for that string, and the character which caused that move, the “first character”. Similarly, at any point, the current state is the (n th ) state moved to on the current (n th ) character.
For each pattern we will typically perform the following steps. Start with the initial state and move to the first state for that pattern. Using the transition on the 2 nd character of our pattern, move to the second state. From this point on, repeat the following through the accepting/final state.
Check the initial state to see if there is a transition on the current character of pattern. If one is found, we place the card representing that transition's state next to the current state card. We then copy all transitions from that state to our current state, excepting any transitions on our current character. In addition, if that state is an accepting state, we add that information to our current state.
If we have placed state cards next to our previous state card, check to see if there is a transition on our current character out of that state. If there is, place the state card for that transition next to our current state card, and copy all transitions from that state to our current state, excepting any transition on our current character, copying our accepting state information, if any, as well. Move to the next state, using the transition on the next character.
For our example machine, we apply the technique above as follows:
For our first-pattern, “free”, we move according to the transition, ‘f’ 1 , from state 0 to state 1 . We then move to state 2 , on ‘r’. Then we check the initial state to see if there is a transition on our current character, ‘r’. There is none. We now make the transition on ‘e’ to state 3 . We check state 0 for a transition on ‘e’. There is one, to state 5 . We place the state 5 card next to our current state ( 3 ) card, and cannot copy the transition “e, 6 ”, since we already have a transition on ‘e’. We then move to state 4 on ‘e’, and move on ‘e’ from the previously placed state 5 card to state 6 , place the state 6 card next to our current state, copying the ‘i’ 7 transition to our current state. Looking again at state 0 , we find the transition on ‘e’, copying the transition from the state 5 card.
We follow the same procedure for our second pattern, “eel”. FIG. 3 demonstrates the steps we have just described.
After having repeated the above procedure on the two patterns, “free”, and “eel”, we now have a machine which how has 10 transitions or edges, as opposed to the original 7 , and is capable of matching each of our patterns, no matter where they occur in any input stream, including overlapping patterns. FIG. 4 is a state transition diagram for our completed FSA for “free”, and “eel”.
State Transition Diagram for Completed FSA
Our prototype is, by nature object-oriented, i.e. each state is represented in such a way as to encapsulate the data (transitions) which define where to move on a given input. We will now describe, using an object-oriented form of pseudocode, how we implement our method to create a software version of our machine.
Thus, specific embodiments and applications of an object approach to parallel pattern matching have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. | The present invention provides systems and methods for creating a finite state automata (FSA) (FIG. 1 , blocks 110–180 ) that matches patterns in parallel including the steps of creating states of the automata from a set of patterns to be matched (FIG. 2 , blocks 210–280 ) and passing over the patterns a second time adding transitions to the states to match all the possible that can start within the pattern (FIG. 3 , blocks 0–7 ). | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This Application claims the priority of Provisional Application Ser. No. 60/433,334, filed Dec. 13, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to reusable pipe fitting plugs for temporarily sealing an open hub of a non-threaded female pipe fitting.
2. Art Relating to the Invention
Reusable pipe fitting plugs provide an inexpensive means to control the unwanted release of fluids or air from an open pipe connection. Reusable pipe fitting plugs can also be used to isolate various sections of a pipe system during construction or maintenance.
Conventional reusable pipe fitting plugs are designed with an expandable rubber sealing means that is capable of forming a watertight seal between the pipe fitting plug and the inner surface of the pipe fitting hub.
In a typical design, the pipe fitting plug is shaped as a cylinder with a diameter of slightly less than the diameter of the pipe fitting hub that is desired to be plugged. The pipe fitting plug therefore covers the majority of the diameter of the inside of the pipe fitting hub. The expandable rubber sealing means is provided along the circumference of the pipe fitting plug and is capable of filling the gap between the outside of the pipe fitting plug and the inside of the pipe fitting hub. Fluid flow is restricted upon the plugging of the gap with the rubber sealing means.
Conventional pipe fitting plugs have a rubber sealing element located within a recess of the cylinder. A tightening means is designed to exert a force through the body of the pipe fitting plug so as to decrease the recess and expand the rubber sealing element. The rubber sealing element expands under the pressure exerted by the tightening means to form a watertight seal between the pipe fitting plug and the pipe fitting hub.
One of the drawbacks of conventional pipe fitting plugs is that they can only withstand a limited fluid pressure. When the fluid pressure against the pipe fitting plug passes a threshold value, the rubber sealing element can no longer hold the pipe fitting plug in place and the pipe fitting plug is forced out of the pipe fitting hub. This is known as plug blow out, and results in uncontrolled flooding and damage.
Further, debris, dirt and solvent may be deposited within the inner surface of the pipe fitting hub causing slippage between the rubber sealing element and the pipe fitting hub resulting in further undesired consequences.
It is therefore desirable to obtain a reusable pipe fitting plug that is capable of withstanding increased fluid pressures and soiled surfaces without becoming disengaged from the pipe fitting hub and causing flooding.
SUMMARY OF THE INVENTION
The present invention provides a reusable pipe fitting plug for temporarily sealing the open fitting connections of a plumbing system during construction or maintenance which can withstand increased fluid pressure and avoid plug blow out.
The present invention provides maximum seal and hold out strength by the use of a pipe fitting plug having a dedicated seal and a dedicated retaining means.
The seal is a conventional, expandable rubber ring or inflatable bladder which provides a watertight seal between the pipe fitting plug and the inner wall of the pipe fitting hub.
The retaining means is also expandable and provides a means to anchor the pipe fitting plug into the pipe fitting hub. The retaining means enables the pipe fitting plug to withstand increased fluid pressure without failure. The retaining means further prevents slippage caused by debris, dirt and solvent buildup on the inside of the pipe fitting hub.
Broadly, the present invention is a pipe fitting plug comprising:
a body which is watertight; an expandable sealing means surrounding said body for forming a watertight seal between said body and an interior surface of a pipe fitting hub; an expandable retaining means for engaging said interior surface of said pipe fitting hub and retaining said plug in said pipe fitting hub; and one or more adjusting means for causing said sealing means and said retaining means to engage and disengage said interior surface of said pipe fitting hub.
Preferably, the sealing means is an expandable rubber ring which expands to form a watertight seal between the body and the interior surface of the pipe fitting hub. The sealing means can alternatively be in the form of an expandable rubber bladder that inflates to form a watertight seal. The sealing means forms a watertight seal with the pipe fitting hub to prevent fluid from moving through or around the plug because the body itself is solid, i.e., watertight/fluidtight and the seal is watertight/fluidtight thereby blocking the whole interior area of the pipe fitting hub.
Preferably, the retaining means has a one or more piercing edges or projecting teeth which are movable to engage the interior surface of the pipe fitting and retain the plug in the pipe fitting hub. Alternatively, the retaining means can have one or more expandable pins which are movable to engage the interior surface of the pipe fitting hub and retain the plug in the pipe fitting hub. The retaining means can further have a plurality of grit type particles which serve to retain the plug in the pipe fitting hub. The retaining means provides the increased strength to the plug to allow the plug to withstand increased fluid pressure.
The retaining means and the sealing means are both movable so as to engage and disengage the interior surface of the pipe fitting hub. This allows the plug to be inserted into the pipe fitting hub, to seal and be retained in the pipe fitting hub, and to be removed from the pipe fitting hub.
Preferably, there is a single adjusting means which operates on both the retaining means and the sealing means such that both the retaining means and the sealing means expand and retract simultaneously. However, the retaining means and the sealing means can each have their own adjusting means.
According to one embodiment of the present invention, the adjusting means is composed of an end piece affixed to one end of the body, a housing that slides on the other end of the body, and a controlling force means that extends from the body through the housing, preferably along the axis of the housing. The controlling force means can be a carriage bolt with a threaded fastener or the like. The threaded fastener compresses the housing and the end piece and causes the sealing means and the retaining means to expand and contract.
According to another embodiment of the present invention, the adjusting means is composed of an inner chamber within the body, an air valve in communication with the inner chamber and one or more air ports in communication with the sealing means and the inner chamber. The air valve increases the air pressure within the inner chamber and the sealing means through the air ports causing the sealing means and the retaining means to expand.
Preferably, the retaining means and the sealing means are located within a recess of the body of the pipe fitting plug. The recess is created between an end piece of the body and a housing which surrounds the body of the pipe fitting plug. The end piece is fixed to the body while the housing moves on the body of the plug. As a result, the adjusting means can cause the housing to move along the body to or from the end piece in order to expand or contract the recess.
In one embodiment of the present invention, the adjusting means applies a corresponding force to the retaining means and the sealing means as the recess contracts. As a result, the retaining means and the sealing means are compressed and compelled to outwardly expand.
In another embodiment of the present invention, the retaining means is further composed of a tapered cone surrounding the controlling force means of the adjusting means. As the housing and the end piece contract, the expandable pins slide along the outer surface of the tapered cone causing the expandable pins to outwardly expand.
In yet another embodiment of the present invention, the sealing means is composed of an inflatable rubber bladder. The retaining means is composed of a plurality of grit type particles. The grit type particles of the retaining means are located within a recess of the sealing means. As the air valve pressurizes the inner chamber of the body, the rubber bladder is forced to inflate and expand outward.
This outward expansion causes the piercing edges, the expandable pins or the grit type particles of the retaining means to engage with the inside surface of the pipe fitting hub and also causes the sealing means to conform to the inner wall of the pipe fitting hub to provide a fluidtight seal.
The present invention is primarily designed for use in plumbing systems constructed of non-threaded pipes and fittings such as ABS, PVC, polypropylene and the like. In addition, the present invention can be modified to plug a pipe itself, rather than a pipe fitting hub. The plug must be therefore sized accordingly in order to fit the dimensions of the pipe.
The present invention is also designed to fit conventional sized piping, namely 1.5, 2, 3, and 4 inch piping, however, any size of piping can be plugged by the present invention.
Suitably, the housing can extend in an axial direction outward from the body such that the overall shape of the plug is cylindrical and allow the plug to be inserted a depth into the pipe or pipe fitting hub and to extend a distance out from the end of the pipe or pipe fitting hub.
These and other aspects of the present invention may be more fully understood by reference to the following drawings and description which are intended for illustrative purposes only.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of one of the embodiments of the pipe fitting plug of the present invention;
FIGS. 2 a – 2 c are an installed view of a pipe fitting plug according to one of the embodiments of the present invention;
FIG. 3 a is a pre-installation view of one of the embodiments of the present invention;
FIG. 3 b is an installed view of a pipe fitting plug according to one of the embodiments of the present invention; and
FIGS. 4 a – 4 b illustrate a top view and a side view, respectively, of the movable piercing edges of the retaining means according to one embodiment of the present invention;
FIG. 5 illustrates an alternative embodiment of the present invention;
FIG. 6 illustrates a sectional view of an alternative embodiment of the present invention;
FIG. 7 illustrates a sectional view of an alternative embodiment of the present invention; and
FIG. 8 illustrates a top view of the grit type particles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a preferred embodiment of the present invention.
As shown in FIG. 1 , pipe fitting plug 7 is composed of body 15 , end piece 2 and cylindrical housing 8 . End piece 2 is affixed around the outer circumference of body 15 so that the majority of body 15 can be encompassed by housing 8 . Such an arrangement enables housing 8 to horizontally slide along a surface of body 15 and abut end piece 2 .
Housing 8 is guided by controlling force means 11 as housing 8 moves along a surface of body 15 . Controlling force means 11 protrudes through the center of body 15 , end piece 2 and housing 8 and provides a means by which housing 8 and end piece 2 can be tightened together using hex nut 10 . Rubber washer 1 provides a leak-proof seal around the head of controlling force means 11 as controlling force means 11 passes through end piece 2 . Controlling force means 11 can be any threaded fastener or a carriage bolt as illustrated in FIG. 1 .
FIG. 1 illustrates the positioning of recess 14 in which the sealing means and retaining means are preferably located. The sealing means and retaining means are preferably sized so as to be substantially the same size as recess 14 .
The retaining means is comprised of front and rear push rings 4 a and 4 b , retaining ring 5 and O-ring 6 .
Front push ring 4 a and rear push ring 4 b have inner angled surfaces designed to mate with an angled surface of retaining ring 5 . These angled surfaces work in conjunction to cause retaining ring 5 to protrude towards and anchor into the inside wall of a pipe fitting hub that is desired to be plugged.
FIGS. 1 and 2 illustrate a preferred arrangement of retaining ring 5 , front push ring 4 a and rear push ring 4 b . The angled surfaces of front push ring 4 a and rear push ring 4 b serve to wedge beneath or to pinch under retaining ring 5 in order to cause retaining ring 5 to travel away from the center axis of pipe fitting plug 7 and toward pipe fitting hub 12 , see FIG. 2 a . However, it should be understood that any particular arrangement of front push ring 4 a , rear push ring 4 b and retaining ring 5 can be utilized in order to achieve the object of the present invention.
The sealing means comprises end piece 2 , rubber sealing element 3 and ring 4 a . When end piece 2 and ring 4 a compress element 3 , element 3 expands to provide a watertight seal between pipe fitting plug 7 and the inside of the pipe fitting hub. Preferably, sealing element 3 is composed of a rubber material capable of expansion upon the exercise of a squeezing force in the direction of the axis of the pipe fitting plug. Rubber sealing element 3 is also preferably formed of a material capable of conforming to the inner wall of a pipe fitting hub 12 .
FIGS. 2 a , 2 c and 3 a illustrate the operation the pipe fitting plug according to a preferred embodiment of the present invention.
Pipe fitting plug 7 is first inserted into pipe fitting hub 12 at a point of pipe fitting hub 12 that is intended to be plugged.
Once the pipe fitting plug is in position, a user manually tightens hex nut 10 mounted around controlling force means 11 , while nylon washer 9 serves as a bearing surface for hex nut 10 . This tightening movement causes a force to be exerted upon housing 8 , and housing 8 correspondingly moves along body 15 toward end piece 2 . The recess 14 between housing 8 and end piece 2 therefore decreases, because end piece 2 remains in a fixed position relative to the movement of housing 8 .
As recess 14 contracts and decreases in width, sealing element 3 , front push ring 4 a , rear push ring 4 b , retaining ring 5 and O-ring 6 are compressed together.
As shown in FIG. 2 c , the angled surfaces of front push ring 4 a and rear push ring 4 b wedge beneath retaining ring 5 and cause retaining ring 5 to be outwardly extend toward the inner surface of pipe fitting hub 12 . O-ring 6 is provided within retaining ring 5 in order to ensure that retaining ring 5 does not collapse as retaining ring 5 is compressed and allows for expansion of piercing edges of retaining ring 5 to retract from engagement with the inside of pipe fitting hub 12 .
As retaining ring 5 outwardly expands, serrated piercing edges located on the upper surface of retaining ring 5 pierce into pipe fitting hub 12 . Once the piercing edges are firmly engaged into pipe fitting hub 12 , pipe fitting plug 7 is capable of withstanding increased fluid pressures without failure. FIGS. 4 a – 4 b illustrate the configuration of the serrated piercing edges of the retaining means.
Further, sealing element 3 is also caused to expand due to the force applied from front push ring 4 a and end piece 2 . As depicted in FIG. 2 c , a portion of sealing element 3 protrudes and conforms to the inner surface of pipe fitting hub 12 in order to form a fluidtight seal.
Preferably, retaining ring 5 of the present invention is designed in a “V” shape with serrated or jagged outer edges as shown in FIGS. 4 a and 4 b . This “V” shape allows for a sliding along the angled edges of the front and rear push rings as the front and rear push rings are contracted. However, it should be understood that any particular shape of the retaining ring, front push ring and rear push ring can be utilized so as to achieve the object of the present invention.
In order to disengage pipe fitting plug 7 from pipe fitting hub 12 , nut 10 is unscrewed thereby releasing pressure from both sealing element 3 and retaining ring 5 . Sealing element 3 disengages the inside of the pipe fitting hub and returns to its original shape. Retaining ring 5 disengages the inside of the pipe fitting hub and returns to its original shape because of O-ring 6 .
The pipe fitting plug according to the present invention is also capable of extending to reach and plug a portion of a pipe fitting hub that could not ordinarily be reached through conventional means. Housing 8 and controlling force means 11 can be indefinitely extended in order to easily plug a section of a pipe fitting hub from a distance as shown in FIGS. 3 a and 3 b.
FIG. 5 illustrates another embodiment of the present invention wherein housing 8 forms part of ring 4 b . Extension 20 is attached to housing 8 .
FIG. 6 illustrates another preferred embodiment of the present invention where the retaining means contains one or more expandable pins 19 which extend perpendicular to the longitudinal axis of the pipe fitting plug.
As shown in FIG. 6 , housing 8 slides along body 15 and is capable of compressing body 15 against end piece 2 . Controlling force means 11 protrudes through body 15 , end piece 2 and housing 8 and enables body 15 , end piece 2 and housing 8 to be compressed together using wing nut 10 .
The retaining means is composed of one or more expandable pins 19 , tapered cone 16 , clips 17 and spring 18 . Wing nut 10 and controlling force means 11 are capable of compressing housing 8 thereby pushing body 15 toward end piece 2 . As body 15 is pushed toward end piece 2 , expandable pins 19 slide along the outer surface of tapered cone 16 and thereby extend outward toward the inner wall of the pipe fitting hub. As a result, the pipe fitting plug is securely anchored into the pipe fitting hub.
The retaining means according to this embodiment also contains clips 17 and springs 18 . Springs 18 help to retract expanding pins 19 when the plug is not compressed. Clips 17 allow for springs 18 and expanding pins 19 to be mounted to the pipe fitting plug in a firm position.
FIG. 6 also illustrates the positioning of sealing means 3 . Sealing means 3 is located in a recess formed between end piece 2 and body 15 . As end piece 2 and body 15 are compressed together, the recess formed between end piece 2 and body 15 contracts, and sealing means 3 is compelled to outwardly expand. This outward expansion allows for sealing means 3 to form a fluidtight seal between the pipe fitting plug and the pipe fitting hub. Preferably, the sealing means is composed of a rubber-like material that is durable as well as expandable.
In order to disengage the pipe fitting plug from the inner wall of the pipe fitting hub, wing nut 10 is rotated in the opposite direction to allow for housing 8 to decompress body 15 and end piece 2 . As wing nut 10 is loosened, sealing means 3 breaks contact with the inner wall of the pipe fitting hub and expandable pins 19 withdraw from the inner surface of the pipe fitting hub. Thus, the pipe fitting plug can be removed from within the pipe fitting hub and can be reused.
FIG. 7 illustrates yet another preferred embodiment of the present invention where the pipe fitting plug is secured to the pipe fitting hub using a plurality of grit type particles 24 while a fluidtight seal is formed using expandable rubber bladder 20 .
As shown in FIG. 7 , expandable rubber bladder 20 is located within a recess of body 15 of the pipe fitting plug. Expandable rubber bladder 20 contains raised outer seal area 21 which allows for expandable rubber bladder 20 to form a fluidtight seal between the pipe fitting plug and the pipe fitting hub. Furthermore, a plurality of grit type particles 24 attach to the inner surface of the expandable rubber bladder, within outer seal area 21 . The plurality of grit type particles 24 serve to affix the pipe fitting plug to the pipe fitting hub to provide a secure attachment. The plurality of grit type particles located between outer seal area 21 of expandable rubber bladder 20 are illustrated in FIG. 8 .
FIG. 7 also illustrates the operation of the adjusting means that allows for the sealing means and the retaining means to expand and contract.
The adjusting means according to this embodiment is composed of air valve 23 , inner chamber 25 of body 15 and air ports 22 . Air valve 23 is in communication with inner chamber 25 , which is in turn in communication with expandable rubber bladder 20 via air ports 22 .
Air valve 23 is capable of increasing the air pressure within inner chamber 25 . As the pressure within inner chamber 25 increases, so does the pressure within expandable rubber bladder 20 . Thus, air valve 23 is capable of inflating and deflating expandable rubber bladder 20 through the increase or decrease of air pressure within inner chamber 25 . As expandable rubber bladder 20 inflates, a fluidtight seal is formed between the outer seal area 21 of expandable rubber bladder 20 and the pipe fitting hub.
As expandable rubber bladder 20 approaches the inner wall of the pipe fitting hub, plurality of grit type particles 24 impregnated within the perimeter outer seal area 21 of expandable rubber bladder 20 affix to the inner wall of the pipe fitting hub. Thus, plurality of grit type particles 24 allow for the pipe fitting plug to be retained in the pipe fitting hub.
As air pressure is decreased from within inner chamber 25 , expandable rubber bladder 20 deflates, outer seal area 21 and the plurality of grit type particles 24 break contact with the inner wall of the pipe fitting hub and the pipe fitting plug can be disengaged from the pipe fitting hub. The pipe fitting plug can thus be reused.
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 a departure from the spirit and scope of the invention. | A reusable pipe fitting plug for temporarily sealing the open hub on a non-threaded female pipe fitting. The pipe fitting plug has a retainer with piercing edges, expandable pins or grit type particles designed to engage the inner portion of a pipe fitting hub in order to anchor the pipe fitting plug. The pipe fitting plug further has an expandable rubber seal or expandable rubber bladder designed to provide a watertight seal. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority benefit of Taiwan application serial no.90130874, filed on Dec. 13, 2001.
BACKGROUND OF INVENTION
1. Field of Invention
The present invention relates to testing methods of organic light emitting diode (OLED) panels for all pixels on. More particularly, the present invention relates to testing methods of using an anisotropic conductive film (ACF) together with a conductive plate timing control to carry out all pixels testing on organic light emitting diode (OLED) panels.
2. Description of Related Art
An organic light emitting diode (OLED) panel is usually tested using two major methods. One method of testing the OLED panel is to scan the panel using a system containing a driving chip and a control circuit board to scan the panel. The other method is to spread a layer of silver paste over the electrodes of an OLED panel so that the panel is globally driven because all the diode units are connected. If a driving chip is used to conduct a panel test, different driving chip and control circuit board must be used for a panel having different pixel size and pitch. Hence, considerable investment must be made in the design and development of a suitable driving chip to conduct the test. Moreover, a driving chip can hardly sustain a high current or a high voltage and hence the current and voltage that the driving chip can provide to test the panel is quite limited. In addition, the number of panel that can be tested at any one time is also limited by the chip-controlled circuit board.
On the other hand, spreading silver paste to render all the diode units inside the OLED panel connected often leads to other problems. Non-uniformity of the silver paste may lead to some unlit pixels. Moreover, in high temperature or high humidity test, the coated silver paste may peel off leading to a direct effect on the test panel.
Furthermore, if the silver paste is spread non-uniformly, current and voltage may concentrate on a few electrodes. Ultimately, a portion of the pixels on the panel may be damaged after the testing.
SUMMARY OF INVENTION
Accordingly, one object of the present invention is to provide testing methods of organic light emitting diode (OLED) panels for all pixels on that utilizes an anisotropic conductive film together with a conductive plate to light up all the diodes inside the panels.
To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, the invention provides testing methods of OLED panels for all pixels on. The methods include positioning anisotropic conductive films and conductive plates over a set of exposed first electrodes and a set of exposed second electrodes. Through the anisotropic conductive film and the conductive plate, the set of first electrodes and the set of second electrodes conduct. Thereafter, the set of first electrodes is connected to a first voltage and the set of second electrodes is connected to a second voltage. Through the voltage difference between the first voltage and the second voltage, all the pixels inside the OLEO panels are lit to perform the test.
In the testing methods of OLED panels for all pixels on of this invention, the conductive plate can be fabricated from any good conductor such as a copper foil. The first voltage and the second voltage can be provided through a power supplier. In addition, glue may be applied to the edge of the conductive plate to fix the conductive plate after bonding the conductive plate onto the anisotropic conductive film.
Furthermore, the testing methods of OLED panels for all pixels on according to this invention permits the concurrent testing of a plurality of OLED panels. To carry out concurrent testing of multiple OLED panels, a conductive plate is used to connect serially all the first electrodes of the OLED panels or a conductive plate is used to connect serially all the second electrodes of the OLED panels. Alternatively, a first conductive plate is used to connect serially all the first electrodes while a second conductive plate is used to connect serially all the second electrodes of the OLED panels.
It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings are included to provide a further understanding of the Invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings,
FIGS. 1 to 3 are top views showing the steps for carrying out the testing of an OLED panel through anisotropic conductive films and conductive plates according to a first embodiment of this invention;
FIG. 4 is a cross-sectional view of FIG. 3;
FIGS. 5 to 7 are top views showing the steps for carrying out the testing of an OLED panel through anisotropic conductive films and conductive plates according to a second embodiment of this invention;
FIG. 8 is a cross-sectional view of FIG. 7; and
FIGS. 9 and 10 are-top views showing two configurations for carrying out the testing of a plurality of OLED panels concurrently according to a third preferred embodiment of this invention.
DETAILED DESCRIPTION
Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated In the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
FIGS. 1 to 3 are top views showing the steps for carrying out the testing of an organic light emitting diode (OLED) panel through anisotropic conductive films and conductive plates according to a first embodiment of this invention. As shown in FIG. 1, an organic light emitting diode (OLED) panel 100 is provided. The OLED panel 100 has a display region 102 and a non-display region 101 . The non-display region 101 has a plurality of first electrodes 104 and a plurality of second electrodes 106 . Both the first electrodes 104 and the second electrodes 106 extend from the display region 102 . The set of first electrodes 104 and the set of second electrodes 106 are perpendicularly attached to the OLED panel 100 . A light-emitting layer is positioned between the first electrodes 104 and the second electrodes 106 . Through the application of a voltage to the first electrodes 104 and the second electrodes 106 , the light-emitting layer is powered up to emit light so that images are displayed on the panel.
To test the OLED panel 100 , an anisotropic conductive film (ACF) 108 is placed over the first set of electrodes 104 and the second set of electrodes 106 respectively as shown in FIG. 2 .
As shown in FIGS. 3 and 4, where FIG. 4 is a cross-sectional view of FIG. 3, a first conductive plate 110 a and a second conductive plate 110 b made from a highly conductive material such as copper foil are provided. The conductive plates 110 a and 110 b are placed over the respective anisotropic conductive film 108 . Thereafter, pressure and heat are applied so that the conductive plates 110 a and 110 b are electrically connected to the first electrodes 104 and the second electrodes 106 through conductive particles within the anisotropic conductive films 108 .
The conductive plate 110 a renders all the first electrodes 104 conductive and the conductive plate 110 b renders all the second electrodes 106 conductive. Furthermore, the first conductive plate 110 a and the second conductive plate 110 b may be connected to a power supplier 114 . The power supplier 114 supplies a first voltage V1 to the first conductive plate 110 a and a second voltage V2 to the second conductive plate 110 b . Since all the first electrodes 104 and the second electrodes 106 are electrically connected to the first conductive plate 110 a and the second conductive plate 110 b respectively, all the diodes within the OLED panel 100 are powered to perform the test.
FIGS. 5 to 7 are top views showing the steps for carrying out the testing of an OLED panel through anisotropic conductive films and conductive plates according to a second embodiment of this invention. As shown in FIG. 5, an organic light emitting diode (OLED) panel 100 is provided. The OLED panel 100 has a display region 102 and a non-display region 101 . The non-display region 101 has a plurality of first electrodes 104 and a plurality of second electrodes 106 . Both the first electrodes 104 and the second electrodes 106 extend from the display region 102 . The set of first electrodes 104 and the set of second electrodes 106 are perpendicularly attached to the OLED panel 100 . A light-emitting layer is positioned between the first electrodes 104 and the second electrodes 106 . Through the application of a voltage to the first electrodes 104 and the second electrodes 106 , the light-emitting layer is powered up to emit light so that images are displayed on the panel.
To test the OLED panel 100 , an anisotropic conductive film (ACF) 108 is placed over the first set of electrodes 104 and the second set of electrodes 106 respectively as shown in FIG. 6 .
As shown in FIGS. 7 and 8, where FIG. 8 is a cross-sectional view of FIG. 7, a first conductive plate 110 a and a second conductive plate 110 b made from a highly conductive material such as copper foil are provided. The conductive plates 110 a and 110 b are placed over the respective anisotropic conductive film 108 . Thereafter, pressure and heat are applied so that the conductive plates 110 a and 110 b are electrically connected to the first electrodes 104 and the second electrodes 106 through conductive particles within the anisotropic conductive films 108 . Adhesive glue 112 is applied to the edges of the conductive plates 110 a and 110 b so that both conductive plates 110 a and 110 b are stationed on the panel. The adhesive glue 112 can be silicone glue, for example. The application of adhesive glue 112 prevents the conductive plates 110 a and 110 b from peeling off the OLED electrodes.
The conductive plate 110 a renders all the first electrodes 104 conductive and the conductive plate 110 b renders all the second electrodes 106 conductive. Furthermore, the first conductive plate 110 a and the second conductive plate 110 b may be connected to a power supplier 114 . The power supplier 114 supplies a first voltage V1 to the first conductive plate 110 a and a second voltage V2 to the second conductive plate 110 b . Since all the first electrodes 104 and the second electrodes 106 are electrically connected to the first conductive plate 110 a and the second conductive plate 110 b respectively, all the diodes within the OLED panel 100 are powered to perform the test.
FIGS. 9 and 10 are top views showing two configurations for carrying out the testing of a plurality of OLED panels concurrently according to a third preferred embodiment of this invention. When a plurality of OLED panels 100 are lined up as shown in FIG. 9 for a concurrent test, a common conductive plate 110 b connects all the second electrodes 106 . An alternative alignment of the OLED panels 100 is shown in FIG. 10 . Here, a common conductive plate 110 a connects all the first electrodes 104 together.
The arrangement of OLED panels 100 in FIGS. 9 and 10 is able to withstand very high current and voltage. Hence, there is little problem is conducting the testing.
The second electrodes 106 of a plurality of OLED panels 100 are serially connected together through the conductive plate 110 b as shown in FIG. 9 . Meanwhile, the first electrodes 104 of a plurality of OLED panels 100 are serially connected together through the conductive plate 110 a as shown in FIG. 10 . This invention also permits a conductive plate 110 a to connect all the first electrodes 104 of the OLED panels 100 and a conductive plate 110 b to connect all the second electrodes 106 of the OLED panels 100 .
The advantages of using the anisotropic conductive films, the conductive plates and the fastening glue (selectively) to prepare for the test can be compared with a conventional arrangement in Table 1.
TABLE 1
According to this
Items
Invention
Driving Chip
Silver Paste Coating
Cost
Low cost
Expensive to
Cost is intermediate
factor
develop and
between the driving
fabricate
chip method and the
invention.
Time
Any time after
Longer development
Any time after
factor
wiring
period
wiring
Environ-
Not affected by
Driving chip easily
Coverage and
mental
environmental
affected by
reactance influenced
factor
temperature and
environmental
by environmental
humidity
temperature and
temperature,
humidity
humidity
Testing
Highly accurate
Driving chip signal
Error prone due to
accuracy
easily interfered by
poor display effect
environmental
factors
Effect
Display is good
Display is good.
Display is poor.
of Display
In summary, the testing methods of OLED panels for all pixels on according to this invention has the following advantages:
1. Using anisotropic conductive films together with conductive plates to connect up all the diodes inside the panel permits the flow of a larger current or the use of a higher voltage during the testing.
2. A testing of a multiple of OLED panels can be carried out through serial or parallel current connection.
3. The anisotropic conductive films are prevented from peeling off from the panel during testing through the application of some fastening glue.
4. The OLED panel test can be carried out at all sorts of temperature and humidity environment without much adverse effect.
5. Cost of carrying out the test of OLED panels are considerably lower than the conventional methods such as the driving chip or the silver paste coating method.
It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents. | The testing method of OLED panels for all pixels on are provided. The methods include positioning anisotropic conductive films and conductive plates over a set of exposed first electrodes and a set of exposed second electrodes. Through the anisotropic conductive film and the conductive plate, the set of first electrodes and the set of second electrodes conduct. Thereafter, the set of first electrodes is connected to a first voltage and the set of second electrodes is connected to a second voltage. Through the voltage difference between the first voltage and the second voltage, all the inside the OLED panels are lit to perform the test. | 6 |
BACK
[0001] 1. Technical Field
[0002] The present disclosure relates to electronic devices; and more particularly, to an electronic device having a key.
[0003] 2. Description of Related Art
[0004] Electronic devices, such as computers, DVD players and mobile phones, may have a key for receiving users' operations, for example, turning on/off the power. The key includes a key cap having an actuating component, and a switch. The actuating component triggers the switch when the key cap is pressed. However, the key cap is secured to the housing by virtue of other fixing members, which is inconvenient to be assembled.
[0005] Therefore, there is room for improvement in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Many aspects of the embodiments can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0007] FIG. 1 is a perspective view of an electronic device having a key.
[0008] FIG. 2 is a partial disassembled view of the electronic device of FIG. 1 .
[0009] FIG. 3 is similar to FIG. 2 , but viewed from another aspect.
[0010] FIG. 4 is a view of the key in FIG. 3 from another aspect.
[0011] FIG. 5 is a partial assembled view of the electronic device of FIG. 2 .
DETAILED DESCRIPTION
[0012] Referring to FIG. 1 , an electronic device 100 includes a housing 10 , a cover 20 , and a key 50 . The cover 20 rotatably couples to the hosing 10 , and is capable of being closed and opened relative to the housing 10 by an external force. The key 50 is movably arranged on the housing 10 for receiving users' operations. The electronic device 100 may be a computer, DVD player and a mobile phone. In the embodiment, the electronic device 100 is a DVD player.
[0013] The housing 10 is substantially rectangular, and includes a top case 11 , and a bottom case 13 opposite to the top case 11 . The top case 11 engages with the bottom case 13 to define a receiving space (not shown), for receiving components of the electronic device 100 .
[0014] Referring to FIGS. 2 and 3 , the bottom case 13 includes a bottom wall 130 and a plurality of sidewalls extending from the bottom wall 130 . A circuit board 132 is arranged on a surface of the bottom wall 130 opposite to the top case 11 . One of the sidewalls (referred herein as the first sidewall 131 ) includes an outer surface 1310 and an inner surface 1312 opposite to the outer surface 1310 . The outer surface 1310 defines a receiving portion 1313 . The receiving portion 1313 is recessed in the outer surface 1310 and extends in a direction parallel to the bottom wall 130 . The bottom of the receiving portion 1313 defines a mounting hole 1311 allowing the receiving portion 1313 to communicate with the receiving space. The mounting hole 1311 is defined at the middle portion of the bottom of the receiving portion 1313 and extends in the same direction as the receiving portion 1313 . Two friction ribs 1314 protrude from the bottom of the receiving portion 1313 and are arranged at opposite sides of the mounting hole 1311 symmetrically about the center of the mounting hole 1311 . A mounting base 1315 protrudes from the inner surface 1312 . A surface of the mounting base 1315 opposite to the inner surface 1312 is perpendicular to the bottom wall 130 .
[0015] The key 50 is movably coupled to the first sidewall 131 . The key 50 includes a key cap 30 and a switch 40 which can be engaged with the key cap 30 .
[0016] The key cap 30 is slidably secured to the first sidewall 131 for triggering the switch 40 . The key cap 30 includes an operating portion 31 and an actuating component 32 . The operating portion 31 is slidably received in the receiving portion 1313 . The operating component 31 includes a first surface 310 and a second surface 312 opposite to the first surface 310 . The first surface 310 is exposed from the outer surface 1310 . A plurality of skid resisting portions 3101 protrude from the first surface 310 for increasing friction. In the embodiment, the skid resisting portions 3101 are substantially columnar.
[0017] The actuating component 32 protrudes from the second surface 312 and is capable of extending through the mounting hole 1311 for engaging with the switch 40 . The actuating component 32 includes a first arm 321 , a second arm 323 , two positioning components 325 and four contacting ribs 327 . In the embodiment, the actuating component 32 is integrated with the operating component 31 .
[0018] The first arm 321 perpendicularly protrudes from the second surface 312 , and includes an upper surface 3210 and a lower surface 3212 (shown in FIG. 4 ) opposite to the upper surface 3210 . The second arm 323 is substantially an arc, and bends from an end of the first arm 321 away from the second surface 312 . An end of the second arm 323 away from the first arm 321 defines a latching groove 3230 for engaging with the switch 40 .
[0019] Referring to FIG. 4 , the two positioning components 325 are secured to opposite sides of the second arm 32 . The two positioning components 325 are made of elastic material. Each positioning component 325 includes a connecting portion 3250 and a resisting portion 3252 . Each connecting portion 3250 is substantially L-shaped, and includes a first connecting portion 3251 and a second connecting portion 3253 . The first connecting portions 3251 perpendicularly extend from opposite sides of the second arm 323 and are adjacent to the first arm 321 . The second connecting portions 3253 perpendicularly extend from ends of the first connecting portions 3251 away from the second arm 323 , and extend toward the operating component 31 . The second connecting portions 3253 maintain a predetermined gap between themselves and the second arm 323 . The resisting portions 3252 are bent from ends of the corresponding second connecting portions 3253 away from the first connecting portions 3251 . The bending direction of the resisting portions 3252 is the reverse of the bending direction of the second arms 323 . The distance between ends of the resisting portions 3252 away from the first connecting portions 3251 and the second surface 312 is substantially equal to the distance between the outer surface 1310 and an end of the mounting base 1315 opposite to the inner surface 1312 .
[0020] Referring again to FIG. 2 , two of the contacting ribs 327 protrude from the upper surface 3210 and are distanced from each other. The other two contacting ribs 327 protrude from the lower surface 3212 and are symmetrical to the corresponding second ribs 327 on the upper surface 3210 (shown in FIG. 3 ). The distance between ends of the contacting ribs 327 away from the first arm 321 is substantially equal to the vertical width of the mounting hole 1311 .
[0021] The switch 40 is arranged on a surface of the circuit board 132 facing the top case 11 . The switch 40 includes a body 41 and a triggering portion 43 . The body 41 is adjacent to the first sidewall 131 . The triggering portion 43 protrudes from a side of the body 41 and faces the top case 11 . The projection of the triggering portion 43 on the first sidewall 131 substantially corresponds to the mounting hole 1311 . The shape of the triggering portion 43 matches the shape of the latching groove 3230 .
[0022] Referring FIG. 5 , in assembly, the second arm 323 extends through the mounting hole 1311 , and the two resisting portions 3252 elastically deform to allow the operating component 31 to be received in the receiving groove 1313 and to abut the two friction ribs 1314 . The triggering portion 1304 is secured to the latching groove 3230 . In this state, the two resisting portions 3252 rebound and abut the mounting base 1315 . The operating component 31 abuts the outer surface 1310 and cooperates with the two resisting portions 3252 to fix the key 30 to the first sidewall 131 . The four contacting ribs 327 make contact with the edges of the mounting hole 1311 for reducing the friction between the actuating component 32 and the mounting hole 1311 . The second surface 312 makes contact with the two friction ribs 1314 for reducing the friction between the operating component 31 and the receiving groove 1313 . Thus, the key 30 is secured to and stable on the first sidewall 131 , with the operating component 31 slidably received in the mounting hole 1311 for operating the switch 40 .
[0023] Although information and the advantages of the present embodiments have been set forth in the foregoing description, together with details of the structures and functions of the present embodiments, the disclosure is illustrative only; changes may be made in detail, especially in the matters of shape, size, and arrangement of parts within the principles of the present embodiments to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | An electronic device includes a housing and a key. The housing defines a mounting hole. The key is moveably connected to the housing, and includes a switch and a key cap engaging with the switch. The key cap comprises an operating component and an actuating component secured to the operating component. The actuating component includes a positioning component secured to the actuating component. When the actuating component extends through the mounting hole, the positioning component is deformed and cooperates with the operating component to abut opposite sides of the housing, for securing the key to the housing. | 7 |
TECHNICAL FIELD
[0001] The present invention relates, in general, to a method of modulating physiological and pathological processes and, in particular, to a method of modulating cellular levels of oxidants and thereby processes in which such oxidants are a participant. The invention also relates to compounds and compositions suitable for use in such methods.
BACKGROUND
[0002] Oxidants are produced as part of the normal metabolism of all cells but also are an important component of the pathogenesis of many disease processes. Reactive oxygen species, for example, are critical elements of the pathogenesis of diseases of the lung, the central nervous system and skeletal muscle. Oxygen free radicals also play a role in modulating the effects of nitric oxide (NO.). In this context, they contribute to the pathogenesis of vascular disorders, inflammatory diseases and the aging process.
[0003] A critical balance of defensive enzymes against oxidants is required to maintain normal cell and organ function. Superoxide dismutases (SODs) are a family of metalloenzymes that catalyze the intra- and extracellular conversion of O 2 − into H 2 O 2 plus O 2 , and represent the first line of defense against the detrimental effects of superoxide radicals. Mammals produce three distinct SODs. One is a dimeric copper- and zinc-containing enzyme (CuZn SOD) found in the cytosol of all cells. A second is a tetrameric manganese-containing SOD (Mn SOD) found within mitochondria, and the third is a tetrameric, glycosylated, copper- and zinc-containing enzyme (EC-SOD) found in the extracellular fluids and bound to the extracellular matrix. Several other important antioxidant enzymes are known to exist within cells, including catalase and glutathione peroxidase. While extracellular fluids and the extracellular matrix contain only small amounts of these enzymes, other extracellular antioxidants are also known to be present, including radical scavengers and inhibitors of lipid peroxidation, such as ascorbic acid, uric acid, and α-tocopherol (Halliwell et al, Arch. Biochem. Biophys. 280:1 (1990)).
[0004] The present invention relates generally to low molecular weight porphyrin compounds suitable for use in modulating intra- and extracellular processes in which superoxide radicals, or other oxidants such as hydrogen peroxide or peroxynitrite, are a participant. The compounds and methods of the invention find application in various physiologic and pathologic processes in which oxidative stress plays a role.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a method of modulating intra- or extracellular levels of oxidants such as superoxide radicals, hydrogen peroxide, peroxynitrite, lipid peroxides, hydroxyl radicals and thiyl radicals. More particularly, the invention relates to a method of modulating normal or pathological processes involving superoxide radicals, hydrogen peroxide, nitric oxide or peroxynitrite, using low molecular weight antioxidants, and to methine (ie, meso) substituted porphyrins suitable for use in such a method. The substituted porphyrins are also expected to have activity as antibacterial and antiviral agents, and as ionophores and chemotherapeutics. Objects and advantages of the present invention will be clear from the description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 . Mechanism.
[0007] FIG. 2 . Manganese meso-tetrakis-N-alkyl-pyridinium based porphyrins.
[0008] FIG. 3 . SOD activity in vivo ( E. coli ) of 1, 2, 3* and 4* (20 μM) in minimal medium (mixture of atropoisomers, JI=SOD deficient strain, AB=parental strain).
[0009] FIG. 4 . Structures of MnCl x TE-2-PyP 5+ (x=1 to 4).
[0010] FIG. 5 . 1 H-NMR spectrum (porphyrin ring) of H 2 Cl 2a T-2-PyP in CDCl 3 (δ=7.24 ppm). The four protons in alpha position of the four pyridyl nitrogens are taken as integration reference.
[0011] FIG. 6 . Plot of the free energy of activation (ΔG d ) for the O 2 ′ dismutation reaction catalyzed by MnCl x TE-2-PyP 5 +as a function of the ground state free energy change (ΔG d ) for MnCl x TE-2-PyP 5− redox. ΔG d and ΔG o were calculated from k cat and E o 1/2 values reported in Table 4 (F, R, h and k B are Faraday, molar gas, Planck and Boltzmann constants, respectively).
[0000] Numbers 0-4 correspond to x in MnCl x TE-2-PyP 5−
[0000] Corresponding data for one active site of Cu, Zn-SOD (Ellerby et al, J. Am. Chem. Soc. 1118:6556 (1996)).
[0012] FIG. 7 . Illustrated are the chemical structures of three classes of antioxidants. A) The meso-porphyrin class is depicted where: R 1 is either a benzoic acid (tetrakis-(4-benzoic acid) porphyrin (TBAP)) or a N-methyl group in the 2 or 4 position of the pyridyl (tetrakis-(N-methylpyridinium-2(4)-yl) porphyrin (TM-2-PyP, TM-4-PyP)); R 2 is either a hydrogen (H) or a bromide (Br, OBTM-4-PyP) and where the porphyrin is ligated with either a manganese (Mn), cobalt (Co), iron (Fe), or zinc (Zn) metal. B) The vitamin E analog class is represented by trolox. C) The flavanoid class is represented by rutin.
[0013] FIG. 8 . The time course of iron/ascorbate mediated oxidation of rat brain homogenates. Rat brain homogenates were incubated for various times with 0.25 μM FeCl 2 and 1 μM ascorbate, and lipid peroxidation was measured as thiobarbituric acid reactive species (TBARS) spectrophotometrically at 535 nm (n=3).
[0014] FIG. 9 . The comparison of trolox (▪, rutin (▴), bovine CuZnSOD (●), MnOBTM-4-PyP (▾) and MnTM-2-PyP (♦) in their ability to inhibit iron/ascorbate mediated oxidation of rat brain homogenates. Rat brain homogenates were incubated for 30 minutes with 0.25 μM FeCl 2 and 1 μM ascorbate, and lipid peroxidation was measured as thiobarbituric acid reactive species. The amount of TBARS formed in 30 minutes was expressed as 100% lipid peroxidation (n=3-6). Sigmoidal dose response curves were derived from fitting the data to a non-linear regression program.
[0015] FIG. 10 . The comparison of manganic (▴), cobalt (●), iron (▾) and zinc (▪) analogs of TBAP in their ability to inhibit iron/ascorbate mediated oxidation of rat brain homogenates. Rat brain homogenates were incubated for 30 minutes with 0.25 μM FeCl 2 and 1 μM ascorbate, and lipid peroxidation was measured as thiobarbituric acid reactive species. The amount of TBARS formed in 30 minutes was expressed as 100% lipid peroxidation (n=3−6). Sigmoidal dose response curves were derived from fitting the data to a non-linear regression program.
[0016] FIG. 11 . The comparison of manganic (solid) and zinc (open) analogs of TM-4-PyP (squares) and TM-2-PyP (triangles) in their ability to inhibit iron/ascorbate mediated oxidation of rat brain homogenates. Rat brain homogenates were incubated for 30 minutes with 0.25 μM FeCl 2 and 1 μM ascorbate, and lipid peroxidation was measured as thiobarbituric acid reactive species. The amount of TBARS formed in 30 minutes was expressed as 100% lipid peroxidation (n=3−6). Sigmoidal dose response curves were derived from fitting the data to a non-linear regression program.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention relates to methods of protecting against the deleterious effects of oxidants, particularly, superoxide radicals, hydrogen peroxide and peroxynitrite, and to methods of preventing and treating diseases and disorders that involve or result from oxidant stress. The invention also relates methods of modulating biological processes involving oxidants, including superoxide radicals, hydrogen peroxide, nitric-oxide and peroxynitrite. The invention-further relates to compounds and compositions, including low molecular weight antioxidants (eg mimetics of scavengers of reactive oxygen species, including mimetics of SODs, catalases and peroxidases) and formulations thereof, suitable for use in such methods.
[0018] Mimetics of scavengers of reactive oxygen species appropriate for use in the present methods include methine (ie meso) β-substituted porphines, or pharmaceutically acceptable salts thereof. The invention includes both metal-free and metal-bound porphines. In the case of metal-bound porphines, manganic derivatives of methine (meso) β-substituted porphines are preferred, however, metals other than manganese, such as iron (II or III), copper (I or II), cobalt (II or III), or nickel (I or II), can also be used. It will be appreciated that the metal selected can have various valence states, for example, manganese II, III or V can be used. Zinc (II) can also be used even though it does not undergo a valence change and therefore will not directly scavenge superoxide. The choice of the metal can affect selectivity of the oxygen species that is scavenged. Iron-bound porphines, for example, can be used to scavenge NO. while manganese-bound porphines cannot. These metal bound porphines scavenge peroxynitrite; iron, nickel and cobalt bound porphines tend to have the highest reactivity with peroxynitrite.
[0019] Preferred mimetics of the invention are of Formula I or II:
[0020] or pharmaceutically acceptable salt thereof, wherein R is C 1 -C 8 alkyl, preferably, C 1 -C 4 alkyl, more preferably, methyl, ethyl or isopropyl, most preferably methyl. This mimetic can also be present metal-free or bound to a metal other than Mn. All atropoisomers of the above are within the scope of the invention, present in isolated form or as a mixture of at least two. Atropoisomers wherein at least 3, preferably 4, of the R groups are above the porphyrin ring plane can be particularly advantageous.
[0021] One or more of the pyrrole rings of the porphyrin of Formula I or II can be β-substituted at any or all beta carbons, ie: 2, 3, 7, 8, 12, 13, 17 or 18. Such substituents, designated P, can be an electron withdrawing group, for example, each P can, independently, be a NO 2 group, a halogen (eg Cl, Br or F), a nitrile, a vinyl group, or a formyl group. For example, there can be 1, 2, 3, 4, 5, 6, 7 or 8 halogen (eg Br) substituents (when there are less than 8 halogen substituents, the remaining P's are advantageously hydrogen). Such substituents alter the redox potential of the porphyrin and thus enhance its ability to scavenge oxygen radicals. Each P can, independently, also be hydrogen. When P is formyl, it is preferred that there be not more than 2 (on non adjacent carbons), more preferably 1, the remaining P's being hydrogen. When P is NO 2 , it is preferred that there be not more than 4 (on non adjacent carbons), more preferably 1 or 2, the remaining P's being hydrogen.
[0022] Mimetics suitable for use in the present methods can be selected by assaying for SOD, catalase and/or peroxidase activity and stability. Mimetics can also be screened for their ability to inhibit lipid peroxidation in tissue homogenates using iron and ascorbate to initiate the lipid peroxidation and measuring the formation of thiobarbituric acid reactive species (TBARS) (Ohkawa et al, Anal. Biochem. 95:351 (1979) and Yue et al, J. Pharmacol. Exp. Ther. 263:92 (1992)). The selective, reversible and SOD-sensitive inactivation of aconitase by known O − 2 generators can be used as a marker of intracellular O − 2 generation. Thus, suitable mimetics can be selected by assaying for the ability to protect aconitase activity.
[0023] SOD activity can be monitored in the presence and absence of EDTA using the method of McCord and Fridovich (J. Biol. Chem. 244:6049 (1969)). The efficacy of a mimetic can also be determined by measuring the effect of the mimetic on the aerobic growth of a SOD null E. coli strain versus a parental strain lacking the specific mutations. Specifically, parental E. coli (AB1157) and SOD null E. coli . (JI132) can be grown in M9 medium containing 0.2% casamino acids and 0.2% glucose at pH 7.0 and 37° C.; growth can be monitored in terms of turbidity followed at 700 nm. This assay can be made more selective for SOD mimetics by omitting the branched chain, aromatic and sulphur containing amino acids from the medium (glucose minimal medium (M9), plus 5 essential amino acids) (see Example V).
[0024] Efficacy of active mimetics can also be assessed by determining their ability to protect mammalian cells against methylviologen (paraquat)-induced toxicity.
[0025] Specifically, rat L2 cells grown as described below and seeded into 24 well dishes can be pre-incubated with various concentrations of the SOD mimetic and then incubated with a concentration of methylviologen previously shown to produce an LC 75 in control L2 cells.
[0026] Efficacy of the mimetic can be correlated with a decrease in the methylviologen-induced LDH release (St. Clair et al, FEBS Lett. 293:199 (1991)).
[0027] The efficacy of SOD mimetics can be tested in vivo with mouse and/or rat models using both aerosol administration and parenteral injection. For example, male Balb/c mice can be randomized into 4 groups of 8 mice each to form a standard 2×2 contingency statistical model. Animals can be treated with either paraquat (40 mg/kg, ip) or saline and treated with SOD mimetic or vehicle control. Lung injury can be assessed 48 hours after paraquat treatment by analysis of bronchoalveolar lavage fluid (BALF) damage parameters (LDH, protein and % PMN) as previously described (Hampson et al, Tox. Appl. Pharm. 98:206 (1989); Day et al, J. Pharm. Methods 24:1 (1990)). Lungs from 2 mice of each group can be instillation-fixed with 4% paraformaldehyde and processed for histopathology at the light microscopic level.
[0028] Catalase activity can be monitored by measuring absorbance at 240 nm in the presence of hydrogen peroxide (see Beers and Sizer, J. Biol. Chem. 195:133 (1952)) or by measuring oxygen evolution with a Clark oxygen electrode (Del Rio et al, Anal. Biochem. 80:409 (1977)) Peroxidase activity can be measured spectrophotometrically as previously described by Putter and Becker: Peroxidases. In: Methods of Enzymatic Analysis, H. U. Bergmeyer (ed.), Verlag Chemie, Weinheim, pp. 286-292 (1983). Aconitase activity can be measured as described by Gardner and Fridovich (J. Biol. Chem. 266:19328 (1991)). The ability of mimetics to inhibit lipid peroxidation is assessed as described by Ohkawa et al (Anal. Biochem. 95:351 (1979)) and Yue et al (J. Pharmacol. Exp. Ther. 263:92 (1992)).
[0029] Active mimetics can be tested for toxicity in mammalian cell culture by measuring lactate dehydrogenase (LDH) release. Specifically, rat L2 cells (a lung Type II like cell; (Kaighn and Douglas, J. Cell Biol. 59:160a (1973)) can be grown in Ham's F-12 medium with 10% fetal calf serum supplement at pH 7.4 and 37° C.; cells can be seeded at equal densities in 24 well culture dishes and grown to approximately 90% confluence; SOD mimetics can be added to the cells at log doses (eg micromolar doses in minimal essential medium (MEM)) and incubated for 24 hours. Toxicity can be assessed by morphology and by measuring the release of the cytosolic injury marker, LDH (eg on a thermokinetic plate reader), as described by Vassault (In: Methods of Enzymatic Analysis, Bergmeyer (ed) pp. 118-26 (1983); oxidation of NADH is measured at 340 nm).
[0030] Synthesis of mimetics suitable for use in the present method can be effected using art-recognized protocols (see also Examples I, II, III and IV and Sastry et al, Anal. Chem. 41:857 (1969), Pasternack et al, Biochem. 22:2406 (1983); Richards et al, Inorg. Chem. 35:1940 (1996) and U.S. application Ser. No. 08/663,028, particularly the details therein relating to syntheses) Separation of atropoisomers can be effected using a variety of techniques.
[0031] One specific embodiment of the present invention relates to a method of regulating NO. levels by targeting the above-described porphines to strategic locations. NO. is an intercellular signal and, as such, NO. must traverse the extracellular matrix to exert its effects. NO., however, is highly sensitive to inactivation mediated by O − 2 present in the extracellular spaces. The methine (meso) β-substituted porphyrins of the invention can increase bioavalability of NO. by preventing its degradation by O − 2 − .
[0032] In a further embodiment, the mimetics of the invention are used as catalytic scavengers of reactive oxygen species to protect against ischemia reperfusion injuries associated with myocardial infarction, stroke, acute head trauma, organ reperfusion following transplantation, bowel ischemia, hemorrhagic shock, pulmonary infarction, surgical occlusion of blood flow, and soft tissue injury. The mimetics can further be used to protect against skeletal muscle reperfusion injuries. The mimetics can also be used to protect against damage to the eye due to sunlight (and to the skin) as well as glaucoma, and macular degeneration in the eye. The mimetics can also be used to protect against and/or treat cataracts. The mimetics can also be used to protect against and/or treat inflammatory diseases of the skin (e.g., psoriasis). Diseases of the bone are also amenable to treatment with the mimetics. Further, connective tissue disorders associated with defects in collagen synthesis or degradation can be expected to be susceptible to treatment with the present mimetics, as should the generalized deficits of aging.
[0033] In yet another embodiment, the mimetics of the invention can be used as catalytic scavengers of reactive oxygen species to increase the very limited storage viability of transplanted hearts, kidneys, skin and other organs and tissues. The invention also provides methods of inhibiting damage due to autoxidation of substances resulting in the formation of O − 2 including food products, pharmaceuticals, stored blood, etc. To effect this end, the mimetics of the invention are added to food products, pharmaceuticals, stored blood and the like, in an amount sufficient to inhibit or prevent oxidation damage and thereby to inhibit or prevent the degradation associated with the autoxidation reactions. (For other uses of the mimetics of the invention, see U.S. Pat. No. 5,227,405). The amount of mimetic to be used in a particular treatment or to be associated with a particular substance can be determined by one skilled in the art.
[0034] In yet another embodiment, the mimetics of the invention can be used to scavenge hydrogen peroxide and thus protect against formation of the highly reactive hydroxyl radical by interfering with Fenton chemistry (Aruoma and Halliwell, Biochem. J. 241:273 (1987); Mello Filho et al, Biochem. J. 218:273 (1984); Rush and Bielski, J. Phys. Chem. 89:5062 (1985)). The mimetics of the invention may also be used to scavenge peroxynitrite, as demonstrated indirectly by inhibition of the oxidation of dihydrorhodamine 123 to rhodamine 123 and directly by accelerating peroxynitrite degradation by stop flow analysis.
[0035] Further examples of specific diseases/disorders appropriate for treatment using the mimetics of the present invention include diseases of the central nervous system (including AIDS dementia, stroke, amyotrophic lateral sclerosis (ALS), Parkinson's disease and Huntington's disease) and diseases of the musculature (including diaphramic diseases (eg respiratory fatigue in emphysema, bronchitis and cystic fibrosis), cardiac fatigue of congestive heart failure, muscle weakness syndromes associated with myopathies, ALS and multiple sclerosis). Many neurologic disorders (including stroke, Huntington's disease, Parkinson's disease, ALS, Alzheimer's and AIDS dementia) are associated with an over stimulation of the major subtype of glutamate receptor, the NMDA (or N-methyl-D-aspartate) subtype. On stimulation of the NMDA receptor, excessive neuronal calcium concentrations contribute to a series of membrane and cytoplasmic events leading to production of oxygen free radicals and nitric oxide (NO.). Interactions between oxygen free radicals and NO. have been shown to contribute to neuronal cell death. Well-established neuronal cortical culture models of NMDA-toxicity have been developed and used as the basis for drug development. In these same systems, the mimetics of the present invention inhibit NMDA-induced injury. The formation of O − 2 radicals is an obligate step in the intracellular events culminating in excitotoxic death of cortical neurons and further demonstrate that the mimetics of the invention can be used to scavenge O − 2 radicals and thereby-serve as protectants against excitotoxic injury.
[0036] The present invention also relates to methods of treating AIDS. The NfKappa B promoter is used by the HIV virus for replication. This promoter is redox sensitive, therefore, an antioxidant can regulate this process. This has been previously shown for two metalloporphyrins distinct from those of the present invention (Song et al, Antiviral Chem. And Chemother. 8:85 (1997)). The invention also relates to methods of treating arthritis, systemic hypertension, atherosclerosis, edema, septic shock, pulmonary hypertension, including primary pulmonary hypertension, impotence, MED, infertility, endometriosis, premature uterine contractions, microbial infections, gout and in the treatment of Type I and Type II diabetes mellitus. The mimetics of the invention can be used to ameliorate the toxic effects associated with endotoxin, for example, by preserving vascular tone and preventing multi-organ system damage.
[0037] Inflammations, particularly inflammations of the lung, are amenable to treatment using the present invention (note particularly the inflammatory based disorders of asthma, ARDS including oxygen toxicity, pneumonia (especially AIDS-related pneumonia), cystic fibrosis, chronic sinusitis and autoimmune diseases (such as rheumatoid arthritis)). EC-SOD is localized in the interstitial spaces surrounding airways and vasculature smooth muscle cells. EC-SOD and O 2 − mediate the antiinflammatory—proinflammatory balance in the alveolar septum. NO. released by alveolar septal cells acts to suppress inflammation unless it reacts with O 2 − to form ONOO − . By scavenging O 2 − , EC-SOD tips the balance in the alveolar septum against inflammation. Significant amounts of ONOO − will form only when EC-SOD is deficient or when there is greatly increased O 2 − release. Mimetics described herein can be used to protect against destruction caused by hyperoxia.
[0038] The invention further relates to methods of treating memory disorders. It is believed that nitric oxide is a neurotransmitter involved in long-term memory potentiation. Using an EC-SOD knocked-out mouse model (Carlsson et al, Proc. Natl. Acad. Sci. USA 92:6264 (1995)), it can be shown that learning impairment correlates with reduced superoxide scavenging in extracellular spaces of the brain. Reduced scavenging results in higher extracellular O − 2 levels. O − 2 is believed to react with nitric oxide thereby preventing or inhibiting nitric oxide-medicated neurotransmission and thus long-term memory potentiation. The mimetics of the invention can be used to treat dementias and memory/learning disorders.
[0039] The availability of the mimetics of the invention also makes possible studies of processes mediated by O 2 − , hydrogen peroxide, nitric oxide and peroxynitrite.
[0040] The mimetics described above can be formulated into pharmaceutical compositions suitable for use in the present methods. Such compositions include the active agent (mimetic) together with a pharmaceutically acceptable carrier, excipient or diluent. The composition can be present in dosage unit form for example, tablets, capsules or suppositories. The composition can also be in the form of a sterile solution suitable for injection or nebulization. Compositions can also be in a form suitable for opthalmic use. The invention also includes compositions formulated for topical administration, such compositions taking the form, for example, of a lotion, cream, gel or ointment. The concentration of active agent to be included in the composition can be selected based on the nature of the agent, the dosage regimen and the result sought.
[0041] The dosage of the composition of the invention to be administered can be determined without undue experimentation and will be dependent upon various factors including the nature of the active agent, the route of administration, the patient, and the result sought to be achieved. A suitable dosage of mimetic to be administered, for example, IV or topically, can be expected to be in the range of about 0.01 to 100 mg/kg/day, preferably 0.1 to 10 mg/kg/day. For aerosol administration, it is expected that doses will be in the range of 0.01 to 1.0 mg/kg/day. Suitable doses of mimetics will vary, for example, with the mimetic and with the result sought. The results of Faulkner et al (J. Biol. Chem. 269:23471 (1994)) indicate that the in vivo oxidoreductase activity of the mimetics is such that a pharmaceutically effective dose will be low enough to avoid problems of toxicity. Doses that can be used include those in the range of 1 to 50 mg/kg.
[0042] Certain aspects of the present invention will be described in greater detail in the non-limiting Examples that follow.
EXAMPLES
[0043] The following chemicals were utilized in Examples I-V that follow.
[0044] The chloride salts of ortho and meta metal-free ligands (H 2 TM-2-PyPCl 5 and H 2 TM-3-PyPCl 5 ) were purchased from MidCentury Chemicals, and the tosylate salts of the para metal-free ligand H 2 TM-4-PyP(CH 5 PhSO 3 ) 5 ) were purchased from Porphyrin Products. The purity was checked in terms of elemental analysis and spectral properties, ie, molar absorptivities and corresponding wave-length of the Soret bands. The Soret band properties of metal-free ligands were ε 413.3nm =2.16×10 5 M −1 cm −1 (H 2 TM-2-PyPCl 4 ), ε 416.6 nm =3.18×10 5 M −1 cm −1 (H 2 TM-3-PyPCl 4 ), ε 422.0 nm =2.35×10 5 M −1 cm −1 (H 2 TM-4-PyPCl 4 ). The non-methylated ortho metal-free ligand (H 2 T-2-PyP) was bought from MidCentury Chemicals and the purity checked in terms or elemental analysis (see below). Iodoethane, 1-iodobutane, anhydrous manganese chloride (MnCl 2 ), MnCl 2 .4H 2 O, tetrabutylammonium chloride (TBA) and ammonium hexafluorophosphate (PF 6 NH 4 ) were purchased from Aldrich.
EXAMPLE I
Synthesis of meso-tetrakis-(N-methylpyridinium-2-yl)porphyrin and meso-tetrakis-(N-methylpyridinium-3-yl)porphyrin
[0045] Metal-free porphyrins meso-tetrakis-(2-pyridyl)porphyrin (H 2 T-2-PyP) and meso-tetrakis-(3-pyridyl)porphyrin (H 2 T-3-PyP) were synthesized via Rothmund condensation with use of a modified Adler procedure (Kalyanasundaram, Inorg. Chem. 23:2453 (1984); (Torrens et al, J. Am. Chem. Soc. 94:4160 (1972)). Into a 100 mL refluxing solution of propionic acid were slowly injected equimolar amounts of freshly distilled pyrrole and pyridine-2- or pyridine-3-carboxyladehyde, and the solution was allowed to reflux for about 45 min, after which the propionic acid was distilled off. The black residues were neutralized with NaOH, washed with methanol, dissolved in CH 2 Cl 2 (dichloromethane) and chromotographed on a neutral Woelm alumina column prepared with acetone. After elution of a pale blue fraction, H 2 TPyP was eluted with the use of CH 2 Cl 2 containing 5-10% of pyridine. Shiny dark purple crystals were recovered from the dark red eluant after removal of solvents on rotavaporator. Methylation of H 2 TPyPs was carried using the excess of methyl-p-toluensulfonate in refluxing chloroform (Kalyanasundaram, Inorg. Chem. 23:2453 (1984); (Hambright et al, Inorg. Chem. 15:2314 (1976′)). Both of the alkylated porphyrins spontaneously precipitated from hot chloroform solutions and were washed with ether and air dried.
EXAMPLE II
Preparation of Manganese Complexes of Ortho, Meta and Para Isomers of H 2 TMPyP 4+
[0046] The metallation was performed in water at room temperature. The porphyrin to metal ratio was 1:5 in the case of meta and ortho isomers and 1:14 in the case of para isomer. The solid MnCl 2 ×4H 2 O (Aldrich) was added to the aqueous metal-free porphyrins after the pH of the solution was brought to ˜pH=10.2. The metallation was completed inside an hour in the cases of all three isomers. For the preparation of ortho and meta compounds, MnTM-2-PyP 5+ and MnTM-3-PyP 5+ +, 300 mg of the metal-free ligand, either H 2 TM-2-PyP 4 or H 2 TM-3PyP 4+ , was dissolved in 100 mL water, pH brought to 10.2 with several drops of 1M NaOH, followed by the addition of 340 mg of MnCl 2 . The metallation was followed spectrally through the disappearance of the Soret band of H 2 TM-2-PyP 4+ or H 2 TM-3-Pyp 4+ at 413.3 nm or 416.6 nm, respectively, and the appearance of the Soret bands of manganese complexes at 454.1 nm and 459.8 nm, respectively.
[0047] The excess of metal was eliminated as follows for all three (ortho, meta and para) isomers of MnTMPyP 5+ . The MnTMPyP 5+ was precipitated as PF 6 salt by adding 50-fold excess of NH 4 PF 6 . The precipitate was washed with 2-propanol:diethylether=1:1, and dried in vacuum at room temperature. Dry PF 6 − salt of MnTMPyP 5− was then dissolved in acetone (370 mg in 100 mL acetone) and 1 g of tetrabutylammonium chloride added. The precipitate was washed with acetone and dried overnight in vacuum at room temperature. In order to obtain a pure compound, the procedure was repeated. The elemental analysis was done for all metallated isomers. The compounds were analyzed in spectral terms and the following data were obtained: Soret bands properties of metallated compounds were: ε 4540.1 nm =12.3×10 4 cm −1 M −1 (MnTM-2-PyPCl 5 ), ε 459.8 nM =13.3×10 4 cm −1 M −1 (MnTM-3-PyPCl 5 ), ε 462.2 nm =13.9×10 4 cm −1 M −1 (MnTM-4-PyPCl 5 ).
[0048] Metallation was performed in methanol as well. In addition, when performed in water, the metal:ligand ratio varied from 1:5, to 1:14 to 1:100. Under all conditions, the given molar absorptivities were obtained. The calculations were based on the metal-free ligands that were analyzed prior to metallation. The molar absorptivities of the metal-free ligands were consistent with literature as well as their elemental analyses.
[0049] The elemental analyses of MnTM2-PyPCl 5 and MnTM-3-PyPCl 5 are shown in Table 1
TABLE 1 C* H* N* MnTM2-PyPCl 5 .6 H 2 O 52.99(52.90) 4.85(4.64) 11.22(11.21) MnTM-3-PyPCl 5 .3 55.41(54.87) 4.97(4.40) 11.10(11.69) H 2 O *Found (calcd).
EXAMPLE III
Synthesis of manganic meso-tetrakis-(N-ethylpyridinium-2-yl) porphyrin
[0050] 50 mg of H 2 T-2-PyP was dissolved in 30 mL of anhydrous dimethylformamide (DMF) and the solution was stirred and heated at 100° C. 20 mg of anhydrous MnCl 2 (20 eq) were added and the solution stirred for 3 days. The completion of the metallation was checked by UV spectroscopy. Upon metallation, the temperature was decreased to 60° C., 0.65 mL of iodoethane (100 eq) was added, and the solution was stirred for 7 days (Perree-Fauvet et al, Tetrahedron 52:13569 (1996)). DMF was evaporated, 10 mL of acetone was added, and the product was precipitated adding 20 mL of a solution of TEA in acetone (0.45 M); indeed, contrary to the iodide salt, the chloride salt precipitates in acetone. The product was purified using the “double precipitation” method, as described above. The product was dried overnight in vacuum, over P 2 O 5 , at 70° C., leading to 125 mg (95%) of a dark purple solid. UV (H 2 O), ε 454.0 nm =1.41×10 5 M −1 cm −1 . Elemental analysis, calcd. for MnC 48 N 8 H 44 Cl 5 .5H 2 O: C (54.64), H (5.16), N (10.62); found: C (54.55), H (5.36), N-(10.88).
EXAMPLE IV
Synthesis of manganic meso-tetrakis-(N-butylpyridinium-2-yl)porphyrin
[0051] The same procedure described above was used. 0.92 mL of 1-iodobutane (100 eq) was added and the mixture stirred at 100° C. for 7 days. Drying of the chloride salt resulted in 70 mg (50%) of a dark purple viscous product. The elemental analysis was thus performed on the hexafluorophosphate salt (non-viscous) The chlorine salt is water-soluble (micelles were not observed). UV(H 2 O) of the chloride salt, ε 454.0 1.21×10 5 M −1 cm −1 . Elemental analysis, calcd. For MnC 56 H 60 N 8 P 5 F 30 .H 2 O: C(40.94), H(3.80), N(6.82); found: C(41.15), H(4.35), N(6.52).
EXAMPLE V
The ortho effect makes manganic meso-tetrakis-(N-alkylpyridinium-2-yl)-porphyrin a powerful superoxide dismutase mimic
[0052] The superoxide dismutase activity of the mimetics of the invention depends on a number of factors, including thermodynamic factors (eg the metal-centered redox-potential see FIG. 1 )), and kinetic factors (eg electrostatic facilitation). In an in vitro enzymatic assay of SOD activity (see McCord and Fridovich, J. Biol. Chem. 244:6049 (1969)), the ortho compound “3” proves to be more than an order of magnitude more active than the para compound “1” (see FIG. 2 (note also Table 2 where “2” is the meta compound and “4” and “5” are ortho compounds that carry 4 ethyl or 4 butyl groups, respectively)).
[0053] The activity in vivo of the mimetics of the invention can be tested on an E. coli strain deleted of the genes coding for both the MnSOD and FeSOD. In this assay, the efficacy of a mimetic is determined by measuring the effect of the mimetic on the aerobic growth of a SOD null E. coli strain versus a parental strain. Specifically, parental E. coli (AB1157) and SOD null E. coli . (JI132) are grown in M9 medium containing 0.2% casamino acids and 0.2% glucose at pH 7.0 and 37° C.; growth is monitored in terms of turbidity followed at 700 nm. This assay is made more selective for SOD mimetics by omitting the branched chain, aromatic and sulphur containing amino acids from the medium (glucose minimal medium (M9), plus 5 essential amino acids). As shown in FIG. 3 , the increase in activity by the “ortho effect” was confirmed in that, under these growth conditions, SOD null cells cultured in the presence of compound “1” did not show an increase in A 700 while such cells cultured in the presence of compounds “3” and “4” (as well as “2”) did.
[0054] The “ortho effect” also decreases the toxicity. It is well known that porphyrins, and particularly cationic porphyrins, interact with DNA and can act as DNA cleavers. This fact can be an issue in the use of metallo-porphyrins as anti-tumor drugs. The present mimetics avoid this interaction. In addition to the increase in activity, the interaction with DNA of the meta “2” and the ortho “3” compounds, is greatly decreased. This is clearly demonstrated by the measurements of the SOD activity in vitro in the presence of DNA (see Table 2), and by the decreased toxicity in vivo ( E. coli ) (see FIG. 3 ).
[0055] In order to maximize the decrease in toxicity due to interaction with DNA, two derivatives of the ortho compound have been prepared which carry four ethyl or four butyl groups (“4” and “5”, respectively). The ethyl derivative “4” was significantly less toxic than the methyl derivative “3” (see Table 2 and FIG. 3 ). However, in comparison to the ethylated derivative “4”, the butylated derivative did not show a further decrease in toxicity (see Table 2). These data indicate that ortho ethyl groups are sufficient to inhibit binding of the porphyrin to DNA.
TABLE 2 Table. UV parameters, redox potential (vs NHE), SOD like activity and DNA interaction parameters of 1, 2, 3 and its atropisomers, 4 and 5 (*mixture of atropisomers, δ SB = Soret band wave-lenght, ε = molecular absortivity of the Soret band, E 1/2 = one-electron metal-centered redox- potential. k = rate constant for the superoxide dismutation reaction, DNA-IC 50 = concentration of DNA for 50% inhibition of the superoxide dismutation reaction). δ SB (nm) ε(10 3 ) E 1/2 (V) k (M −1 S −1 ) DNA-IC 50 1 462.2 139 +0.060 3.8 10 4 7.0 10 −4 2 459.8 133 +0.042 4.1 10 4 2.2 10 −5 3* 454.0 123 4.5 10 7 3.3 10 −5 4* 454.0 141 4.5 10 7 6.7 10 −5 5* 454.0 120 3.0 10 7 6.7 10 −1
EXAMPLE VI
Syntheses and Superoxide Dismutating Activities of Partially (1 to 4) β-Chlorinated Derivatives of Manganese (III) Meso-tetrakis-(N-ethylpyridinium-2-yl)-Porphyrin
[0000] Materials and Methods
[0056] Materials. 5,19,15,20-Tetrakis-(2-pyridyl)-porphyrin (H 2 T-2-PyP) was purchased from Mid-Century chemicals (Posen, Ill.) (Torrens et al, J. Am. Chem. Soc. 94:4160 (1972)). N-Chlorosuccinimide (NCS), ethyl-p-toluenesulfonate (ETS), tetrabutylammonium chloride (98%) (TBAC), ammonium hexafluorophosphate (NH 4 PF 6 ), manganese chloride, sodium L-ascorbate (99%), cytochrome c, xanthine, ethylenedinitrilotetraacetic acid (EDTA), N,N-dimethylformamide (98.8%, anhydrous) and 2-propanol (99.5%) were from Sigma-Aldrich. Ethanol (absolute), acetone, ethyl ether (anhydrous), chloroform and dichloromethane (HPLC grade) were from Mallinckrodt, and used without further purification. Xanthine oxidase was supplied by R. D. Wiley (Waud et al, Arch. Biochem. Biophys. 19:695 (1975)). Thin-layer chromatography (TLC) plates (Baker-flex silica gel IB) were from J. T. Baker (Phillipsburg, N.J.). Wakogel C-300 was from Wako Pure Industry Chemicals, Inc (Richmond, Va.).
[0057] Instrumentation. Proton nuclear magnetic resonance ( 1 H-NMR) spectra were recorded on a Varian Inova 400 spectrometer. Ultravisible/visible (UV/VIS) spectra were recorded on a Shimadzu spectrophotometer Model UV-260. Matrix-assisted laser desorption/ionization—time of flight—(MALDI-TOFMS) and electrospray/ionization (ESMS) mass spectrometry were performed on a Bruker Proflex III™ and a Fisons Instruments VG Bio-Q triple quadrupole spectrometers, respectively.
[0058] H 2 Cl 1 T-2-PyP. 50 mg (8.1×10 −5 moles) of H 2 T-2-PyP was reflexed in chloroform with 43 mg (3.22×10 −1 moles) of NCS (Ochsenbein et al, Angew. Chem. Int. Ed. Engl. 33:348 (1994). The reaction was followed by normal phase silica TLC using a mixture EtOH/CH 2 Cl 2 (5:95) as eluant. After 6 hours of reaction the solution was washed once with distilled water. The chloroform was evaporated and the products of the reaction were chromatographed over 100 g of Wakogel C-300 on a 2.5×50 cm column using the same eluant. The fraction corresponding to H 2 Cl 1 T-2-PyP was purified again using the same system leading to 16 mg of a black purple solid (30%). TLC: R f =0.47. UV/VIS (CHCl 3 ): λ nm (logε) 419.6 (5.44), 515.2 (4.21), 590.0 (3.72), 645.8 (3.25). MALDI-TOFMS: m/z=654 (M+H − ). 1 H-NMR (CDCl 3 ): δ ppm -2.91 (2H, NH); 7.66-7.74 (m, 4H); 7.99-8.21 (m, 8H); 7.68 (s, 1H); 8.74 (d, 1H, J 6 Hz); 8.76 (d, 1H, J 6 Hz); 8.76 (d, 1H, J 6 Hz); 8.88 (d, 1H, J 6 Hz); 8.90 (d, 1H, J 6 Hz); 8.94 (d, 1H, J 6 Hz); 9.04-9.14 (m, 4H).
[0059] H 2 C 2a T-2-PyP. The same procedure as described above, leading to 5.3 mg of a black purple solid (10%). TLC: R f =0.50. UV/VIS (CHCl 3 ): λ nm (logε) 421.4 (5.38), 517.8 (4.21), 591.4 (3.78), 647.6 (3.51). MALDI-TOFMS: m/z=688 (M+H − ). 1 H-NMR (CDCl 3 ): δ ppm -2.98 (2H, NH); 7.66-7.74 (m, 4H); 8.00-8.20 (m, 8H); 8.70 (s, 2H); 8.82 (d, 2H, J 6 Hz); 8.91 (d, 2H, J 6 Hz); 9.06-9.14 (m, 4H).
[0060] H 2 Cl 2b−2c T-2-PyP. The same procedure leading to 11 mg of a black purple solid (20%). TLC: R f =0.53. UV/VIS (CHCl 3 ): A (logε) 421.4 (5.42), 516.8 (4.25), 593.2 (3.74), 646.2 (3.31); MALDI-TOFMS, m/z=688 (M+H − ). 1 H-NMR (CDCl 3 ): δ ppm -3.04 (2H, NH); -2.84 (1H, NH); -2.87 (1H, NH; 7.66-7.74 (m, 8H); 7.98-8.20 (m, 16H); 8.59 (s, 1H); 8.61 (s, 1H); 8.73 (d, 2H, J<2 Hz); 8:78 (d, 2H, J 6 Hz); 8.87 (d, 2H, J 6 Hz); 8.93 (d, 2H, J<2 Hz); 9.02-9.14 (m, 8H).
[0061] H 2 Cl 3 T-2-PyP. The same procedure using 65 mg (4.87×10 −4 moles) of NCS, leading to 8.4 mg of a black purple solid (14%). TLC: R f =0.55. UV/VIS (CHCl 3 ): λ nm (logε) 422.8 (5.37), 519.4 (4.21), 593.8 (3.71), 651.4 (3.37). MALDI-TOFMS: m/z=723 (M+H − ). 1 H-NMR (CDCl 3 ): δ ppm -3.08 (1H, NH); -3.15 (1H, NH); 7.66-7.74 (m, 4H); 8.00-8.18 (m, 8H); 8.56 (s, 1H), 8.72 (d, 1H, J 6 Hz); 8.76 (d, 1H, J 6 Hz); 8.82 (d, 1H, J 6 Hz); 8.88 (d, 1H, J 6 Hz); 9.04-9.14 (m, 4H).
[0062] H 2 Cl 4 T-2-PyP. The same procedure using 65 mg (4.87×10 −1 moles) of NCS, leading to 7.3 mg of a black purple solid (12%). TLC: R f =0.58. UV/VIS (CHCl 3 ): λ nm (logε) 423.4 (5.33), 520.0 (4.19), 595.6 (3.66), 651.0 (3.33). MALDI-TOFMS: m/z=758 (M+H − ). 1 H-NMR (CDCl 3 ): δ ppm -3.14 (2H, NH); 7.66-7.74 (m, 4H); 7.98-8.16 (m, 8H); 8.74 (d, 4H, J<2 Hz); 9.06-9.12 (m, 4H).
[0063] MnTE-2-PyP 5− . 100 mg (1.62×10 −1 moles) of H 2 T-2-PyP was dissolved in 5 mL of warm DMF (anhydrous), 5.5 mL (3.22×10 −2 moles) of ethyl-p-toluenesulfonate (ETS) was added under stirring at 90° C. and allowed to react for 24-48 hours. The completion of tetra-N-ethylation was followed by normal phase silica TLC using a mixture KNO 3sat /H 2 O/CH 3 CN (1:1:8) as eluant (Batinic-Haberle et al, J. Biol. Chem. 273:24521 (1998)). Upon the completion of the reaction, the DMF was removed in vacuo and 5 mL of acetone was then added. To this solution, a concentrated solution of tetrabutylammonium chloride (TBAC) in acetone (˜1 g/10 mL acetone) was added dropwise under stirring until precipitation of the chloride was complete. The resulting purple solid was dissolved in 10 mL of water, the pH of the solution was raised to 12 with NaOH and 640 mg of MnCl 2 4H 2 O (3.23×10 −3 moles) was added (Batinic-Haberle et al, J. Biol. Chem. 273:24521 (1998). Upon completion of metallation, the pH was lowered between 4 and 7 in order to facilitate the auto-oxidation of Mn (II) into Mn (III), and the excess of metal was eliminated as follows. The solution was filtered, and a concentrated aqueous solution of NH 4 PF 6 was added to precipitate the metalloporphyrin as the PF 6 − salt (Batinic-Haberle et al, Arch. Biochem. Biophy. 343:225 (1997); Richards et al, Inorg. Chem. 35:1940 (1996)). The precipitate was thoroughly washed with a mixture 2-propanol/ethyl ether (1:1), dried in vacuo at room temperature. The resulting solid was then dissolved in acetone and a concentrated solution of TBAC was added to isolate the metalloporphyrin in the form of its chloride salt. The precipitate was washed thoroughly with acetone and dried in vacuo at room temperature leading to 150 mg of a black red solid (95%). TLC: R f =0.18. UV/VIS (H 2 O): λ nm (logε) 364.0 (4.64), 453.8 (5.14), 558.6 (4.05). ESMS: m/z=157.4 (M 5− /5). Anal. calcd. for MnC 48 N 8 H 44 Cl 5 H 2 O: C. 54.64; H. 5.16; N. 10.62. Found: C. 54.55; H. 5.40; N. 10.39. (See FIG. 4 for compound structures).
[0064] MnCl 1 TE-2-PyP 5− . The same procedure as described above starting from 10 mg (1.53×10 −5 moles) of H 2 Cl 1 T-2-PyP and 0.5 mL (2.94×10 −3 moles) of ETS in 1 mL of DMF. TLC: R f =0.20. UV/VIS (H 2 O): λ nm (logε) 365.6 (4.63), 455.6 (5.13), 560.6 (4.02). ESMS: m/z=164.3 (M 5− /5). Anal. calcd. for MnC 48 N 8 H 43 Cl 6 5H 2 O: C. 52.91; H. 4.90; N. 10.28. Found: C. 52.59; H. 5.28; N. 10.14.
[0065] MnCl 2a TE-2-PyP 5− . The same procedure starting from 5 mg (7.28×10 −6 moles) of H 2 Cl 2a T-2-PyP and 0.25 mL (1.47×10 −3 moles) of ETS, leading to 7.5 mg of a black red solid (95%). TLC: R f =0.21. UV/VIS (H 2 O): λ nm (logε) 365.8 (4.58), 456.4 (5.05), 562.2 (4.00). ESMS: m/z=171.1 (M 5+ /5). Anal. calcd. for MnC 48 N 8 H 42 Cl 7 6H 2 O: C. 50.48; H. 4.77; N. 9.81. Found: C. 50.08; H. 4.60; N. 10.01.
[0066] MnCl 2b−2c TE-2-PyP 5+ . The same procedure starting from 5 mg (7.28×10 −6 moles) of H 2 Cl 2b−2c T-2-PyP, leading to 7.5 mg of a black red solid (95%). TLC: R f =0.22. UV/VIS (H 2 O): λ nm (logε) 365.2 (4.63), 457.4 (5.08), 462.2 (4.06). ESMS: m/z=171.1 (M 5+ /5). Anal. calcd. for MnC 48 N 8 H 42 Cl 7 5H 2 O: C. 51.29; H. 4.66; N. 9.97. Found: C. 51.31; H. 5.19; N. 9.68.
[0067] MnCl 3 TE-2-PyP 5− . The same procedure starting from 5 mg (6.93×10 −6 moles) of H 2 Cl 3 T-2-PyP, leading to 7.5 mg of a black brown solid (95%). TLC: R f =0.23. UV/VIS (H 2 O): λ nm (logε) 364.8 (4.58), 458.0 (4.98), 466.4 (4.00). ESMS: m/z=178.1 (M 5− /5). Anal. calcd. for MnC 48 N 8 H 41 Cl 8 6H 2 O: C. 49.00; H. 4.54; N. 9.52. Found: C. 48.40; H. 4.26; N. 9.59.
[0068] MnCl 4 TE-2-PyP 5− . The same procedure starting from 5 mg (6.61×10 −6 moles) of H 2 Cl 4 T-2-PyP, leading to 7.5 mg of a black brown solid (95%). TLC: R, =0.24. UV/VIS (H 2 O): λ nm (logε) 365.8 (4.52), 459.2 (4.90), 567.0 (3.96). ESMS: m/=184.9 (M 5− /5). Anal. calcd. for MnC 48 N 8 H 40 Cl 9 5H 2 O: C. 48.33; H. 4.22; N. 9.39. Found: C. 48.38; H. 4.45; N. 9.53.
[0069] Electrochemistry. The electrochemical characterization was performed as described previously on a Voltammetric Analyzer Model 600 (CH instrument) using a glassy carbon electrode (Ag/AgCl reference and Pt auxiliary electrodes), at 0.5 mM porphyrin, pH 7.8 (0.05 M phosphate buffer), 0.1 M NaCl. The potentials were standardized against potassium ferricyanide/potassium ferrocyanide couple (Batinic-Haberle et al, Arch. Biochem. Biophys. 343:225 (1997); Kolthof et al, J. Phys. Chem. 39:945 (1974)).
[0070] Superoxide dismuting activity. The SOD-like activities were measured using the xanthine/xanthine oxidase system as a source of O 2 − and ferricytochrome c as its indicating scavenger (McCord et al, J. Biol. Chem. 244:6049 (1969)). O 2 − was produced at the rate of 1.2 μM per minute and reduction of ferricytochrome c was followed at 550 nm. Assays were conducted in presence of 0.1 mM EDTA in 0.05 M phosphate buffer (pH 7.8). Rate constants for the reaction of the compounds were based upon competition with 10 μM cytochrome c, k cyr c =2.6×10 5 M −1 s −1 (Butler et al, J. Biol. Chem. 257:10747 (1982)). All measurements were done at 25° C. Cytochrome c concentration was at least 10 3 -fold higher than the concentrations of the SOD mimics and the rates were linear for at least two minutes, during which the compounds intercepted ˜100 equivalents of O 2 − , thus confirming the catalytic nature of O 2 − dismutation in presence of the mimics.
[0000] Results
[0071] Despite increasing knowledge on the purification of water soluble porphyrins, the separation of halogenated uncharged porphyrins followed by Ar-alkylation and metallation still appeared easier for the successful preparation of MnCl x TE-2-PyP 5+ (Scheme A) (Richards et al, Inorg. Chem. 35:1940 (1996); Kaufman et al, Inorg. Chem. 34:5073 (1995)):
[0072] Synthesis of H 2 T-2-PyP β-chlorinated derivatives. β-Chlorination of H 2 T-2-PyP was performed as described in the literature for H 2 TPP analogues, using N-chlorosuccinimide (NCS) in chloroform under refluxing conditions (Ochsenbein et al, Angew. Chem. Int. Ed. Engl. 33:348 (1994)). The number of NCS equivalents used can be 4 or 6, depending on the degree of substitution desired (Table 3). The reaction can be followed by TLC (silica gel) using a mixture ethanol/dichloromethane (5:95) as eluant (Table 3 and Scheme B).
TABLE 3 H 2 Cl x T-2-PyP (x = 1 to 4): R Soret band data and yields with 4 and 6 equivalents of NCS. Yield (%) c Porphyrin R a λnm (ε/10 5 M −1 cm −1 ) b 4 eq 6 eq H 2 T-2-PyP 0.43 418.4 β-Cl 1 0.47 419.6 (2.74) 30 — β-Cl 2a 0.50 421.4 (2.39) 10 5 β-Cl 2b-2c 0.53 421.4 (2.62) 20 10 β-Cl 3 0.55 422.8 (2.33) 10 15 β-Cl 4 0.58 423.6 (2.13) 7 12 a TLC on silica with EtOH/CH 2 Cl 2 (5:95) as eluant. b in CHCl 3 (estimated errors for ε are within 10%). c in refluxing CHCl 3 during 6 hours (c˜2 μM).
[0073]
[0074] Each compound was purified by chromatography on silica gel (Wakogel C-300) using the same eluant. The structures of the main isomers were identified by mass spectrometry, and UV/VIS and 1 H-NMR spectroscopies (Table 3 and Scheme B). The bathochromic shift of the Soret band per chlorine on H 2 T-2-PyP was only 1.3 nm compared to 3.5 nm reported previously for H 2 TPP derivatives (Table 3) (Hoffmann et al, Bull. Soc. Chem. Fr. 129:85 (1992); Chorghade et al, Synthesis 1320 (1996); Wijesekera et al, Bull. Chem. Fr. 133:765 (1996)). Only one of the three dichlorinated regioisomers (β-Cl 2a derivative) was purified by chromatography on silica gel. Its two other regioisomers (β-Cl 2b and β-Cl 2c derivatives) exhibited the same R f . Preliminary results showed that purification of H 2 Br x T-4-PyP (x=1 to 4) is more difficult. Indeed, using the same TLC system, β-Br 1 and β-Br 2a derivatives both have the same R f , and no difference of R f between β-Br 2b , β-Br 2c , β-Br 3 and β-Br 4 derivatives was observed, showing clearly that, in this case, R f depends on the number of pyrroles β-substituted and not on the number of β-protons β-substituted.
[0075] 1 H-NMR identification of H 2 T-2-PyP β-chlorinated derivatives. 1 H-NMR allowed the identification of the products of the substitution reaction (Table 4 and FIG. 5 ). As described in the literature for H 2 TPP analogues, the main regioisomer of H 2 Cl 4 T-2-PyP has chlorines in positions 7,8,17,18. Indeed, its 1 H-NMR spectrum shows an apparent singlet (doublet with J lower than 2 Hz), corresponding to four chemically equivalent β-protons coupled with the two pyrrolic protons which have lost their delocalization (Crossley et al, J. Chem. Soc., Chem. Commun. 1564 (1991). Nevertheless, another less polar fraction (R f =0.60) was identified, according to its mass spectrum, as a mixture of other tetrachloro-regioisomers ( 1 H-NMR spectrum uninterpretable), representing approximately 50% by weight of both β-Cl 4 fractions, and showing that the β-substitution is only partially regioselective. According to the 1 H-NMR spectrum of the corresponding H 2 Cl 3 T-2-PyP 5− fraction, there are no apparent other regioisomers. The spectrum presents one singlet corresponding to the β-proton of the monoβ-substituted pyrrole and four doublets corresponding to the four β-protons of the two non-β-substituted pyrroles. Moreover, the asymmetry of this compound leads to a differentiation of the two NH protons. According to yields and 1 H-NMR spectra of H 2 Cl 2a T-2-PyP ( FIG. 5 ) and H 2 Cl 2b+2c T-2-PyP, no predominant β-Cl 2 regioisomer was observed. Finally, the H 2 C 1 T-2-PyP spectrum shows one singlet and six doublets, but only one NH signal suggesting that in this case the asymmetry is too weak for the differentiation of the two NH protons.
TABLE 4 H 2 Cl x T-2-PyP (x = 1 to 4): 1 H-NMR data (porphyrin ring) in CDCl 3 δ ppm (mult., Hz) a H 2 Cl 1 T-2-PyP NH −2.91(2H) CH 7.68(s, 1H) 8.74(d, 1H, 5.5) 8.76(d, 1H, 5.5) 8.76(d, 1H, 6.0) 8.88(d, 1H, 6.0) 8.90(d, 1H, 6.0) 8.94(d, 1H, 6.0) H 2 Cl 2a T-2-PyP NH −2.98(2H) CH 8.70(s, 2H) 8.82(d, 2H, 6.0) 8.91(d, 2H, 6.0) H 2 Cl 2b T-2-PyP b NH −3.04(2H) CH 8.59(s, 2H) 8.78(d, 2H, 6.0) 8.87(d, 2H, 6.0) H 2 Cl 2c T-2-PyP b NH −2.84(1H) −2.87(1H) CH 8.61(s, 2H) 8.73(d, 2H, <2.0) 8.93(d, 2H, <2.0) H 2 Cl 3 T-2-PyP NH −3.08(1H) −3.15(1H) CH 8.56(s, 1H) 8.72(d, 1H, 6.5) 8.76(d, 1H, 6.5) 8.82(d, 1H, 6.5) 8.88(d, 1H, 6.5) H 2 Cl 4 T-2-PyP NH −3.14(2H) CH 8.74(d, 4H, <2.0) a chemical shifts in ppm expressed relative to TMS by setting CDCl 3 = 7.24 ppm. b one spectrum for the mixture of the two regioisomers (˜1:1 ratio).
[0076] N-ethylation and metallation. The N-ethylation of H 2 T-2-PyP was efficiently accomplished using ethyl-p-toluenesulfonate, diethylsulfate or iodoethane as reagents, but the high toxicity of diethylsulfate and the low reactivity of iodoethane makes ethyl-p-toluenesulfonate (ETS) the best choice (Chen et al, J. Electroanal. Chem. 280:189 (1990); Kalyamasundaram, Inorg. Chem. 23:2453 (1984); Hambright et al, Inorg. Chem.: 15:1314 (1976); Alder et al, Chem. Brit. 14:324 (1978); Perree-Fauvet et al, 52:13569 (1996)). Some authors prefer performing N-alkylation after metallation in order to protect the pyrrole nitrogens (Perree-Fauvet et al, Tetrahedron 52:13569 (1996)). However, with direct treatment on the present free ligands, no N-ethylation of the pyrrole nitrogens was observed (subsequent metallation in aqueous solution was complete). The completion of ethylation as well as metallation can be followed by TLC (normal silica) using a highly polar eluant, a mixture of an aqueous solution of saturated potassium nitrate with acetonitrile (Batinic-Haberle et al, J. Biol. Chem. 273:24521 (1998)). The yields of this step (N-ethylation and metallation) were almost 100% (approximately 5% loss during the purification process). Since N-ethylation (or N-methylation) limits the free rotation of the pyridinium rings, each compound is in fact a mixture of four atropoisomers, and a further purification of each atropoisomer can be considered (Kaufmann et al, Inorg. Chem. 34:5073 (1995)). All the manganese porphyrins prepared had metal in the 3+state as demonstrated by the 20 nm hypsochromic shift of the Soret band (accompanied by the loss of splitting) upon the reduction of the metal-center by ascorbic acid.
[0077] Electrochemistry. The metal-entered redox behavior of all metalloporphyrin products was reversible. The half-wave potentials (E O 1/2 ) were calculated as the average of the cathodic and anodic peaks and are given in mV vs NHE (Table 5). The average shift per chlorine is +55 mV (Table 5), which is in agreement with the values previously reported for H 2 TPP derivatives (between +50 and +70 mV) (Sen et al, Chem. Soc. Faraday Trans. 93:4281 (1997); Autret et al, J. Chem. Soc. Dalton Trans. 2793 (1996); Hariprasad et al, J. Chem. Soc. Dalton Trans. 3429 (1996); Tagliatesta et al, Inorg. Chem. 35:5570 (1996); Ghosh, J. Am. Chem. Soc. 117:4691 (1995); Takeuchi et al, J. Am. Chem. Soc. 116:9730 (−1994); Binstead et al, Inorg. Chem. 30:1259-(1991); Giraudeau et al, J. Am. Chem. Soc. 101:3857 (1979)). This shift appears to be higher (˜+65 mV) between 0 and 1, and between 2 and 3 chlorines (Table 5). E O 1/2 values of β-Cl 2a and the mixture β-Cl 2b+2c were not significantly different. The manganese redox state of MnCl 4 TE-2-PyP 5− (E 0 1/2 =+448 mV) and MnOBTMPyP 4+ (E O 1/2 =+480 mV) is 3+ and 2+, respectively. This difference may be explained by their difference in terms of redox potential (˜30 mV) but also by structural considerations, for instance an increased distortion of the porphyrin ring in the case of MnOBTMPyP 4+ . (Batinic-Haberle et al, Arch. Biochem. Biophys. 343:225 (1997); Ochsenbein et al, Angew. Chem. Int. Ed. Engl. 33:348 (1994)).
TABLE 5 MnCl x TE-2-PyP 5− (x = 1 to 4): Soret band data, redox potentials and SOD activities. λnm (ε/ IC 50 / k cat / Mn-porphyrin 10 4 M −1 cm −1 ) a E o 1/2 (Δ) b 10 −9 M c 10 7 M −1 s −1 MnTE-2-PyP 5− 453.8 (14.0) +228 (71) 45 5.7 β-Cl 1 455.6 (12.5) +293 (65) 25 10 β-Cl 2a 456.4 (10.6) +342 (70) 20 13 β-Cl 2b-2c 457.4 (11.2) +344 (65) 20 13 β-Cl 3 458.0 (9.5) +408 (67) 10 26 β-Cl 4 459.2 (8.0) +448 (79) 6.5 40 MnTM-4-PyP 5− +060 0.4 MnTM-2-PyP 5− +220 6.0 MnOBTMPyP 4− +480 22 Cu,ZnSOD +260 200 a in H 2 O (estimated errors for ε are within 10%). b mV vs NHE, with estimated errors of 5 mV (Δ = peak to peak separation), and in the following conditions: 0.5 mM porphyrin, 0.1 M NaCl, 0.05 M phosphate buffer (pH 7.8). c concentration that causes 50% inhibition of cytochrome c reduction by O 2 − (estimated errors are within 10%).
[0078] Superoxide dismuting activities. SOD-like activities were measured as described previously, based on competition with cytochrome c (McCord et al, J. Biol. Chem. 244:6049 (1969)). MnCl x TE-2-PyP 5+ SOD-like activities are reported in Table 5, IC 50 (M) representing the concentration for one unit of activity (or the concentration that causes 50% inhibition of cytochrome c reduction by O 2 − ) and k cat (M −1 s −1 ) representing the rate constant for the superoxide dismutation reaction. The SOD-like activity per mole of MnCl 4 TE-2-PyP 5− is approximately 2-, 7- and 100-fold higher than MnOBTMPyP 4+ , MnTM-2-PyP 5+ and MnTM-4PyP 5+ , respectively (Faulkner et al, J. Biol. Chem. 269:23471 (1994); Batinic-Haberle et al, Arch. Biochem. Biophys. 343:225 (1997); Batinic-Haberle et al, J. Biol. Chem. 273:24521 (1998)). The SOD-like activity of MnCl 4 TE-2-PyP 5+ represents 20% of the activity of the Cu, Zn-SOD enzyme on a molar basis (40% per active site considering that the enzyme has two active sites) (Klug-Roth et al, J. Am. Chem. Soc. 95:2786 (1973)).
[0079] Test of stability. Each additional degree of chlorination increases the redox potential which is expected to be followed by the decrease in the pKa values of pyrrole nitrogens, as found for the series of meso-phenyl and meso-pyridyl β-substituted porphyrins as well as for β-substituted ones (Worthington et al, Inorg. Nucl. Chem. Lett. 16:441 (1980); Kadish et al, Inorg. Chem. 15:980 (1976)). The pKa, as a measure of the ligand-proton stability, is in turn a measure of the metal-ligand stability as well. Thus, the tetrachloro-compound is expected to be of decreased stability as compared to lesser chlorinated analogues. The stability of MnCl 4 TE-2-PyP 5+ was tested by measuring its SOD-like activity in the presence of excess EDTA. In the presence of a 10 2 -fold excess of EDTA, MnCl 4 TE-2-PyP 5− (c=5×10 −6 M) maintains its activity for sixteen hours (at 25° C.). A loss of activity (˜25%) was observed after forty hours, thus indicating the formation of some manganese—EDTA complex (K=10 14.05 ). These results confirm a relatively good stability of MnCl 4 TE-2-PyP 5− when compared to MnOBTMPyP 4+ (K=10 8.08 ) (Batinic-Haberle et al, Arch Biochem. Biophys. 343:225 (1997)).
[0080] Relationship between redox properties and SOD-like activities. The Cu, Zn-SOD enzyme is a dimer of two identical subunits, and thus has two active sites, which exhibit a redox potential close to the midpoint of the two half reaction values, as well as the same rate constants for each half reaction (Scheme C and Table 5) (Ellerby et al, J. am. Chem. Soc. 118:6556 (1996); Klug-Roth, J. Am. Chem. Soc. 95:2786 (1973)):
[0081] On the other hand, previous studies of O 2 dismutation catalyzed by MnTM-4-PyP 5+ (E O 1/2 =+60 mV), using pulse radiolysis and stopped flow techniques, showed that the rate of the reduction of the metal by O 2 − is 10 2 -fold to 10 3 -fold lower than the rate of reoxidation of the metal (Faraggi, Oxygen Radicals in Chemistry and Biology, Bors et al (Eds): Walter de Gruyter and Co.; Berlin, Germany 1984, p. 419; Lee et al, J. Am. Chem. Soc. 120:6053 (1998)). Whereas a peak of SOD-like activity somewhere between +200 and +450 mV was first expected, plotting k cat vs E O 1/2 for MnCl x TE-2-PyP 5+ shows an exponential increase of the SOD-like activity, strongly suggesting that the limiting factor is still the reduction of the metal. This hypothesis however must be confirmed by measuring the rates of each half reaction as catalyzed by each. MnCl x TE-2-PyP 5− compound. The relationship between activation free energy (ΔG d ) for superoxide dismutation and free energy change (ΔG o ) for MnCl x TE-2-PyP 5− redox is linear (slope ˜+0.2), clearly showing the predominance of kinetic over thermodynamic factors in the theoretical optimal redox potential region ( FIG. 6 ). According to this behavior, the activity of the Cu, Zn-SOD enzyme (k cat =10 9 M −1 s −1 per active site) may be reached at approximately E o 1/2 =+570 mV ( FIG. 3 ). However, due to both steric (distortion of the porphyrin ring) and thermodynamic factors, introducing a higher degree of β-chlorination is expected to stabilize the manganese in the 2+redox state, and thus, as in the case of MnOBTMPyP 4+ , limiting the rate of the reoxidation of the metal as well as inducing Mn (II) dissociation (Batinic-Haberle et al, Arch. Biochem. Biophys. 343:225 (1997); Ochsenbein et al, Angew. Chem. Int. Ed. Engl. 33:348 (1994)).
EXAMPLE VII
[0082] The ortho, meta and para isomers of manganese (II) 5,10,15,20-tetrakis(N-methylpyridyl)porphyrin, MnTM-2-PyP 5+ , MnTM-3-PyP 5+ , and MnTM-4-PyP 5+ , respectively, were analyzed in terms of their superoxide dismutase (SOD) activity in vitro and in vivo. The impact of their interaction with DNA and RNA on the SOD activity in vivo and in vitro was also analyzed. Differences in their behavior are due to the combined steric and electrostatic factors. In vitro catalytic activities are closely related to their redox potentials. The half-wave potentials (E 1/2 ) are +0.220 mV, +0.052 mV and +0.060 V vs normal hydrogen electrode (NHE), while the rates of dismutation (k cat ), are 6.0×10 7 M −1 s −1 , 4.1×10 6 M −1 s −1 and 3.8×10 6 M −1 s −1 for the ortho, meta and para isomers, respectively.
[0083] However, the in vitro activity is not a sufficient predictor of in vivo efficacy. The ortho and meta isomers, although of significantly different in vitro SOD activities, have fairly close in vivo SOD efficacy due to their similarly weak interactions with DNA. In contrast, due to a higher degree of interaction with DNA, the para isomer inhibited growth of SOD-deficient Escherichia coli . For details, see Batinic-Haberle et al, J. Biol. Chem. 273(38):24521-8 (Sep. 18, 1998).
EXAMPLE VIII
Metalloporphyrins are Potent Inhibitors of Lipid Peroxidation
[0000] Materials and Methods
[0084] L-Ascorbic acid, n-butanol, butylated hydroxytoluene, cobalt chloride, iron (II) chloride, phosphoric acid (85%), sodium hydroxide, potassium phosphate, tetrabutylammonium chloride, and 1,1,3,3-tetramethoxypropane were purchased from Sigma (St. Louis, Mo.). Acetone, concentrated hydrochloric acid, 4,6-dihydroxy-2-mercaptopyrimidine (thiobarbituric acid), NH 4 PF 6 , zinc chloride, 5,10, 15, 20-tetrakis (4-benzoic acid) porphyrin (H 2 TBAP)*, 5,10,15,20-tetrakis (N-methylpyridinium-4-yl) porphyrin (H 2 TM-4-PyP), and Trolox were purchased from Aldrich (Milwaukee, Wis.). Ferric 5,10,15,20-tetrakis (4-benzoic acid) porphyrin (FeTBAP) was purchased from Porphyrin Products (Logan, Utah). 5,10,15,20-tetrakis (N-methylpyridinium-2-yl) porphyrin (H 2 TM-2-PyP) was purchased from MidCentury Chemicals (Posen, Ill.). (+)-Rutin was purchased from Calbiochem (La Jolla, Calif.). Manganese chloride was purchased from Fisher (Fair Lawn, N.J.) and ethanol USP was purchased from AAPER *Also known as 5,10,15,20-tetrakis (4-carboxyphenyl) porphyrin (H 2 TCPP) Alcohol and Chemical Co. (Shelbville, Ky.). All solutions were prepared in Milli-Q Plus PF water (Millipore, Bedford, Mass.).
[0000] Preparation and Analysis of Metalloporphyrins
[0085] The metalloporphyrins MnTBAP, CoTBAP and ZnTBAP were made using methods described previously (Day et al, J. Pharmacol. Exp. Ther. 275:1227 (1995)). MnTM-4-PyP, CoTM-4-PyP and ZnTM-4-PyP were synthesized by the following method. A 1.5 molar excess of manganese, cobalt or zinc chloride was mixed with H 2 TM-4-PyP that was dissolved in de-ionized water. The reaction mixture was heated to 80° C. and metal ligation was followed spectrophotometrically (UV-2401PC, Shimadzu, Columbia, Md.). Excess metal was removed by passing the mixture through a column containing Bio-Gel P-2 (BioRad, Richmond, Calif.) that selectively retained MnTM-4-PyP. MnTM-4-PyP was eluted with 0.01 N HCl after extensive washing of the column with water. MnTM-4-PyP, CoTM-4-PyP and ZnTM-4-PyP were characterized in terms of their reported Soret bands. The Soret band for MnTM-4-PyP is at 463 nm with an extinction coefficient of (ε)=1.3×10 5 M −1 cm −1 , the Soret band for ZnTM-4-PyP is at 437 nm with an extinction coefficient of (ε)=2.0×10 5 M −1 cm −1 (Pasternack et al, Inorg. Chem. 12:2606 (1973)) and the Soret band for CoTM-4-PyP is at 434 nm with an extinction coefficient of (E)=2.15×10 5 M −1 cm −1 (Pasternack et al, Biochemistry 22:2406 (1983)). Manganese β-octabromo-meso-tetrakis-(N-methylpyridiniumyl) porphyrin. (MnOBTM-4-PyP) was synthesized as previously described (Batinic-Haberle et al, Arch. Biochem. Biophys. 343:225 (1997)) and has a Soret band at 490 nm with an extinction coefficient (ε)=8.56×10 4 M −1 cm −1 . H 2 TM-2-PyP was metallated with a 1:20 porphyrin to manganese ratio in water (pH>11) at room temperature. Upon completion of metallation, MnTM-2-PyP was precipitated by the addition of a concentrated aqueous solution of NH 4 PF 6 . The precipitate was washed with 2-propanol:diethyl ether (1:1) and dried in vacuo at room temperature. The PF 6 − salt of MnTM-2-PyP was dissolved in acetone, filtered and a concentrated acetone solution of tetrabutylammonium chloride was added until the porphyrin had precipitated as its chloride salt. The precipitate was washed with acetone and dried in vacuo at room temperature. The Soret band for MnTM-2-PyP was found at 453 nm with an extinction coefficient (ε)=1.29×10 5 M −1 cm −1 .
[0000] Preparation of Rat Brain Homogenates
[0086] Frozen adult Sprague-Dawley rat brains (Pel-Freez, Rogers, A R) were homogenized with a polytron (Turrax T25, Germany) in 5 volumes of ice cold 50 mM potassium phosphate at pH 7.4. Homogenate protein concentration was determined with the Coomassie Plus protein assay (Pierce, Rockford, Ill.) using bovine serum albumin as a standard. The homogenate volume was adjusted with buffer to give a final protein concentration of 10 mg/ml and frozen as aliquots at −80° C.
[0000] Oxidation of Rat Brain Homogenates
[0087] Rat brain homogenates (2 mg protein) were incubated with varying concentrations of antioxidant at 37° C. for 15 minutes. Oxidation of the rat brain homogenate was initiated by the addition of 0.1 ml of a freshly prepared anaerobic stock solution containing iron (II) chloride (0.25 mM) and ascorbate (1 mM) as previously reported (Braughler et al, J. Biol. Chem. to 262:10438 (1987)). Samples (final volume 1 ml) were placed in a shaking water bath at 37° C. for 30 minutes. The reactions were stopped by the addition of 0.1 ml of a stock butylated hydroxytoluene (60 mM) solution in ethanol.
[0000] Lipid Peroxidation Measurement
[0088] The concentration of thiobarbituric acid reactive species (TBARS) in rat brain homogenates was used as a index of lipid peroxidation (Bernhem et al, J. Biol. Chem. 174:257 (1948); Witz et al, J. Free Rad. Biol. Med. 2:33 (1986); Kikugawa et al, Anal. Biochem. 202:249 (1992); Jentzsch et al, Free Rad. Biol. Med. 20P251 (1996)). Malondialdehyde standards were obtained by adding 8.2 μl of 1,1,3,3-tetramethoxypropane in 10 ml of 0.01 M HCl and mixing for 10 minutes at room temperature. This stock was further diluted in water to give standards that ranged from 0.25 to 25 μM. Samples or standards (200 μl) were acidified with 200 μl of 0.2 M phosphoric acid in 1.5 ml locking microfuge tubes. The color reaction was initiated by the addition of 25 μl of a 0.11M thiobarbituric acid solution and samples were placed in a 90° C. heating block for 45 minutes. TBARS were extracted with 0.5 ml of n-butanol by vortexing samples for 3 minute and chilling on ice for 1 minute. The samples were then centrifuged at 12,000×g for 3 minutes, 150 μl aliquots of the n-butanol phase were placed in each well of a 96-well plate and read at 535 nm in a Thermomax platereader (Molecular Devices, Sunnyvale, Calif.) at 25° C. Sample absorbencies were converted to MDA equivalencies (μM) by extrapolation from the MDA standard curve. None of the antioxidants at concentrations employed in these studies affected the reaction of MDA standards with thiobarbituric is acid and reactions without TBA were used as subtraction blanks.
[0000] Statistical Analyses
[0089] Data were presented as their means±SE. The inhibitory concentration of antioxidants that decreased the degree of lipid peroxidation by 50% (IC 50 ) and respective 95% confidence intervals (Cl) were determined by fitting a sigmoidal curve with variable slope to the data (GraphPad Prizm, San Diego, Calif.).
[0000] Results
[0000] Comparison of metalloporphyrins with other antioxidants in iron/ascorbate-mediated lipid peroxidation.
[0090] The objective of these studies was to investigate whether metalloporphyrins could inhibit lipid peroxidation and to compare their to potencies with those of previously characterized antioxidants that include enzymatic antioxidants (SOD and catalase) and non-enzymatic antioxidants (water soluble vitamin E analog, trolox, and plant polyphenolic flavonoid, rutin) ( FIG. 7 ). The time course of lipid peroxidation was determined in rat brain homogenates using iron and ascorbate as initiators of lipid oxidation and the formation of thiobarbituric reactive species (TBARS) as an index of lipid peroxidation. A linear increase in the formation of TBARS occurred between 15 to 90 minutes of incubation at 37° C. ( FIG. 8 ). Based on this result, an incubation time of 30 minutes was selected to test the ability of metalloporphyrins and other antioxidants to inhibit lipid peroxidation. ( FIG. 9 ). Of the agents tested, the manganese porphyrins that have the highest SOD activities, MnOBTM-4-PyP and MnTM-2-PyP, were found to be the most potent lipid peroxidation inhibitors with calculated IC 50 s of 1.3 and 1.0 μM respectively. (Table 6). Bovine CuZnSOD was moderately active with a calculated IC 50 of 15 μM while trolox and rutin were much less potent with calculated IC 50 s of 204 and 112 μM, respectively. In this system, catalase (up to concentrations of 1 mg/ml) did not inhibit iron/ascorbate-initiated lipid peroxidation.
TABLE 6 Comparison of Antioxidant Properties SOD Redox Potential Lipid Peroxidation c Antioxidants (U/mg) a (E 1/2 , V) b IC 50 [μM] 95% Cl [μM] CuZnSOD 5,100 +0.35 15 13-17 Trolox — — 204 135-308 Rutin — — 113 99-129 MnTM-2-PyP 8,500 +0.22 1.0 0.4-2.2 MnOBTM-4-PyP 18,460 +0.48 1.3 0.8-2.2 MnTM-4-PyP 547 +0.06 16 12-22 MnTBAP 179 −0.19 29 23-37 CoTM-4-PyP 113 +0.42 17 14-22 CoTBAP 24 +0.20 21 13-33 FeTBAP 24 +0.01 212 144-311 ZnTM-4-PyP trace — 241 159-364 ZnTM-2-PyP trace — 591 423-827 ZnTBAP trace — 843 428-1660 a Unit of SOD activity defined as the amount of compound that inhibits one half the reduction of cytochrome c or photoreduction of NBT. b Metal centered redox potentials vs NHE (Mn +3 /Mn +2 ; Co +3 /Co +2 ; Fe +3 /Fe +2 ). If not otherwise specified, E 1/2 were obtained at pH 7.8. c The amount of thiobarbaturic acid reactive substances produced in a rat brain homogenate by 30 minutes of incubation of iron and ascorbate.
Effect of Different Metal Chelates on the Ability of Porphyrins to Inhibit Lipid Peroxidation.
[0091] A wide range of metals can be covalently ligated by porphyrins and that confers different redox potentials and SOD activities (Table 6). The ability of different metal chelates to influence a porphyrin's ability to inhibit lipid peroxidation was tested. Several different metal analogs of TBAP were examined in the iron/ascorbate-initiated lipid peroxidation model ( FIG. 10 ). Both the manganese and cobalt TBAP analogs had similar efficacy with calculated IC 50 of 29 and 21 μM, respectively. The FeTBAP analog was an order of magnitude less potent with a calculated IC 50 of 212 μM. The ZnTBAP analog was much less active than the other metal analogs with a calculated IC 50 of 946 μM. This potency difference between the zinc and the other metals reflects the importance of metal centered verses ring structure redox chemistry since zinc can not readily change its valence. The ranked potencies of tested metalloporphyrins based on IC 50 s were as follows: MnTM-2-PyP═MnOBTM-4-PyP>MnTM-4-PyP═CoTM-4-PyP>CoTBAP═MnTBAP>FeTBAP═ZnTM-4-PyP>ZnTM-2-PyP>ZnTBAP.
[0000] Comparison of a Series of Tetrakis N-Methylpyridyl Porphyrin (TMPyP) Analogs as Inhibitors of Lipid Peroxidation.
[0092] Recently, several manganese analogs of N-methylpyridyl porphyrins have been found to possess large differences in SOD activities (Table 6). MnTM-2-PyP and MnTM-4PyP differ structurally with respect to the position of the N-methylpyridyl group to the porphyrin ring (ortho vs para) as well as in SOD activity by a factor of six. Substitution of zinc in these porphyrin analogs results in loss of SOD activity. These TMPyP analogs were compared for their ability to inhibit lipid peroxidation ( FIG. 11 ). The movement of the N-methylpyridyl group from the para- to the ortho-position in the manganese porphyrin resulted in a 15-fold increase in potency. Since MnTM-2-PyP possesses a more positive redox potential than MnTM-4-PyP (+0.22 vs +0.06, respectively), this data suggests that both the redox potential and the related SOD activity may contribute to the increased potency of the MnTM-2-PyP analog.
EXAMPLE IX
Demonstration That Mn TE-2-PyP Can Be Effectively Used to Attenuate Oxidant Stress Mediated Tissue Injury
[0093] The ability of Mn TE-2-PyP to attenuate injury associated with 60 minutes of global ischemia followed by 90 minutes of reperfusion was assessed in an isolated, perfused mouse liver model. Excised livers were perfused with a buffered salt solution for 15 minutes after which the metalloporphyrin was introduced into the perfusate and the liver perfused in a recirculating system for ar additional 15 minutes. The livers were then rendered globally ischemic under normal thermic conditions for 60 minutes. Following the ischemic period the livers were perfused for 90 minutes with perfusate supplemented with 10 μm Mn TE-2-PyP. In this model the ischemia/reperfused livers have a marked release of hepatocellular enzymes, aspartate transaminase, alanine transaminase, and lactate dehydrogenase during the first 2½ minutes of reperfusion. This is followed by a progressive release of hepatocellular enzymes indicating hepatocellular injury over the 90 minute perfusion period. Administration of Mn TE-2-PyP was highly efficacious in attenuating the liver injury, blocking virtually all of the acute hepatocellular enzyme release and blocking progressive hepatocellular enzyme release over the 90 minute perfusion period. At the end of the experiments liver is treated with the metalloporphyrin. It has demonstrated excellent oxygen consumption and a normal perfusion pattern. They remain firm and with a normal texture to gross morphologic examination. Livers with no drug treatment did not consume oxygen normally and became edematous, soft, and had a mottled appearance consistent with poor perfusion.
EXAMPLE X
Effects of Mn TNI-2-PyP on Vascular Tone
[0094] Rats were anesthetized and a femoral vein and carotid artery were cannulated. While blood pressure was monitored by the carotid artery, Mn TM-2-PyP was injected i.v. at doses ranging from 0.1 to 3.0 mg/kg. Mean arterial pressure fell from 100-125 mmHg to 50-60 mmHg within five to ten minutes. The effect was transient, lasting up to 30 minutes at doses of 0.1 to 0.25 mg/kg. At doses of 1-3 mg/kg the effect was prolonged, lasting up to two hours. The effect can be blocked by administration of inhibitors of nitric oxide synthase demonstrating that the role of Mn TM-2-PyP is being modulated by nitric oxide. Scavenging of superoxide in vascular walls would potentiate the effects of nitric oxide producing hypotension.
EXAMPLE XI
Regulation of Airway Reactivity Using Nin TM-2-PyP
[0095] Mice were sensitized by intraperitoneal injection of ovalbumin twice, 14 days apart. Fourteen days after the second i.p. injection they were challenged with aerosolized ovalbumin daily for three days. Forty-eight hours after the third inhalation of ovalbumin they were given a 1 minute methacholine challenge and airway hyperreactivity followed using a Buxco body plethysmograph. Significant increases in airway resistance as measured by the PENH index occurred at doses of 20, 30 and 40 mg/ml of methacholine. At all doses of methacholine prior intratracheal instillations of 2 μg Mn TM-2-PyP given daily for 4 days resulted in a statistically significant reduction in the airway hyperreactivity. This dose of Mn TM-2-PyP is equivalent to 0.8 mg/kg whole body dose.
EXAMPLE XII
Treatment of Bronchopulmonary Dysplasia Using Mn TE-2-PyP
[0096] Neonatal baboons were delivered prematurely by Caesarian section and then treated either with 100% oxygen or only sufficient PRN FIO 2 to maintain adequate arterial oxygenation. To establish the model, thirteen 100% oxygen treated animals and twelve PRN control animals were studied. Treatment with 100% oxygen results in extensive lung injury manifested by days 9 or 10 of exposure and characterized by delayed alveolarization, lung parenchymal inflammation, and poor oxygenation. This is characteristic of the human disease, bronchopulmonary dysplasia and is thought to be mediated, at least in part, by oxidative stress on the developing neonatal lung. In a first trial of Mn TE-2-PyP, a neonatal baboon was delivered at 140 days gestation and placed in 100% oxygen. The animal received 0.5 mg/kg/24 hr Mn TE-2-PyP qd given i.v. in a continuous infusion over the entire 10 day study period. This animal showed marked improvement of the oxygenation index. There was no evidence of clinical decompensation of the lungs at days 9 and 10. Lung pathology demonstrated absence of inflammation and a marked decrease in the lung injury found in the prior animals treated with 100% oxygen under identical conditions. This suggests that Mn TE-2-PyP can be used to treat oxidant stress in the premature newborn.
[0097] All documents cited above are hereby incorporated in their entirety by reference. Appln. No. 60/064,116, filed Nov. 3, 1997, is also incorporated in its entirety by reference.
[0098] One skilled in the art will appreciate from a reading of this disclosure that various changes in form and detail can be made without departing from the true scope of the invention. | The present invention relates, in general, to a method of modulating physiological and pathological processes and, in particular, to a method of modulating cellular levels of oxidants and thereby processes in which such oxidants are a participant. The invention also relates to compounds and compositions suitable for use in such methods. | 0 |
The contents of the following Japanese patent application are incorporated herein by reference: No. 2012-122349 filed on May 29, 2012.
BACKGROUND
1. Technical Field
The present invention relates to eyewear.
2. Related Art
An eyewear-type electro-oculogram measuring apparatus is known which detects the eye potential using two pairs of electrodes positioned around the eye of a user, for example as described in Patent Document No. 1.
Patent Document 1: Japanese Patent Application Publication No. 2004-254876
However, the two pairs of electrodes have had an impact on the skins of users, and discomfort on them. Besides, the electrodes are not excellent in design.
SUMMARY
In order to solve the above problem, according to a first aspect related to the innovations herein, provided is eyewear including: a frame; a pair of nose pads; and a first electrode and a second electrode respectively provided on the surface of the pair of nose pads, the first electrode and the second electrode detecting eye potential.
The stated eyewear may further include a first electric wire and a second electric wire buried in the frame, and respectively electrically connected to the first electrode and the second electrode. The stated eyewear may further include a third electrode provided on the surface of a bridge of the frame and detecting eye potential. The stated eyewear may further include a third electric wire electrically connected to the third electrode and buried in the frame.
The stated eyewear may further include a transmitting section that transmits, to an external apparatus, an electro-oculogram signal representing the eye potential detected by the first electrode and the second electrode; and a power supply section that supplies power to the transmitting section. The stated eyewear may further include a processing section that processes the electro-oculogram signal, where the transmitting section transmits, to the external apparatus, the electro-oculogram signal having undergone processing by the processing section.
The summary clause does not necessarily describe all necessary features of the embodiments of the present invention. The present invention may also be a sub-combination of the features described above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows an example of a pair of glasses 100 .
FIG. 2 schematically shows positions at which the electrodes make contact with a user.
FIG. 3 schematically shows an exemplary electro-oculogram when the user looked down immediately after when he looked up.
FIG. 4 schematically shows an exemplary electro-oculogram when the user looked up immediately after when he looked down.
FIG. 5 schematically shows an exemplary electro-oculogram when the user looked in the left immediately after he looked right.
FIG. 6 schematically shows an exemplary electro-oculogram when the user looked in the right immediately after he looked left.
FIG. 7 schematically shows an exemplary electro-oculogram when he blinks.
FIG. 8 schematically shows an example of the pair of glasses 100 viewed from the backside.
FIG. 9 schematically shows an example of a partially enlarged view of the pair of glasses 100 viewed from the backside.
FIG. 10 shows a flowchart of a visual line detection processing performed by an external apparatus.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
Hereinafter, some embodiments of the present invention will be described. The embodiments do not limit the invention according to the claims, and all the combinations of the features described in the embodiments are not necessarily essential to means provided by aspects of the invention. The following describes embodiments of the present invention using drawings, and portions that are identical or similar are given the same reference numerals. The drawings are schematic views, and may not accurately reflect the actual relation or ratio between the plane size and the thickness.
FIG. 1 schematically shows an example of a pair of glasses 100 . The pair of glasses 100 includes a pair of lenses 110 and a frame 120 . The pair of glasses 100 and the frame 120 may be an example of eyewear.
The frame 120 supports the pair of lenses 110 . The frame 120 may include a rim 122 , a bridge 124 , an end piece 126 , a hinge 128 , a temple 130 , an ear pad 132 , a pair of nose pads 140 , a first electrode 152 , a second electrode 154 , a third electrode 156 , a ground electrode 158 , and an electric wire 160 . The pair of nose pads 140 include a right nose pad 142 and a left nose pad 144 .
The rim 122 , the end piece 126 , the hinge 128 , the temple 130 , and the ear pad 132 are provided on the right side and the left side. The rim 122 supports the lens 110 . The end piece 126 corresponds to the outer region of the rim 122 , and the hinge 128 is used to support the temple 130 to be rotatable. The temples 130 press together the upper parts of the ears of a user. The ear pad 132 is provided at the tip of the temple 130 . The ear pad 132 contacts the upper part of the ear of a user.
The first electrode 152 and the second electrode 154 are provided on respective surfaces of the pair of nose pads 140 , to detect the eye potential. The first electrode 152 detects the eye potential of the right eye of a user. The second electrode 154 detects the eye potential of the left eye of a user. By providing an eye-potential-detecting electrode on a surface of the nose pad that inevitably contacts the skin of a user, the burden on the skin of a user can be alleviated, when compared to two pairs of electrodes which are made to contact the surrounding area of the eyes of a user.
The third electrode 156 is provided on a surface of the bridge 124 , to detect the eye potential. The ground electrode 158 is provided on a surface of the ear pad 132 . In this particular embodiment, the ground electrode 158 is provided on a surface of the left ear pad 132 . The potential detected by the first electrode 152 , the second electrode 154 , and the third electrode 156 can be obtained relative to the potential detected by the ground electrode 158 .
The pair of glasses 100 are connected to the electro-oculogram processing unit 200 via the electric wire 160 . The electro-oculogram processing unit 200 may include a processing unit 210 , a transmitting unit 220 , and a power supply section 230 . The first electrode 152 , the second electrode 154 , the third electrode 156 , and the ground electrode 158 are connected to the processing section 210 via the electric wire 160 .
The processing section 210 processes an electro-oculogram signal representing the eye potential detected by the first electrode 152 and the second electrode 154 . In an example, the processing section 210 may process an electro-oculogram signal representing the potential of the first electrode 152 relative to the third electrode 156 . The processing section 210 may also process an electro-oculogram signal representing the potential of the second electrode 154 relative to the third electrode 156 . The processing of the electro-oculogram signal performed by the processing section 210 may include adding and subtracting processing by which the potential detected by the first electrode 152 and the potential detected by the second electrode 154 are adjusted. The processing of the electro-oculogram signal performed by the processing section 210 may include at least one of performing signal amplification or digital processing onto the electro-oculogram signal. The processing of the electro-oculogram signal performed by the processing section 210 may include transmitting the electro-oculogram signal representing the eye potential detected by the first electrode 152 and the second electrode 154 to the transmitting section 220 as it is.
The transmitting section 220 transmits the electro-oculogram signal having undergone the processing by the processing section 210 , to an external apparatus 300 . The transmitting section 220 may use wireless communication (e.g., Bluetooth (registered trademark), wireless LAN) or wired communication to transmit the electro-oculogram signal to the external apparatus 300 . The power supply section 230 supplies power to the processing section 210 and the transmitting section 220 .
The external apparatus 300 may be a computer terminal having a communication function. An exemplary external apparatus 300 is a mobile communication terminal (e.g., a portable phone, a smart phone) owned by a user. The external apparatus 300 may execute processing based on the electro-oculogram signal received from the transmitting section 220 . For example, when having detected that the number of times of brinks of a user is increasing by referring to the received electro-oculogram signal, the external apparatus 300 may issue warning to prevent the user from falling asleep.
FIG. 2 schematically shows positions at which the electrodes make contact with a user. A first contact position 452 represents the contact position of the first electrode 152 . A second contact position 454 represents the contact position of the second electrode 154 . A third contact position 456 represents the contact position of the third electrode 156 . A horizontal center line 460 is defined as a center line in the horizontal direction connecting the center of the right eye 402 and the center of the left eye 404 . A vertical center line 462 is defined as a center line that is orthogonal to the horizontal center line 460 and that passes through the center between the right eye 402 and the left eye 404 and.
The first contact position 452 and the second contact position 454 may desirably be positioned below the horizontal center line 460 . The line connecting the center of the first contact position 452 and the center of the second contact position 454 may desirably be parallel to the horizontal center line 460 . The distance between the first contact position 452 and the right eye 402 may desirably be equal to the distance between the second contact position 454 and the left eye 404 . The first contact position 452 may desirably be distanced from the second contact position 454 by a certain length.
It is desirable that the third contact position 456 be positioned somewhere along the vertical center line 462 . The third contact position 456 may desirably be in a position above the horizontal center line 460 and distanced from both of the first contact section 452 and the second contact section 454 . In one example, the distance between the third contact position 456 and the right eye 402 may be set to be larger than the distance between the right eye 402 and the first contact position 452 , and the distance between the third contact position 456 and the left eye 404 may be set to be larger than the distance between the left eye 404 and the second contact position 454 .
In an eye ball, the corneal side has a positive charge and the retina side has a negative charge. Therefore, when a person looks up, the potential of the first electrode 152 obtained in relation to the third electrode 156 as well as the potential of the second electrode 154 obtained in relation to the third electrode 156 become negative. On the contrary, when a person looks down, the potential of the first electrode 152 obtained in relation to the third electrode 156 as well as the potential of the second electrode 154 obtained in relation to the third electrode 156 become positive. When a person looks to the right, the potential of the first electrode 152 obtained in relation to the third electrode 156 becomes negative, and the potential of the second electrode 154 obtained in relation to the third electrode 156 becomes positive. When a person looks to the left, the potential of the first electrode 152 obtained relative to the third electrode 156 becomes positive, and the potential of the second electrode 154 obtained in relation to the third electrode 156 becomes negative.
By detecting the potential of the first electrode 152 relative to the third electrode 156 as well as the potential of the second electrode 154 relative to the third electrode 156 , the effect of noise can be effectively alleviated. The bridge 124 may be arranged at the upper end the rim 122 or in its vicinity, so as to distance the third contact position 456 from the first contact position 452 and the second contact position 454 as far as possible. The third electrode 156 may be provided above the center of the bridge 124 . In such a case, it is desirable to adopt a bridge 124 that is wide in the vertical direction.
In stead of detecting the potential of the first electrode 152 relative to the third electrode 156 , it is possible to subtract the potential of the third electrode 156 relative to the reference electrode, from the potential of the first electrode 152 relative to the reference electrode. Likewise, in stead of detecting the potential of the second electrode 154 relative to the third electrode 156 , it is possible to subtract the potential of the third electrode 156 relative to the reference electrode, from the potential of the second electrode 154 relative to the reference electrode.
An example of the reference electrode is the ground electrode 158 . In addition, another reference electrode may be provided in a position distanced from the first electrode 152 , the second electrode 154 , and the third electrode 156 of the pair of glasses 100 . For example, a reference electrode may be provided on the right ear pad 132 . The reference electrode may be provided at a position of the right temple 130 to be in contact with the skin of a user. The processing to subtract the potential of the third electrode 156 from the potential of the first electrode 152 relative to the reference electrode and the processing to subtract the potential of the third electrode 156 from the potential of the second electrode 154 relative to the reference electrode may be performed by the processing section 210 or by the external apparatus 300 .
FIG. 3 shows an exemplary electro-oculogram when the user looked down immediately after when he looked up. The upper electro-oculogram represents the electro-oculogram for the right eye showing the chronological change of the potential V 1 of the first electrode 152 relative to the third electrode 156 . The lower electro-oculogram represents the electro-oculogram for the left eye showing the chronological change of the potential V 2 of the second electrode 154 relative to the third electrode 156 . The longitudinal axis represents the voltage value. The lengthwise axis represents the time. The arrow 503 represents the timing at which the user looked up. At the timing shown by the arrow 503 , both of the right-eye electro-oculogram and the left-eye electro-oculogram have a negative potential.
FIG. 4 shows an exemplary electro-oculogram when the user looked up immediately after when he looked down. The arrow 504 represents the timing at which the user looked down. At the timing shown by the arrow 504 , both of the right-eye electro-oculogram and the left-eye electro-oculogram have a positive potential.
FIG. 5 shows an exemplary electro-oculogram when the user looked in the left direction immediately after he looked to the right. The arrow 505 represents the timing at which the user looked to the right. At the timing shown by the arrow 505 , the right-eye electro-oculogram has a negative potential, and the left-eye electro-oculogram has a positive potential.
FIG. 6 shows an exemplary electro-oculogram when the user looked in the right immediately after he looked left. The arrow 506 represents the timing at which the user looked left. At the timing shown by the arrow 506 , the right-eye electro-oculogram has a positive potential, and the left-eye electro-oculogram has a negative potential.
In this way, when the negative potential has been indicated in the right-eye electro-oculogram and the left-eye electro-oculogram, the user is identified to look up. When the positive potential has been indicated in the right-eye electro-oculogram and the left-eye electro-oculogram, the user is identified to look down. When the negative potential is indicated in the right-eye electro-oculogram and that the positive potential is indicated in the left-eye electro-oculogram, the user is identified to look right. When the positive potential is indicated in the right-eye electro-oculogram and that the negative potential is indicated in the left-eye electro-oculogram, the user is identified to look left.
It is further possible to enhance the detection accuracy of the visual line, by adding and subtracting the potential V 1 of the right-eye electro-oculogram and the potential V 2 of the left-eye electro-oculogram. For example when V 1 +V 2 indicates a negative value and V 1 −V 2 equals substantially zero, the user is identified to look up. When V 1 +V 2 indicates a positive value and V 1 −V 2 equals substantially zero, the user is identified to look down. When V 1 +V 2 equals substantially zero and V 1 −V 2 indicates a negative value, the user is identified to look to the right. When V 1 +V 2 equals substantially zero and V 1 −V 2 indicates a positive value, the user is identified to look to the left. By adding and subtracting the V 1 and V 2 , the positive value and the negative value resulting after calculation will respectively become large. This means that the threshold value can be set large, and so misdetection to detect noise as visual line movement can be reduced.
FIG. 7 schematically shows an exemplary electro-oculogram when he blinks. The arrow 507 represents the timing at which the user has blinked. The processing section 210 and the external apparatus 300 may detect that the user has blinked, when having detected a sequence of pulses of approximately the same level of amplitude within a certain period of time in both of the right-eye electro-oculogram and the left-eye electro-oculogram. For example in FIG. 7 , the user can be detected to have blinked when there occurred four consecutive pulses of −100 μV in 5 seconds.
FIG. 8 schematically shows an example of the pair of glasses 100 viewed from the backside. The electric wire 160 may include a first electric wire 162 , a second electric wire 164 , a third electric wire 166 , and a fourth electric wire 168 . The first electric wire 162 may be electrically connected to the first electrode 152 , and buried in the frame 120 . The second electric wire 164 may be electrically connected to the second electrode 154 , and buried in the frame 120 . The third electric wire 166 may be electrically connected to the third electrode 156 , and buried in the frame 120 . The fourth electric wire 168 may be electrically connected to the ground electrode 158 .
The first electric wire 162 , the second electric wire 164 , the third electric wire 166 , and the fourth electric wire 168 may be an insulation electric wire. The shape of the insulation electric wire may be round or flat, and may even be a film wire. It is also possible to make the frame 120 from an insulator material, and the first electric wire 162 , the second electric wire 164 , and the third electric wire 166 from an uncoated conductive wire.
The first electric wire 162 passes the first electrode 152 , the lower part of the right rim 122 , the end piece 126 , the hinge 128 , the temple 130 , and the ear pad 132 , and then is exposed to outside. The second electric wire 164 passes the second electrode 154 , the lower part of the left rim 122 , the end piece 126 , the hinge 128 , the temple 130 , and the ear pad 132 and then is exposed to outside. The third electric wire 166 passes the third electrode 156 , the upper part of the right rim 122 and the left rim 122 , the end piece 126 , the hinge 128 , the temple 130 , and the ear pad 132 , and then is exposed to outside. By burying the electric wires within the frame and not exposing them outside, the electric wires are prevented from being damaged. Moreover, the design of the pair of glasses 100 improves when compared to glasses having their electric wires exposed outside.
By burying the third electric wire 166 in both sides (left and right) of the frame 120 , the pair of glasses 100 will have a well balanced weight on the right and left. Moreover, since the frame 120 has the same structure at the right and the left, the production process can be simpler than burying the third electric wire in the left or the right.
Alternatively, the third electric wire 166 can be buried in either the left or the right of the frame 120 . In such a case, the amount of electric wire used can be reduced, to reduce the cost of the pair of glasses 100 . When burying the third electric wire 166 in one side (i.e. the left or the right) of the frame 120 , it should be desirable to burry the third electric wire 166 in the side which is opposite to the side in which the ground electrode 158 has been provided. By doing so, the number of electric wires that come out from the right ear pad 132 and the left ear pad 132 can be equaled.
As shown in FIG. 8 , the first electrode 152 and the second electrode 154 can be provided below the center of the nose pad 140 . By doing so, the first electrode 152 and the second electrode 154 can be prevented from being positioned right beside the user's eyes. If the first electrode 152 and the second electrode 154 are provided right beside the user's eyes, the visual line detection accuracy may be degraded because the potential detected will be similar between a case in which the user has looked up and a case in which the user has looked down. By providing the first electrode 152 and the second electrode 154 below the nose pad 140 , the potential can be clearly differentiated between in a case in which the user has looked up and in a case in which the user has looked down, to prevent worsening of visual line detection accuracy.
FIG. 9 schematically shows an example of a partially enlarged view of the glasses 100 viewed from the backside. The hinge 128 may include a first hinge 902 and a second hinge 904 . The first hinge 902 and the second hinge 904 may be made of an electrically conductive material. The first hinge 902 makes contact with the portion of the third electric wire 166 which is buried in the rim 122 , and the portion of the third electric wire 166 which is buried in the temple 130 . By doing so, the portion of the third electric wire 166 which is buried in the rim 122 can be in electrical conduction with the portion of the third electric wire 166 which is buried in the temple 130 .
The second hinge 904 makes contact with the portion of the first electric wire 162 which is buried in the rim 122 , and the portion of the first electric wire 162 which is buried in the temple 130 . By doing so, the portion of the first electric wire 162 which is buried in the rim 122 can be in electrical conduction with the portion of the first electric wire 162 which is buried in the temple 130 . The hinge 128 on the left side can also have the similar structure. By having two hinges distanced from each other, the first electric wire 162 can be electrically isolated from the third electric wire 166 , as well as electrically isolating the second electric wire 164 from the third electric wire 166 .
FIG. 10 shows a flowchart of a visual line detection processing performed by an external apparatus 300 . The operation in the flow chart starts by bringing the first electrode 152 , the second electrode 154 , the third electrode 156 , and the ground electrode 158 into contact with the skin of a user wearing the pair of glasses 100 , and by moving into the operation mode in which the external apparatus 300 executes visual line detection processing.
In Step S 1002 , the external apparatus 300 receives an electro-oculogram signal from the transmitting section 220 . The following explains the operation, by taking an example in which the potential detected by each electrode is received as it is.
In Step S 1004 , the external apparatus 300 determines whether there is abnormality in the received electro-oculogram signal. The external apparatus 300 will determine abnormality, when at least one of the first electrode 152 , the second electrode 154 , and the third electrode 156 has detected the potential of zero for a certain period of time or longer. For example, the external apparatus 300 determines that there is abnormality when at least one of the first electrode 152 , the second electrode 154 , and the third electrode 156 has detected the potential that exceeds a predetermined threshold value. When there is no abnormality found in Step S 1004 , the control proceeds to Step S 1006 .
In Step S 1006 , the external apparatus 300 determines whether the potential detected by the first electrode 152 relative to the third electrode 156 and the potential detected by the second electrode 154 relative to the third electrode 156 match a pre-registered pattern. An example of the pre-registered pattern may be as shown in FIG. 3 through FIG. 7 . When there is determined a match with any of the pre-registered patterns in Step S 1006 , the control proceeds to Step S 1008 , and when there is not determined any match, the control returns to Step S 1002 .
In Step S 1008 , the external apparatus 300 determines the visual line of the user. The external apparatus 300 determines that the user is looking up, when the pre-registered pattern that has matched in Step S 1006 has matched to the pattern shown in FIG. 3 . The external apparatus 300 may execute the processing corresponding to the determined visual line. After having determined the visual line in Step S 1008 , the control returns to Step S 1002 .
When abnormality is found in Step S 1004 , the control proceeds to Step S 1010 . In Step S 1010 , the external apparatus 300 determines whether the abnormality indicates distancing away of all the electrodes. In other words, it is determined whether all the first electrodes 152 , the second electrode 154 , the third electrode 156 are distanced away from the skin of a user. The external apparatus 300 may determine that all the electrodes are distanced away when all the potential detected by the first electrode 152 , the second electrode 154 , and the third electrode 156 are zero for a certain period of time or longer.
In Step S 1010 , when it is determined that not all the electrodes are distanced, the control proceeds to Step S 1012 . In Step S 1012 , the external apparatus 300 warns the user. For example, when any one of the first electrode 152 , the second electrode 154 , and the third electrode 156 is distanced, the external apparatus 300 issues warning to notify the user of the existence of the distanced electrode(s). By warning the user, the user can be urged to adjust the position of the pair of glasses 100 to keep the electrodes in contact with him.
In Step S 1010 , when it is determined that all the electrodes are distanced away, the control proceeds to Step S 1014 . When all the electrodes are distanced away, it means that the pair of glasses 100 is removed from the user. Therefore in Step S 1014 , the external apparatus 300 moves onto the wait mode in which the external apparatus 300 waits before executing the next visual line detection processing. This ends the current visual line detection processing of the external apparatus 300 . When the external apparatus 300 executes the visual line detection processing as described above, the visual line of the user can be detected. For example, when a part of the electrodes is distanced due to displacement of the pair of glasses 100 from the face of the user, the user can be notified and urged to adjust the position of the pair of glasses 100 .
In the present embodiment, the pair of glasses is used as an example of eyewear. However, the eyewear is not limited to a pair of glasses. The eyewear can be anything that a user can wear, and may include glasses, sunglasses, goggles, a head mount display, and anything that can wear on the face or on the head.
In the present embodiment, the pair of glasses 100 includes the third electrode 156 and the third electric wire 166 . However, the pair of glasses 100 is not necessarily limited to this configuration. A configuration is also possible in which the pair of glasses 100 does not include any of the third electrode 156 and the third electric wire 166 . In such a configuration, the electro-oculogram showing the potential of the first electrode 152 relative to the reference electrode and the electro-oculogram showing the second electrode 154 relative to the reference electrode may be transmitted to the eternal apparatus 300 . Here, the ground electrode 158 may be provided in the position of the third electrode 156 to use it as the reference electrode. Also, the ground electrode 158 provided on the left ear pad may be used as the reference electrode, or an additional electrode provided in a position distanced from the first electrode 152 and the second electrode 154 may be used as the reference electrode.
The electro-oculogram shown by the potential of the first electrode 152 relative to the reference electrode and the electro-oculogram shown by the potential of the second electrode 154 relative to the reference electrode have the characteristics similar to the characteristics of the electro-oculogram shown in FIG. 3 - FIG. 6 . The electro-oculogram shown by the potential of the first electrode 152 relative to the reference electrode and the electro-oculogram shown by the potential of the second electrode 154 relative to the reference electrode enable the external apparatus 300 to determine the visual line of a user. In this way, a configuration of not providing any of the third electrode 156 and the third electric wire 166 realizes an advantageous effect of reducing the number of electrodes and electric wires, which leads to reducing the weight and the cost of the pair of glasses 100 .
The present embodiment has dealt with a pair of glasses 100 which has its nose pad 140 integrated with the rim 122 . However, the pair of glasses 100 is not limited to this configuration. The pair of glasses 100 may include clings provided for the rim 122 and the nose pad 140 attached to the clings. In this case, the electrode provided on the surface of the nose pad 140 is electrically connected through the clings to the electric wire buried in the frame.
In the present embodiment, the pair of glasses 100 includes the first electric wire 162 , the second electric wire 164 , and the third electric wire 166 buried in the frame 120 . However, the pair of glasses 100 is not limited to this configuration. The pair of glasses 100 includes the first electric wire 162 , the second electric wire 164 , and the third electric wire 166 provided along the surface of the frame 120 .
The present embodiment has dealt with a case in which the first electrode 152 and the second electrode 154 are provided below the center of the nose pad 140 . However, the present invention is not limited to this configuration. For example, the nose pad 140 can have an elongated section that elongates downward and that is provided with the first electrode 152 and the second electrode 154 . By adopting this configuration, the first electrode 152 and the second electrode 154 can be brought in contact to the skin below the eyes of a user, even if the user has such a face configuration that the nose pad inevitably comes right beside his eyes.
The present embodiment has the third electrode 156 provided on the surface of the bridge 124 . However, the present embodiment is not limited to this configuration. It is also possible to provide the bridge 124 with an elongated section that elongates upward, and to provide this elongated section with the third electrode 156 . It is further possible to provide a movable section between the elongated section and the bridge 124 , and move the elongated section up and down using this movable section for adjusting the position of the third electrode 156 . By adopting this configuration, the contact position of the third electrode 156 can be adjusted to be away from the eyes, even if the user has such a face configuration that the third electrode 156 inevitably comes close to his eyes when wearing the pair of glasses.
The present embodiment has dealt with a case in which the first electric wire 162 , the second electric wire 164 , and the third electric wire 166 are exposed outside the ear pad 132 . However, the present invention is not limited to this configuration. The first electric wire 162 , the second electric wire 164 , and the third electric wire 166 may extend from other portions. For example, the first electric wire 162 , the second electric wire 164 , and the third electric wire 166 can extend from the temple 130 or the end piece 126 .
The present embodiment has taken an example that the external apparatus 300 is a mobile communication terminal such as a portable phone, a smart phone, or the like that is a separate body from the electro-oculogram processing unit 200 . However, the present invention is not limited to this configuration. The external apparatus 300 may be provided as one piece with the electro-oculogram processing unit 200 . In addition, although the electro-oculogram processing unit 200 was explained to be connected by the electric wire 160 to the pair of glasses 100 distanced apart from the electro-oculogram processing unit 200 in the present embodiment, the present invention is not limited to this configuration. In fact, the electro-oculogram processing unit 200 may be attached to the frame 120 .
While the embodiments of the present invention have been described, the technical scope of the invention is not limited to the above described embodiments. It is apparent to persons skilled in the art that various alterations and improvements can be added to the above-described embodiments. It is also apparent from the scope of the claims that the embodiments added with such alterations or improvements can be included in the technical scope of the invention.
The operations, procedures, steps, and stages of each process performed by an apparatus, system, program, and method shown in the claims, embodiments, or diagrams can be performed in any order as long as the order is not indicated by “prior to,” “before,” or the like and as long as the output from a previous process is not used in a later process. Even if the process flow is described using phrases such as “first” or “next” in the claims, embodiments, or diagrams, it does not necessarily mean that the process must be performed in this order. | A problem related to a known eyewear-type electro-oculogram measuring apparatus which detects the eye potential using a pair of electrodes positioned outside both the eyes of a user and a pair of electrodes respectively positioned above and below one eye is that the two pairs of electrodes have had an impact on the skins of users, and discomfort on them. Besides, the electrodes are not excellent in design. The present invention provides eyewear including: a frame; a pair of nose pads; and a first electrode and a second electrode respectively provided on the surface of the pair of nose pads, the first electrode and the second electrode detecting eye potential. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a 35 U.S.C. §111(a) continuation of PCT international application number PCT/US2012/000497 filed on Oct. 3, 2012, incorporated herein by reference in its entirety, which claims the benefit of U.S. provisional patent application Ser. No. 61/542,591 filed on Oct. 3, 2011, incorporated herein by reference in its entirety. Priority is claimed to each of the foregoing applications.
[0002] The above-referenced PCT international application was published as PCT International Publication No. WO 2013/103332 on Jul. 11, 2013 and republished on Oct. 10, 2013, which publications are incorporated herein by reference in their entireties
[0003] This application is also related to PCT international application number PCT/US11/31478, filed on Apr. 6, 2011, which is claims priority to U.S. provisional patent application Ser. No. 61/321,338 filed on Apr. 6, 2010, incorporated herein by reference in its entirety. The foregoing PCT international application was published as PCT International Publication No. WO 2011/127218 on Oct. 13, 2011 and republished on Feb. 2, 2012, and is incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0004] This invention was made with Government support under EPS-0447679 awarded by North Dakota EPSCoR/National Science Foundation and under H94003-09-2-0905 awarded by the DoD Defense Microelectronics Activity (DMEA). The Government has certain rights in the invention.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED IN A COMPUTER PROGRAM APPENDIX
[0005] Not Applicable
BACKGROUND OF THE INVENTION
[0006] 1. Field of the Invention
[0007] This invention pertains generally to synthesis schemes and methods for producing silicon based nanostructures and materials, and more particularly to compositions and methods for synthesis of silicon-based nanowires and composites from four-component inks comprising a liquid silane, a polymer, an accelerant and a solvent and five-component inks comprising a liquid silane, a polymer, an accelerant, a solid phase and a solvent.
[0008] 2. Description of Related Art
[0009] The beneficial electrical and electrochemical properties of silicon have been demonstrated in integrated circuits, solar cells and battery electrodes. However, such materials are typically produced by chemical vapor deposition or by etching a Si wafer and these processes are not amendable to continuous manufacturing schemes such as roll-to-roll manufacturing.
[0010] There is also increased interest in replacing carbon-based materials with silicon or silicon-based compounds in the anodes of next-generation lithium ion batteries (LIBs). Silicon has a theoretical capacity of approximately 4200 mAh/g, which is more than ten times greater than the 372 mAh/g capacity of conventional graphite anode materials. Therefore, Si-based anodes could increase the energy density of lithium ion batteries significantly.
[0011] However, fully lithiated silicon (Li 22 Si 5 ) undergoes a greater than 300% volume expansion during the lithiation and delithiation process which leads to mechanical failure of the silicon structure within a few cycles producing a significant and permanent loss of capacity. A number of approaches toward the development of silicon-containing anodes have been attempted. One approach was the use of a homogeneous dispersion of silicon particles within a suitable matrix to give composites that have improved mechanical stability and electrical conductivity versus pure silicon. It has been shown that silicon nanowires or fibers are able to accommodate the expansion that occurs during cycling. However, significant numbers of Si-nanowires (SiNWs) are needed for practical anode applications.
[0012] A Vapor Induced Solid-Liquid-Solid (VI-SLS) route to produce Si-nanowires has been proposed that uses bulk silicon powders thus offering the possibility of scalable and cost-effective mass manufacture without the need for a localized catalyst on a substrate. The VI-SLS process, however, is complicated by high process temperatures that tend toward the formation of carbide and oxide phases that limit electrochemical capacity and rate capabilities.
[0013] Another approach to the production of silicon nanowires is through electrospinning where the electrospun polymer fiber serves only as a template for the growth of silicon coatings by hot-wire chemical vapor deposition (CVD) or plasma enhanced CVD (PECVD). While these synthesis routes do allow the growth of a-Si nanowires with hollow cores, hot-wire and PECVD methods suffer from poor precursor utilization and traditionally slow rates of growth.
[0014] Accordingly, there is a need for an apparatus and method for reliably producing silicon based nanowires and films that are inexpensive and amenable to continuous roll-to-roll operation. The present invention satisfies these needs as well as others and is generally an improvement over the art.
BRIEF SUMMARY OF THE INVENTION
[0015] The present invention is directed to materials and methods for producing silicon based micro and nanofibers that can be used in a variety of applications including material composites, electronic devices, sensors, photodetectors, batteries, ultracapacitors, and photosensitive substrates and the like.
[0016] Liquid silanes have been considered as precursors in direct-write fabrication of printed electronics as well as in the production of silicon microwires and nanowires. Cyclohexasilane (Si 6 H 12 ), for example, can be transformed into solid polydihydrosilane (SiH 2 ) n by thermal treatment or light activation via radical polymerization. Additional thermolysis causes evolution of H 2 (g) giving a-Si:H at approximately 350° C. and crystalline silicon at approximately 750° C.
[0017] Marked microstructural changes, however, are associated with this thermolytic transformation. The thermal conversion of Si 6 H 12 -derived films and/or (SiH 2 ) n into a-Si occurs with marked shrinkage at around 290° C. and it appears to be related to the evolution of SiH 2 and SiH 3 fragments. This phenomenon may limit electrical transport as a result of microcracking within these thin films. This shrinkage does not lead to cracking when the films are less than a thickness of approximately 200 nm. The electrospinning methods of the present invention appear to manage the stress, in part, by reducing the dimensionality from 2D films to 1D wires.
[0018] Electrospinning, according to the invention, is a viable method for utilizing liquid cyclosilanes (i.e., Si n H 2n ) and linear or branched silanes (i.e., Si n H 2n+2 ) in the fabrication of electronic materials as these monomers are transformed directly into a useful form (i.e., a nanowire) prior to the formation of the insoluble (SiH 2 ) n network polymer. The lateral cohesive stresses that promote cracking in the aforementioned 2D thin films are well managed in 1D wires where radial shrinkage does not lead to the observed deleterious microstructural changes of larger silicon structures.
[0019] Electrospinning is a continuous nanofabrication technique based on the principle of electrohydrodynamics, and it is capable of producing nanowires of synthetic and natural polymers, ceramics, carbon, and semiconductor materials with the diameter in the range of 1 nm to 2000 nm. While the Taylor cone instability associated with electrospinning was historically used for nozzle-based systems, the surface instability of thin polymer-in-solution films in the presence of an electric field enabled the development of needleless electrospinning whereby numerous jets spin coincidently allowing a continuous, roll-to-roll manufacturing process. Additionally, continuous needleless electrospinning that utilizes a rotating cone as the spinneret has been demonstrated with production throughput of up to 10 g/minute.
[0020] This is in stark contrast to the two common silicon nanowire preparation methods known in the art where the ability to scale up appears to be limited by wafer size (i.e., when forming Si nanowires via wafer etching) or a growth temperature of approximately 363° C. (i.e., Au—Si eutectic in vapor-liquid-solid growth). In each instance, the transition to a continuous roll-to-roll manufacturing process is not straightforward and may not be possible.
[0021] It has been observed that the liquid silane monomers that are used in the invention are relatively unaffected by the high-voltage electrospinning process and remains associated with the polymeric carrier (i.e., poly(methyl methacrylate (PMMA) or polypropylene carbonate/polycyclohexene carbonate (QPAC100™, Empower Materials)) upon evaporation of the toluene or other solvent. Light-induced or heat-induced radical polymerization of the Si 6 H 12 gives a viscous polydihydrosilane deposit that assumes a geometry that is related to the structure of the copolymer. The structure of the silicon nanowires prepared from Si 6 H 12 /polymer carrier in toluene mixtures appears to be governed by the physics of the copolymer mixtures. For example, scanning electron micrograph (SEM) data shows that a fibrous structure is formed after treatment of an electrospun composite formed from a 1.0:2.6 wt % ratio of Si 6 H 12 /PMMA in toluene ink. This structure appears to be related to wetting of the polymer by the liquid silane after solvent evaporation. By way of comparison, thermolysis of the composite formed by electrospinning a 1.0:2.0 wt % ratio of Si 6 H 12 /QPAC100 in toluene precursor gives a porous wire where it appears the liquid silane and polymer carrier exist as a microemulsion and phase separate after solvent evaporation.
[0022] It has also been observed that the electrospinning of four-component Si 6 H 12 /polymer/accelerant inks gives products where the active silicon agent forms after the precursor is transformed to nanosized material. The approach offers the ability to tailor chemical composition of Si wires by adjusting precursor chemistries to give electrospun composites that possess targeted conductivities (electrical, thermal and ionic) and maintain structural stability throughout a lifetime of charge/discharge cycles. Barring any undesirable chemical reactivity with Si—Si or Si—H bonds, particles of carbon, metals and solid electrolytes can also be introduced into liquid silane-based electrospinning inks using standard dispersion chemistry to produce a five-component ink. Because the spun wires convert to amorphous silicon at relatively low temperature, formation of excessive surface oxide and carbide phases can be avoided, which otherwise negatively affect capacity and rate capabilities. It is important to note that other routes to Si wires yield crystalline products that become amorphous after lithium intercalation in LIBs.
[0023] The four-component and five-component inks that are disclosed are particularly useful with electrospinning procedures and the formation of micro and nanofibers are used as an illustration. However, the inks can also be used with other deposition techniques such as thin film deposition techniques. In addition, single or coaxial nozzle formation of nanofibers is used to illustrate the methods. However, it will be understood that the inks and methods of the invention are appropriate for any electrospinning technique including use with devices that have multiple nozzles, drums or films.
[0024] By way of example, and not of limitation, a preferred method for making silicon-containing wires with a four-component ink generally comprises the steps of: (a) combining a liquid silane of the formula Si n H 2n or Si n H 2n+2 , a polymer, an accelerant and a solvent to form a viscous solution; (b) expelling the solution from a source while exposing the stream of viscous solution to a high electric field resulting in the formation of continuous fibers that are deposited onto a substrate; and (c) transforming the deposited fibers, normally with thermal processing.
[0025] In another embodiment of the invention, a preferred method for making silicon-containing wires with a five-component ink generally comprises: (a) combining a liquid silane of the formula Si n H 2n or Si n H 2n+2 , a polymer, a solid phase, an accelerant and a solvent to form a viscous solution; (b) expelling the viscous solution and exposing the viscous solution to a high electric field whereby continuous fibers form from the solution and are deposited onto a substrate; and (c) transforming the electrospun deposit.
[0026] The solid phase components are preferably particulates of many different types such as metal spheres, silicon nanowires, and carbon particulates including nanotubes, as well as dopants, and metal reagents. For example, metal silicide wires can be formed with addition of metal reagents.
[0027] The polymers are preferably either an acrylate such as poly(methyl methacrylate) or a polycarbonate. The preferred solvents are toluene, xylene, cyclooctane, 1,2,4-trichlorobenzene, dichloromethane or mixtures thereof.
[0028] A wide variety of polyhydropolysilanes can act as accelerants for the polymerization of cyclohexasilane, Si 6 H 12 (CHS). Polyhydropolysilanes of formula Si n H n+2 , linear or branched, individually, or in combination, accelerate the polymerization of CHS when added to CHS. Polyhydropolysilanes composed of one or more polyhydrocyclopolysilane rings attached to another polyhydrocyclopolysilane, with or without the presence of substituents on the ring, will accelerate the polymerization of CHS when added to CHS.
[0029] CPS (cyclopentasilane, Si 5 H 10 ), when mixed with CHS, will accelerate the polymerization of CHS when added to CHS. Silylcyclopentasilane also accelerates polymerization and film formation. This structure has the formula of Si 6 H 12 , but is comprised of a five membered ring of silicon atoms with the 6 th silicon attached to the ring.
[0030] The substrate is preferably a metal foil. However, the substrate may also be a carbon fiber matte, metal web or rotating mandrel.
[0031] Transformation of the deposit is preferably by thermal treatment or light activation via radical polymerization. Transformation of the deposited nanofibers can take place at any time or location and need not take place on the substrate.
[0032] In certain embodiments, the methods for producing silicon based nanofibers may further include the step of coating the fibers with an electrically conductive material. The preferred coating is a coherent, ion conductive coating of carbon such as graphite, C black, graphene, KB carbon or carbon nanotubes. The coating of the fibers is preferably applied by chemical vapor deposition or solution deposition.
[0033] The silicon-based materials and nanofibers that are produced by the three- and four-component inks can be used in a variety of applications including as an active component in other composite materials. For example, electrically-conducting silicon composite electrodes can be produced with a four-component ink according to the invention by (a) combining a liquid silane of the formula Si n H 2n , or Si n H 2n+2 , a polymer and accelerant and a solvent to form a viscous solution; (b) expelling the viscous solution into the presence of a high electric field where continuous fibers are formed and deposited onto a substrate; (c) transforming the deposit into a material that contains a polysilane, an amorphous silicon and/or a crystalline silicon fraction with or without a binder; (d) forming a coherent, conductive coating on the external porosity of the silicon-containing fraction and (e) binding the material with one or more binders. The preferred binders include poly(vinylidene fluoride-co-hexafluoropropylene) or sodium carboxymethylcellulose or an elastic carbon such as KB carbon. Some binders can be thermally decomposable.
[0034] Another example of a composite material that can be produced is an electrically-conducting photoactive silicon-composite electrode material using a five-component ink. This material can be produced by (a) combining a liquid silane of the formula Si n H 2n or Si n H 2n+2 , a polymer, a photoactive solid phase, an accelerant and a solvent to form a viscous mixture; (b) expelling the viscous mixture into the presence of a high electric field where continuous fibers of the mixture are formed and deposited onto a substrate; (c) transforming the deposit into a material that contains an amorphous silicon and/or a crystalline silicon fraction and a photoactive phase; and binding the transformed material with a binder. The preferred photoactive phase can be a carbon fullerene, a carbon nanotube, a quantum dot of CdSe, PbS, Si or Ge, a core-shell quantum dot of ZnSe/CdSe or Si/Ge.
[0035] Accordingly, an aspect of the invention is to provide four-component or five-component silane inks that can be used in the formation of silicon based films and nanofibers and composite materials.
[0036] Another aspect of the invention is to provide liquid silane electro-spinning inks that include an accelerant for increased setting or curing times
[0037] Another aspect of the invention is to provide methods for producing polysilane nanowires and materials.
[0038] Another aspect of the invention is to provide a method for continuous production of nanofiber strands and coated nanofiber strands.
[0039] A further aspect of the invention is to provide silicon based fibers that can be used as a component in a variety of composite materials such as electrode composites.
[0040] Further aspects of the invention will be brought out in the following portions of the specification, wherein the detailed description is for the purpose of fully disclosing preferred embodiments of the invention without placing limitations thereon.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0041] The invention will be more fully understood by reference to the following drawings which are for illustrative purposes only:
[0042] FIG. 1 is a flow diagram of a method of forming silicon based nanofibers from a three-component ink according to one embodiment of the invention.
[0043] FIG. 2 is a flow diagram of a method of forming silicon based nanofibers from a four-component ink according to another embodiment of the invention.
[0044] FIG. 3 is a flow diagram of a method for producing an electrode material from carbon coated silicon nanofibers formed according to one embodiment of the invention.
[0045] FIG. 4 is a schematic diagram of the processing of cyclohexasilane and PMMA in toluene, a three-component ink, to produce transformed nanofibers.
[0046] FIG. 5 is a schematic diagram of the processing of cyclohexasilane and QPAC100 in toluene, a three-component ink, to produce transformed nanofibers.
[0047] FIG. 6 shows Raman spectra of electrospun four-component samples after heat treatment at 550° C. for one hour and laser crystallization for CdSe, C black, graphite, Ag, amphiphilic invertible micelle (AIP), BBr 3 and PBr 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0048] Referring more specifically to the drawings, for illustrative purposes one embodiment of the present invention is depicted in the methods generally shown in FIG. 1 through FIG. 6 . It will be appreciated that the methods may vary as to the specific steps and sequence and the apparatus may vary as to structural details, without departing from the basic concepts as disclosed herein. The steps depicted and/or used in methods herein may be performed in a different order than as depicted in the figures or stated. The steps are merely exemplary of the order these steps may occur. The steps may occur in any order that is desired, such that it still performs the goals of the claimed invention.
[0049] The present invention provides methods for producing silicon containing nanowire/fiber composites and thin films that are produced from liquid silane inks by electrospinning as an illustration of an adaptation of the invention. Nanowire products from four-component and five-component liquid silane based “ink” compositions are produced and characterized to demonstrate the compositions and methods. The exemplary nanowires that are produced by the methods can be used as a component of other material compositions such as an anode for a lithium ion battery.
[0050] Turning now to FIG. 1 , the steps according to a preferred embodiment 10 of the present method for producing a silicon based nanowire material using four-component liquid silane inks with an optional conductive coating is illustrated. At block 12 , a solution of a liquid silane, a polymer, an accelerant and a solvent is provided. The resulting viscous solution preferably has a viscosity of between approximately 100 cP to approximately 10,000 cP for electrospinning procedures.
[0051] The preferred liquid silane has the formula Si n H 2n , where n=3, 4, 5, 6, 7 or 8. Linear and branched liquid silanes of the formula Si n H 2n+2 , where n=3, 4, 5, 6, 7 or 8 may also be used. Mixtures of one or more of these silanes may also be used.
[0052] Cyclohexasilane (Si 6 H 12 ) is a particularly preferred cyclosilane. Liquid Si 6 H 12 is preferably synthesized by reduction of a chlorinated salt prepared from trichlorosilane (HSiCl 3 ). Cyclohexasilane is a high melting point liquid (18° C.) that is stable toward reduced-pressure distillation as well as ambient light. Si 6 H 12 has been shown to be stable to room temperature fluorescent light for days and it can be stored for months in the solid state without marked degradation. Si 6 H 12 is stable toward ultrasonic atomization and has been used as a precursor in collimated aerosol beam direct write deposition of a-Si lines. In addition, Si 6 H 12 is stable when subjected to high voltage processing and electrospinning procedures to yield a-Si nanowires that may find application as anodes in lithium ion batteries and other materials.
[0053] In the embodiment shown in FIG. 1 , Si 6 H 12 undergoes ring opening polymerization under heat or prolonged exposure to laser light with additional thermal treatment transforming the solid polydihydrosilane (SiH 2 ) n into amorphous silicon first and then crystalline silicon material. Specifically, Si 6 H 12 can be transformed into solid polydihydrosilane (SiH 2 ) n by thermal treatment or light activation via radical polymerization. Additional thermolysis causes evolution of H 2 (g) giving a-Si:H at approximately 350° C. and crystalline silicon at approximately 850° C.
[0054] In another preferred embodiment, the liquid silane is cyclopentasilane, cyclohexasilane and/or 1-silylcyclopentasilane corresponding to Si n H 2n where n=5 or 6.
[0055] The preferred polymer is poly(methyl methacrylate). However, a polycarbonate such as polypropylene carbonate/polycyclohexene carbonate or poly(vinylidene fluoride-co-hexafluoropropylene) and polyvinyl butryal may also be used in the embodiment shown at block 12 of FIG. 1 .
[0056] In one embodiment, the percentage of silane to organic polymer in the viscous solution is kept within the range of approximately 5% to 20% silane, with the range of 10% to 16% silane preferred.
[0057] The preferred accelerant that is part of the composition at block 12 is a polyhydropolysilane. A wide variety of polyhydropolysilanes act as accelerants for the polymerization of cyclohexasilane, Si 6 H 12 (CHS). Polyhydropolysilanes with linear, branched, and cyclic structures have been shown to accelerate the polymerization of CHS when one or more of these compounds are added to CHS and the resulting mixture is exposed to energy from thermal, electromagnetic, or mechanical sources. There is a significant advantage to the use of polyhydropolysilanes as “promoters” or “accelerants” to the polymerization, or film forming process. Since they are composed of only Si and H, they are therefore completely compatible with the product material. Accelerants are usually distinctly different from the materials they accelerate and thus become impurities in the final product(s).
[0058] For example, polyhydropolysilanes of formula Si n H n+2 , linear or branched, individually, or in combination, accelerate the polymerization of CHS when added to CHS. For example, linear and branched polyhydropolysilanes of formula Si n H n+2 , where n ranges from 2-10,000, when mixed with CHS, accelerates polymerization to form films that can be placed in a variety of devices that respond to light, e.g., solar cells.
[0059] Polyhydropolysilanes composed of one or more polyhydrocyclopolysilane rings attached to another polyhydrocyclopolysilane, with or without the presence of substituents on the ring, will accelerate the polymerization of CHS when added to CHS. Similarly, polyhydropolysilanes composed of one or more cyclopolysilane rings, with or without the presence of substituents on the ring, will accelerate the polymerization of CHS when added to CHS.
[0060] CPS (cyclopentasilane, Si 5 H 10 ), when mixed with CHS, will accelerate the polymerization of CHS when added to CHS. Derivatives of CPS with one or more silyl groups attached to the ring, when mixed with CHS, accelerate polymerization of CHS.
[0061] Silylcyclopentasilane also accelerates polymerization and film formation. This structure has the formula of Si 6 H 12 , but is comprised of a five membered ring of silicon atoms with the 6 th silicon attached to the ring.
[0062] Additionally, derivatives of CHS with one or more linear or branched silyl-groups attached to the ring, when mixed with CHS will accelerate polymerization. It was also observed that partially or fully halogenated silanes and polysilanes accelerate polymerization of CPS and CHS.
[0063] The preferred solvents at block 12 include toluene, xylene, cyclooctane, 1,2,4-trichlorobenzene, and dichloromethane or mixtures thereof. However, although these solvents are preferred, it will be understood that other solvents may be selected based on the polymers and the silanes that are employed.
[0064] At block 14 of FIG. 1 , the viscous solution that was produced at block 12 is expelled from a nozzle or drawn from a film and exposed to a high electric field and continuous fibers arising from the solution are formed and deposited onto a substrate.
[0065] In one embodiment of the method, the high-voltage environment is formed by applying a direct current bias from the point where the solution is expelled from a nozzle to the collecting substrate. The voltage used for the electrospinning process normally ranges from approximately 5000V to approximately 20,000V with approximately 7000V to 11,000V typically used. In a preferred embodiment, a direct current bias that is greater than approximately 2 kV is applied across a gap of 10 cm in a nitrogen environment.
[0066] The electrospinning apparatus can also have a nozzle with an inner annulus and an outer annulus. In this configuration, liquid silane is expelled through the inner annulus of a coaxial delivery tube while viscous polymer solution is expelled through the outer annulus and both fluids are exposed to a high electric field resulting in the continuous formation of fibers that are deposited onto a substrate.
[0067] In one preferred configuration, the liquid silane that is directed through the inner annulus is Si 6 H 12 cyclohexasilane, Si 6 H 12 , 1-silyl-cyclopentasilane or Si 5 H 10 cyclopentasilane and the solution flowing through the outer annulus is polyacrylonitrile in dimethylformamide.
[0068] The strand of nanofiber material that is formed from solution expelled from the nozzle in a high electric field at block 14 is deposited and collected on a substrate at block 16 . In the embodiment shown in FIG. 1 , the substrate consists of a metallic foil such as copper foil or aluminum foil. In one configuration, the substrate includes conductive metallic portions and insulating portions and the silicon-containing wires that are produced span the insulating portions of the substrate. In another embodiment, the substrate is a conducting carbon fiber matte including a carbon fiber matte constructed of carbon nanotubes. The substrate may also be a rotating mandrel or a moving metal web of foil such as copper foil.
[0069] At block 18 of FIG. 1 the deposited and collected nanowires are transformed using thermal processing or laser processing. With cyclohexasilane based solutions, for example, the deposit can be transformed using thermal processing at temperatures ranging from approximately 150° C. to 300° C. to produce polysilane-containing materials. The deposit can also be transformed using thermal processing at temperatures ranging from about 300° C. to about 850° C., producing amorphous silicon-containing materials. The deposit from block 16 can be transformed using thermal processing at temperatures from approximately 850° C. to 1414° C. producing crystalline silicon-containing materials. As an illustration, the thermal treatment of cyclohexasilane and polymer solvent expelled through a coaxial nozzle consists of 350° C. under N 2 for one hour followed by 350° C. in air for one hour followed by 800° C. in N 2 for one hour. The deposit can also be transformed using laser processing to produce crystalline silicon-containing materials.
[0070] Optionally, at block 20 , the transformed fibers can be coated with a coherent, conductive coating and the coated transformed fibers can be used as a component of composite materials such as an anode material for a lithium ion battery, for example.
[0071] In one embodiment, the conductive coating is deposited by chemical vapor deposition using argon/acetylene, hydrogen/methane or nitrogen/methane as precursor gases. In another embodiment, the coherent, conductive coating is deposited at block 20 by solution deposition. For example, the solution deposition may employ a dispersion of conducting carbon milled together with the silicon-containing fraction in solvent. The conductive carbon can be graphite, carbon black, graphene, or carbon nanotubes in this embodiment.
[0072] Referring now to FIG. 2 , the steps according to a preferred embodiment 100 of the present method for producing a silicon-based nanowire material using five-component liquid silane inks with an optional conductive coating is illustrated. Five-component inks, according to the invention, may have essentially the same components as the four-component inks described herein with the addition of a solid phase. The solid phase component may be a particulate, photoactive or a reactive compound. Processing of the five-component inks is typically the same as the processing of the four-component inks.
[0073] At block 110 , a viscous solution is formed by combining a liquid silane preferably of the formula Si n H 2n , a polymer, a solid phase, an accelerant and a solvent. As with the four-component inks, the components may be combined sequentially in any order or by pairs.
[0074] The preferred liquid silane has the formula Si n H 2n , where n=3, 4, 5, 6, 7 or 8. Linear and branched liquid silanes of the formula Si n H 2n+2 , where n=3, 4, 5, 6, 7 or 8 may also be used. Mixtures of one or more of these silanes may also be used.
[0075] The preferred polymer is poly(methyl methacrylate) or a polycarbonate in the embodiment shown at block 110 of FIG. 2 . The preferred solvents at block 110 of FIG. 2 include toluene, xylene, cyclooctane, 1,2,4-trichlorobenzene, and dichloromethane or mixtures thereof. However, although these polymers and solvents are preferred, it will be understood that other polymers and solvents may be selected based on the polymers, the solid phases and the silanes that are employed.
[0076] One or more solid phase components can be part of the ink mixture provided at block 110 of FIG. 2 . For example, the solid phase can comprise a plurality of metallic particles, preferably nanoscale particles, which may be spherical or have a high aspect ratio. In one embodiment, the metallic particles are made of a metal such as Al, Au, Ag, Cu, In—Sn—O, fluorine-doped tin oxide, or a metal alloy. In another embodiment, the particles may be made from graphite, carbon black, or graphene. The metallic particles may also be composed of wires or tubes of suitable dimensions such as carbon nanotubes or silicon nanowires.
[0077] In other embodiments, the solid phase component of the ink contains elements that are known to substitutionally-dope silicon such as boron, phosphorous, arsenic or antimony containing compounds. The solid phase component can also be semiconducting particles formed from materials such as carbon nanotubes, CdSe, CdTe, PbS, PbSe, ZnO or Si.
[0078] The solid phase component can also include polydihydrosilane —(SiH 2 ) n —, formed by UV-irradiation of Si n H 2n (n=5,6) corresponding to cyclopentasilane, cyclohexasilane and/or 1-silylcyclopentasilane.
[0079] In another embodiment, metal silicide wires are formed where the solid phase at block 110 of FIG. 2 comprises a metal reagent. Examples of solid phase metal reagents includes CaH 2 , CaBr 2 , Cp 2 Ti(CO) 2 , V(CO) 6 , Cr(CO) 6 , Cp 2 Cr, Mn 2 (CO) 10 , CpMn(CO) 3 , Fe 2 (CO) 9 , Co 2 (CO) 8 , CO 4 (CO) 12 , Cp 2 Co, Cp 2 Ni, Ni(COD) 2 , BaH 2 , [Ru(CO) 4 ] ∞ , Os 3 (CO) 12 , Ru 3 (CO) 12 , HFeCo 3 (CO) 12 , Co 2 (CO) 8 and H 2 FeRu 3 (CO) 13 . Metal reagents at block 110 may also be a liquid such as TiCl 4 or Fe(CO) 5 .
[0080] In another embodiment, the solid phase is a photoactive solid phase. For, example, the photoactive phase can be particulates of a carbon fullerene, carbon nanotubes, quantum dots of CdSe, PbS, Si or Ge, core-shell quantum dots of ZnSe/CdSe or Si/Ge.
[0081] At block 120 , the solution is ejected through a nozzle in a high electric field to form a substantially continuous nanofiber through an electrospinning process. Although expulsion of a single solution though a single nozzle is described in the embodiment of FIG. 2 , other solution and nozzle configurations can be used with the four and five-component inks. For example, a coaxial nozzle and dispenser system can be used that has an inner annulus and an outer annulus. The polymer, solid phase, and a solvent can be combined to form a viscous solution that is the source of fluid flowing through the outer annulus. The selected liquid silane and accelerant is a second source of fluid that is expressed through the inner annulus.
[0082] For example, the liquid silane flowing through the inner annulus is Si 6 H 12 cyclohexasilane, Si 6 H 12 1-silyl-cyclopentasilane or Si 5 H 10 cyclopentasilane and the solution flowing through the outer annulus is polyacrylonitrile in dimethylformamide and metal particulates or carbon nanotubes.
[0083] In another embodiment, a viscous mixture of a polymer and a solvent is produced and that mixture is ejected through the outer annulus of the nozzle while simultaneously ejecting a liquid silane through an inner annulus of the nozzle. The two streams are directed through a high electric field to form Core-Shell Fibers. The fibers are transformed to silicon wires with a carbon outer coating. Many other combinations are also possible with this coaxial nozzle configuration.
[0084] At block 130 of FIG. 2 , the nanofiber that is formed at block 120 from the electrospinning apparatus is deposited on a conductive substrate. The substrate at block 130 is preferably a metallic foil such as copper foil or aluminum foil. The substrate can also be a conducting carbon fiber matte including a carbon fiber matte constructed of carbon nanotubes. In one configuration, the substrate includes conductive metallic portions and insulating portions and the silicon-containing wires that are produced span the insulating portions of the substrate.
[0085] The produced fiber collected at block 130 can be transformed to amorphous silicon or crystalline silicon composites through thermal treatment or light activation via radical polymerization at block 140 . The deposited material can also be collected and transformed at a different time and location.
[0086] As with the four-component inks, the fibers produced from the five-component inks are typically transformed using thermal processing at temperatures from 150° C. to 300° C. to give polysilane-containing materials. The deposit can also be transformed using thermal processing at temperatures from 300° C. to 850° C. to produce amorphous silicon-containing materials. The deposit can also be transformed using thermal processing at temperatures from approximately 850° C. to 1414° C. giving crystalline silicon-containing materials. Some variation in these temperature ranges may be seen depending on the nature of the particular solid phase that is used in the ink. Finally, the deposit can be transformed using laser processing to give crystalline silicon-containing materials at block 140 .
[0087] An optional coherent, conductive coating may be applied to the transformed materials before or after the thermal treatments at block 150 of FIG. 2 . The coatings at block 150 can be applied by chemical vapor deposition using argon/acetylene, hydrogen/methane or nitrogen/methane as precursor gases. The coatings can also be applied by solution deposition using a dispersion of conducting carbon milled together with the silicon containing fraction and a solvent and graphite, C black, graphene, nanotubes or wires as a carbon source.
[0088] It can be seen that the coated or non-coated nanofibers or wires that are produced according to the invention can be used as components of other composite materials with further processing. This can be illustrated with the production of an electrically-conducting silicon-composite electrode with a four-component ink or a five-component ink. Referring also to FIG. 3 , a method 200 for producing an anode material according to the invention is schematically shown. At block 210 , nanofibers are produced by electrospinning four or five-component inks. The fibers are transformed at block 220 by thermal or laser processing. The processed fibers are coated with carbon at block 230 . The carbon coating can be applied with chemical vapor deposition or by solution deposition. Carbon coatings preferably include coatings of graphite, carbon black, graphene, or nanotubes or nanowires.
[0089] At block 240 the coated fibers are combined with an ion conducting binder to form the body of the electrode. The polymer binder may either be inherently lithium ion conducting, or may become lithium ion conducting by absorbing an electrolyte solution. The coated nanofibers are mixed with a binder to give a material structure that can be further sized and shaped. For example, the binder may include poly(vinylidene fluoride-co-hexafluoropropylene) or sodium carboxymethylcellulose. Some binders may be volatile and capable of being removed with additional thermal or laser treatments. Other binders may also be ion or electrically conductive or have a conductive filler such as a carbon particulate like KB carbon or graphite.
[0090] Electrodes with coated silicon fibers are resistant to cracking from the sizeable volume changes that occur during the lithiation and delithiation processes during cycling, for example. KB carbon is an elastic carbon and is capable of stretching and compressing during ordinary volume changes and is a preferred conductive binder or filler at block 240 .
[0091] In one embodiment, an electrode can be produced by: (a) combining a liquid silane of the formula Si n H 2n , with a polymer such as poly(methyl methacrylate), polycarbonate, poly(vinylidene fluoride-co-hexafluoropropylene), sodium carboxymethylcellulose or a mixture of polymers, an accelerant and a solvent to form a viscous solution; (b) exposing the viscous solution to a high electric field where continuous fibers are formed and deposited onto a metal foil substrate; (c) transforming the deposit into a material that contains a polysilane, an amorphous silicon and/or a crystalline silicon fraction by thermal treatment under inert gas at a temperature <400° C.; (d) forming a coherent, ion conductive coating on the external porosity of the silicon-containing fraction deposited by vapor or solution deposition; and (e) mixing the coated silicon nanofiber material with a binder of poly(vinylidene fluoride-co-hexafluoropropylene), sodium carboxymethylcellulose and/or KB carbon to form an electrode.
[0092] The invention may be better understood with reference to the accompanying examples, which are intended for purposes of illustration only and should not be construed as in any sense limiting the scope of the present invention as defined in the claims appended hereto.
Example 1
[0093] In order to demonstrate the functionality of the electrospinning methods with different formulations of liquid silane inks, a test reactor was constructed. All electrospinning processing and post-deposition treatments were performed inside inert nitrogen gas gloveboxes with active oxygen scrubbing unless otherwise specified. After appropriate ink formulation, ink solutions and/or mixtures were taken up into 1 mL HDPE syringes fitted with blunt-nosed 18 gauge stainless steel needles 2.5 cm in length. The ink-containing syringe and needle were placed into a syringe pump in horizontal position with a needle-to-substrate standoff distance of approximately 25 cm.
[0094] Metallic copper foil pieces (5 cm×5 cm×0.8 mm) were employed as the electrode substrate in the electrospinning process and were cleaned according to the following protocol: rinsing with approximately 5 mL isopropanol using a squirt bottle; rinsing with approximately 5 mL 1.5 M hydrochloric acid using a squirt bottle; rinsing with approximately 10 mL deionized water using a squirt bottle; and, drying with a stream of particulate-filtered high-purity nitrogen gas. These substrates were then introduced into an electrospinning process glovebox.
[0095] The substrates were then placed into deposition position by connecting the metallic foil to an acrylic backdrop using an alligator clip that also served to make electrical connection to the ground of the power supply. A high voltage source (Gamma High Voltage Research Inc. Model ES40P-12 W/DDPM) was connected with the positive terminal on the needle and the negative (ground) on the metallic substrate. The syringe pump (Cole Parmer model EW-74900-00) was set to a flow rate of 0.4-0.5 mL/h and allowed to run until the needle was primed with liquid. Once a droplet formed on the outside of the needle, the power source was adjusted to 15 kV. A collimated halogen light source was used to visualize the spinning solution/mixture. Immediately after the 15 kV was applied, spinning fibers were seen moving from the needle horizontally to the substrate. The ground plate and needle location were adjusted so that the fibers were deposited at the center of the foil.
[0096] Cyclosilanes such as Si 6 H 12 and Si 5 H 10 were prepared and distilled under reduced vacuum yielding 99+% pure colorless liquid (by 1 H NMR). The Si 5 H 10 was prepared by reacting Si 5 Cl 10 with LiAlH 4 and used without additional purification. Inert atmosphere gloveboxes and standard Schlenk techniques were used to preclude the oxidation of liquid silane. This is necessary because Si 6 H 12 and Si 5 H 10 are pyrophoric liquids that burn upon contact with air and are treated as an ignition source and handled in inert atmosphere. In addition, (SiH 2 ) n reacts slowly with air and moisture to give amorphous silica.
[0097] An three-component ink, Si 6 H 12 /PMMA in toluene, was first used to demonstrate the electrospinning methods and the thermolysis products without the accelerant were characterized as a baseline for comparison as shown in FIG. 4 . A solution of PMMA in toluene was prepared by adding 4.60 g of dry toluene to a flame-dried vial with 0.52 grams of PMMA (Aldrich P/N 182265-500G Lot#07227DH, MW=996,000) mixed via magnetic stirring. The mixture was heated to 75° C. to expedite dissolution of the polymer. Next, 500 μL of this PMMA/toluene solution was cooled to room temperature and 100 μL of Si 6 H 12 was added dropwise giving two colorless immiscible phases with one being rather viscous. After stirring for 15 minutes, the mixture appeared to be homogeneous with an apparent viscosity that was higher than either of the immiscible phases indicating the formation of a three-component microemulsion or a single-phase mixture. Electrospinning was realized as described above using a copper foil as the substrate. After electrospinning, a piece of the sample was cut off with a scissors and heat treated to approximately 350° C. for 30 minutes.
[0098] Samples of inks with a variety of potential accelerants were prepared at room temperature in an oxygen free atmosphere using syringe techniques following degassing of the individual compounds using 3 or more freeze-thaw cycles. Polymerization rates of various candidates were compared with the baseline.
Example 2
[0099] Electrospinning of a three-component ink, Si 6 H 12 /PMMA using the solvent dichloromethane (DCM), without the accelerant was conducted to demonstrate an alternative solvent and to characterize performance of the resulting material as an electrode. A solution of PMMA in DCM was prepared by adding 18.0 mL of dry DCM to a flame-dried vial with 2.681 g of PMMA mixed via magnetic stirring at 500 RPM for 3 h. Next, 8.220 g of this PMMA/DCM solution, 858 μL of DCM and 418 μL of Si 6 H 12 were added dropwise while magnetically stirring to give a mixture of two immiscible liquids. After stirring for 15 minutes, the mixture appeared to be homogeneous with an apparent viscosity that was higher than either of the immiscible phases indicating the formation of a three-component microemulsion or a single-phase mixture. Electrospinning was realized as described above using a copper foil as the substrate.
[0100] Immediately after electrospinning each 1 mL aliquot, the deposited wires were scraped off of the copper foil and placed inside a flame-dried vial. The vials containing the samples were then heated on a ceramic hotplate with an aluminum shroud to 550° C. with a ramp rate no slower than 16° C./minute, and held for 1 h. The microstructure of the heat-treated deposit was probed using high-resolution scanning electron microscope and shown to consist of porous wires and agglomerates with primary particle size ˜150 nm in diameter. Raman microscope characterization of the product confirmed the existence of amorphous silicon phase given the characteristic broad band at 485 cm −1 . The Raman laser could also transform the a-Si wires into crystalline Si as evidenced by a band at 516 cm −1 that was observed after the laser beam was focused to ˜100 kW/cm 2 .
[0101] Optical micrographs of the electrospun deposit subjected to the higher power density showed clear signs of melting and densification in the wire. An 80 mg sample of the heated sample was sent to Galbraith Laboratories (Knoxville, Tenn.) for ICP-OES and combustion analysis where duplicate analyses showed 83.6 wt % silicon and 6.6 wt % carbon.
[0102] The produced nanowire materials were then used to make anodes in electrochemical cells. Before assembly in pouch cells, the a-Si wires were exposed to air and loaded into a chemical vapor chamber where a thin conducting carbon layer ˜10 nm thick was deposited. Afterwards, the C-coated a-Si wires were moved into a second inert atmosphere argon-filled glove box (H 2 O and O 2 <1 ppm). Lithium metal/a-Si wire half-cells were fabricated using Celgard-2300 as the separator and 1 M LiPF 6 in ethylene carbonate:diethyl carbonate 1:1 as the electrolyte with a mass loading of 4 mg/cm 2 . Electrochemical testing was performed by cycling between 0.02 and 1.50 V at 100 mA/g using an Arbin model B2000 tester. Charge/discharge data for a half-cell comprised of lithium metal and chemical vapor deposition carbon-coated a-Si nanowires was obtained. Specific capacity data showed an initial capacity of 3400 mAh/g, a 2nd cycle capacity of 2693 mAh/g with a fade of 16.6% after 21 cycles.
Example 3
[0103] The product of a second three-component ink, Si 5 H 10 /PMMA in DCM, without the accelerant using a post deposit treatment of 550° C. for 60 minutes and laser exposure was characterized. A 10 wt % polymer solution was prepared by adding dried and nitrogen-sparged DCM into a flame-dried glass vial with PMMA dissolved by stirring for ˜12 h. At that time, 45 μL of Si 5 H 10 was added to the solution using a micropipette and this mixture was stirred for 10 minutes using a PTFE-coated magnetic stir bar. The copper foil substrate was cleaned and moved into the electrospinning glovebox before being mounted and connected to the apparatus. Electrospinning was performed with a 20 cm stand-off distance, a 12 kV excitation, 0.5 mL/h ink flow rate and a total solution volume of ˜75 μL was dispensed.
[0104] Post thermal treatment of the electrospun sample on copper foil was conducted in a nitrogen ambient (<1 ppm O 2 and H 2 O). The sample was placed on a room temperature ceramic hotplate, and covered with an aluminum heat shield to improve temperature uniformity. The hotplate was ramped to 550° C. no slower than 30° C./minute and held at nominally 550° C. for one hour after which time, the sample was removed from the hotplate and placed on a room temperature aluminum plate and allowed to quickly cool to ambient.
[0105] Optical micrographs of the electrospun collected sample depicted wires that were ˜1 μm in diameter. Raman characterization of these wires showed the existence of crystalline silicon after melting with the Raman laser.
Example 4
[0106] The product of a three-component ink Si 6 H 12 /QPAC100 in toluene, without the accelerant was characterized by two different post deposit treatments: heating at 350° C. for 20 minutes; or 355 nm laser exposure followed by heating at 350° C. for 20 minutes. The latter of these two processes is shown schematically in FIG. 5 .
[0107] A polymer solution was prepared by placing 1.06 g of dried toluene into a flame-dried vial and adding 120 mg QPAC100 while stirring with a PTFE-coated magnetic stir bar for 2.5 h at 500 rpm. At this time, 50 μL Si 6 H 12 was added via pipette and a slight immiscibility was noted. The mixture was stirred for ˜40 h yielding a homogeneous mixture. The copper foil substrate was cleaned and moved into the electrospinning glovebox before being mounted and connected to the apparatus. Prior to electrospinning, the substrate was heat treated for one minute at 350° C. to desorb any trace water. Electrospinning was performed with a 30 cm stand-off distance, 0.5 mL/h ink flow rate and a 10 kV excitation.
[0108] After spinning for one hour, the sample was removed and cut into pieces with one being subjected to thermal treatment at 350° C. for 20 minutes. Interestingly, no wire like deposit was noted by optical microscopy after this thermal treatment. Scanning electron microscopy characterization showed dark areas that originated from the electrospun deposits with Raman characterization indicating the presence of a-Si on the substrate.
[0109] A description of this phenomenon can be envisioned by consideration of the thermal properties of each of the constituents of this three-component ink. Firstly, Si 6 H 12 shows that evaporation begins at around 225° C. with some polymerization that gives 32.9% residual mass after heating to 350° C. Secondly, QPAC100 begins to thermalize around 150° C. with 50% mass loss observed at 270° C. and less than 1% residue at 350° C. Therefore, when the electrospun wire formed by the three-component Si 6 H 12 /QPAC100 ink without the accelerant was thermally-treated, the polymer component volatized prior to the formation of a structurally stable poly(dihydrosilane). As the Si 6 H 12 fraction was yet unpolymerized, nanosized Si films appeared as shadows of the original wires.
[0110] After spinning for one hour, the second sample was cut into pieces and one was placed in an air-tight container and transferred into a glovebox that contained a beam from a HIPPO laser (355 nm illumination, Spectra Physics Inc.). Variable laser powers of 500 mW, 1 W, 2 W, 3 W, and 4 W for 1 minute and also 500 mW and 4 W for 5 minutes transformed the Si 6 H 12 into polysilane as evidenced by the appearance of yellow/brown discolorations for incident areas of the Si 6 H 12 /QPAC100 deposit. After this photolysis step, the (SiH 2 ) n /QPAC100 sample was placed on a room temperature hotplate and heated to 341° C. for a total of 20 minutes. The a-Si wires that were formed were characterized by high-resolution scanning electron microscopy and shown to possess significant porosity. Raman characterization of the product confirmed the existence of amorphous silicon phase that was melted by focusing the Raman laser.
Example 5
[0111] The electrospun fibers of the ink PMMA/Si 6 H 12 /Co 2 (CO) 10 in DCM without an accelerant and the resulting thermolysis products were characterized. A solution of PMMA in toluene was prepared by adding 10.38 mL of dry toluene to a flame-dried vial with 980 mg of PMMA mixed via magnetic stirring. 50 mg of a cobalt/silicon solution and 1 mL of the PMMA/toluene solution were mixed in a 4 mL flame-dried vial. After stirring for 15 minutes, the mixture appeared to be homogeneous. Electrospinning was realized as described above using a copper foil as the substrate.
[0112] After electrospinning, a piece of the sample was cut off with a scissors and rapidly thermal annealed to ˜600° C. using an IR lamp. A piece of this sample was adhered to a glass slide with silver contacts which were deposited with a wood toothpick using fast-drying silver paint. Resistance across the two silver contacts was measured using a two-point method with the Agilent B1500A semiconductor analyzer using I-V analysis. Resistivity values were obtained by manually approximating the amount of wires which were connecting between the electrodes and approximating the length between the electrodes (2 mm) and approximating the wire diameter (3-4 μm). The resistance was measured and resistivity calculated to be 4×10 4 Ω-m.
[0113] The microstructure of the heat-treated wires was probed using a high resolution scanning electron microscope and shown to consist of wires with diameters from 1 to 3 μm. EDS mapping confirms the presence of cobalt and silicon within the wires. The non-polymer components of this four-component electrospinning ink (i.e., Si 6 H 12 and Co 2 (CO) 8 ) have previously been reported as reagents for forming silicon-cobalt films.
Example 6
[0114] Another ink, PMMA/Si 6 H 12 /CdSe in DCM, without an accelerant and its thermolysis products were characterized. A 10 wt % solution of PMMA in dried and nitrogen-sparged DCM was mixed for ˜12 h and then 0.931 g of this solution was added to a flame-dried glass vial. To that solution, 46 μL of Si 6 H 12 and 47 μL of CdSe quantum dots in toluene (Lumidot® 480 nm excitation, 5 mg/mL in toluene, Sigma Aldrich P/N662356) were stirred for 10 minutes using a Teflon-coated magnetic stir bar. Electrospinning employed a copper substrate and was performed as described above.
[0115] Post-deposition treatment of electrospun deposit was performed in a nitrogen ambient (<1 ppm O 2 and H 2 O). The sample was placed on a room temperature ceramic hotplate, and covered with an aluminum heat shield to improve temperature uniformity. The hotplate was ramped to 550° C. no slower than 30° C./minute and held at nominally 550° C. for one hour. Thereafter, the sample was removed from the hotplate and placed on a room temperature aluminum plate and allowed to quickly cool to ambient temperature. The sample was then analyzed by Raman spectroscopy and the characteristic peak for crystalline silicon was noted after treatment with the Raman laser as shown in FIG. 6 .
Example 7
[0116] A third ink, PMMA/Si 6 H 12 /Carbon Black in DCM, without an accelerant and its thermolysis products were characterized. A suspension of carbon black (Cabot Industries, Black Pearls 2000) was prepared by mixing 52 mg of the carbon black with 1 mL of dried and nitrogen-sparged DCM in a flame-dried glass vial and sonicated for 30 minutes.
[0117] In a second flame-dried glass vial was placed 0.963 g of a 10 wt % solution of PMMA in dried and nitrogen-sparged DCM was mixed for ˜12 h. To that solution, 48 μL of Si 6 H 12 and 12 mg of the dried sonicated carbon black suspension were stirred for 10 minutes using a Teflon-coated magnetic stir bar. Electrospinning employed a copper substrate and was performed as described previously.
[0118] Post-deposition treatment of the electrospun deposit was performed in a nitrogen ambient (<1 ppm O 2 and H 2 O) atmosphere. The sample was then placed on a room temperature ceramic hotplate, and covered with an aluminum heat shield to improve temperature uniformity. The hotplate was ramped to 550° C. no slower than 30° C./minute and held at nominally 550° C. for one hour after which time, the sample was removed from the hotplate and placed on a room temperature aluminum plate and allowed to quickly cool to ambient temperature. The sample was analyzed by Raman and the characteristic peak for crystalline silicon was noted after treatment with the Raman laser as shown in FIG. 6 .
Example 8
[0119] For comparison, a fourth ink, PMMA/Si 6 H 12 /graphite in DCM without an accelerant and its thermolysis products were characterized. A suspension of graphite (Asbury Carbon, grade 4934) was prepared by mixing 52 mg of the graphite with 1 mL of dried and nitrogen-sparged DCM in a flame-dried glass vial and sonicated for 30 minutes. A 10 wt % solution of PMMA in dried and nitrogen sparged DCM was mixed for ˜12 h and 0.942 g of this solution was added to a flame-dried glass vial. To that solution, 47 μL of Si 6 H 12 and 47 μL of the sonicated graphite suspension were stirred for 10 minutes using a Teflon-coated magnetic stir bar. Electrospinning employed a copper substrate and was performed as described above.
[0120] Post-deposition treatment of the electrospun deposit was performed in a nitrogen ambient (<1 ppm O 2 and H 2 O). The sample was placed on a room temperature ceramic hotplate, and covered with an aluminum heat shield to reduce temperature inhomogeneity. The hotplate was ramped to 550° C. no slower than 30° C./minute and held at nominally 550° C. for one hour after which time, the sample was removed from the hotplate and placed on a room temperature aluminum plate and allowed to quickly cool to ambient. The sample was analyzed by Raman and the characteristic peak for crystalline silicon was noted after treatment with the Raman laser as shown in FIG. 6 .
Example 9
[0121] The product of a fifth ink, PMMA/Si 6 H 12 /Ag in DCM without an accelerant was characterized for comparison. In this illustration, a suspension of silver nanoparticles (<100 nm diameter, Sigma Alrich P/N 576832) was prepared by mixing 35 mg of the silver nanopowder with 700 μL of dried and nitrogen-sparged DCM in a flame-dried glass vial and sonicated for 30 minutes. A 10 wt % solution of PMMA in dried and nitrogen-sparged DCM was mixed for ˜12 h at which time 0.923 g of this solution was added to a flame-dried glass vial. To that solution, 46 μL of Si 6 H 12 and 46 μL of the sonicated silver nanoparticle suspension were stirred for 10 minutes using a Teflon coated magnetic stir bar. Electrospinning employed a copper substrate and was performed as described above.
[0122] Post-deposition treatment of the electrospun deposit was performed in a nitrogen ambient (<1 ppm O 2 and H 2 O). The sample was placed on a room temperature ceramic hotplate, and covered with an aluminum heat shield to improve temperature uniformity. The hotplate was ramped to 550° C. no slower than 30° C./minute and held at nominally 550° C. for one hour after which time, the sample was removed from the hotplate and placed on a room temperature aluminum plate and allowed to quickly cool to ambient. The sample was analyzed by Raman and the characteristic peak for crystalline silicon was observed after treatment with the Raman laser as shown in FIG. 6 .
Example 10
[0123] A sixth ink, PMMA/Si 6 H 12 /AIP in DCM, without an accelerant was characterized to further demonstrate the breadth of the methods. A 10 wt % solution of PMMA in dried and nitrogen-sparged DCM was mixed for ˜12 h after which time 0.949 g of this solution was added to a flame-dried glass vial. To that solution, 47 μL of Si 6 H 12 and 47 μL of an amphiphilic invertible polymer (AIP) (synthesized from poly(ethylene glycol) (PEG) and aliphatic dicarboxylic acids) were stirred for 10 minutes using a Teflon coated magnetic stir bar. Electrospinning employed a copper substrate and was performed as described above.
[0124] Post-deposition treatment of electrospun deposit was performed in a nitrogen ambient (<1 ppm O 2 and H 2 O). The sample was placed on a room temperature ceramic hotplate, and covered with an aluminum heat shield to improve temperature uniformity. The hotplate was ramped to 550° C. no slower than 30° C./minute and held at nominally 550° C. for one hour after which time, the sample was removed from the hotplate and placed on a room temperature aluminum plate and allowed to quickly cool to ambient. The sample was analyzed by Raman and the characteristic peak for crystalline silicon was noted after treatment with the Raman laser as shown in FIG. 6 .
Example 11
[0125] The products of a seventh ink, PMMA/Si 6 H 12 /BBr 3 in DCM without an accelerant were also characterized. A 10 wt % solution of PMMA in dried and nitrogen-sparged DCM was mixed for ˜12 h and 0.931 g of this solution was added to a flame-dried glass vial. To that solution, 46 μL of Si 6 H 12 and 1.5 μL of BBr 3 (>99.99% pure, Sigma Aldrich P/N 230367) were added and stirred for 10 minutes using a Teflon-coated magnetic stir bar. Electrospinning employed a copper substrate and was performed as described above.
[0126] Post-deposition treatment of the electrospun deposit was performed in a nitrogen ambient (<1 ppm O 2 and H 2 O). The sample was placed on a room temperature ceramic hotplate, and covered with an aluminum heat shield to improve temperature uniformity. The hotplate was ramped to 550° C. no slower than 30° C./minute and held at nominally 550° C. for one hour after which time, the sample was removed from the hotplate and placed on a room temperature aluminum plate and allowed to quickly cool to ambient. The sample was analyzed by Raman and the characteristic peak for crystalline silicon was noted after treatment with the Raman laser as shown in FIG. 6 .
Example 12
[0127] The electrospin products of an eighth ink, PMMA/Si 6 H 12 /PBr 3 in DCM, without an accelerant were characterized for comparison. A 10 wt % solution of PMMA in dried and nitrogen-sparged DCM was mixed for ˜12 h at which time 1.522 g of this solution was added to a flame-dried glass vial. To that solution, 75 μL of Si 6 H 12 and 2.3 μL of PBr 3 (>99.99% pure, Sigma Aldrich P/N 288462) were stirred for 10 minutes using a Teflon coated magnetic stir bar. Electrospinning employed a copper substrate and was performed as described above.
[0128] Post-deposition treatment of the electrospun deposit was performed in a nitrogen ambient (<1 ppm O 2 and H 2 O). The sample was placed on a room temperature ceramic hotplate, and covered with an aluminum heat shield to improve temperature uniformity. The hotplate was ramped to 550° C. no slower than 30° C./minute and held at nominally 550° C. for one hour after which time, the sample was removed from the hotplate and placed on a room temperature aluminum plate and allowed to quickly cool to ambient. The sample was analyzed by Raman and the characteristic peak for crystalline silicon was noted after treatment with the Raman laser as shown in FIG. 6 .
Example 13
[0129] The products of a ninth ink, PMMA/Si 6 H 12 /CNTs in DCM without an accelerant were also characterized. A 10 wt % solution of PMMA in dried and nitrogen-sparged DCM was mixed for ˜12 h at which time 1.960 g of this solution was added to a flame-dried glass vial that contained 4.04 mg of carbon nanotubes (Sigma Aldrich P/N 704148). To that solution, 98 μL of Si 6 H 12 were added and stirred for 10 minutes using a Teflon coated magnetic stir bar. Electrospinning employed a copper substrate and was performed as described above.
[0130] Post-deposition treatment of the electrospun deposit was performed in a nitrogen ambient (<1 ppm O 2 and H 2 O). After spinning, the sample was cut into pieces and one was placed in an air-tight container and transferred into a glovebox that contained a beam from a HIPPO laser (355 nm illumination, Spectra Physics Inc.). A laser power of 750 mW with a 1 cm 2 spot size was used to scan across the entire sample at a rate of 5 mm/s. After this photolysis step, the (SiH 2 ) n /PMMA sample was placed on a room temperature hotplate and heated to 350° C. at a ramp rate of 50° C./10 minutes. The sample was analyzed by Raman and the characteristic peak for crystalline silicon, as well as the D and G bands of the carbon nanotubes were noted after treatment with the Raman laser.
Example 14
[0131] The spin coating of thin films using a Si 6 H 12 /PMMA in DCM ink was demonstrated and compared with nanofibers produced by a conventional nozzle. A 10 wt % solution of PMMA in dried and nitrogen-sparged DCM was mixed for ˜12 h at which time 0.862 g of this solution was transferred to a flame-dried glass vial. To that solution, 43 μL of Si 6 H 12 was added and then stirred for 10 minutes using a Teflon-coated magnetic stir bar. The solution volume was then doubled by diluting with additional DCM.
[0132] Fused silica and quartz (1 cm×1 cm×1 mm) were employed as substrate in the spin coating process and were cleaned according to the following protocol: Liquinox™ detergent cleaning by rubbing for 30 sec with a latex glove; rinsing in a stream of hot water for 15 seconds; rinsing with ˜10 mL deionized water using a squirt bottle; rinsing with ˜10 mL acetone using a squirt bottle; rinsing with ˜10 mL isopropanol using a squirt bottle; and, drying with the flame of a propane torch. For the spin-coating procedure, 30 μL of the Si 6 H 12 /PMMA sample was dispensed onto a quartz substrate while spinning at 3000 RPM and under UV irradiation from a Hg(Xe) arc lamp (Newport Corp, lamp model 66142, power density ˜50 mW/cm 2 ) with a dichroic mirror used to filter the infrared photons.
[0133] Thermal treatment of samples deposited on fused silica and quartz was conducted in a nitrogen ambient (<1 ppm O 2 and H 2 O). The samples were placed on a room temperature aluminum hotplate and covered with an aluminum heat shield to improve temperature uniformity. The hotplate was ramped to 350° C. at 250° C./h at which time the thermal treatment was quenched by removing the sample from the hotplate to an aluminum plate at ambient temperature. Raman characterization of these films showed the existence of crystalline silicon after melting with the Raman laser.
Example 15
[0134] Spin coating of thin films using a Si 6 H 12 /PMMA/Ag in DCM ink without an accelerant was conducted to illustrate fiber formation from a thin film for comparison with other fiber producing methods. A mixture of silver nanoparticles (<100 nm diameter, Sigma Alrich P/N 576832) was prepared by mixing 35 mg of the silver nanopowder with 700 μL of dried and nitrogen-sparged DCM in a flame-dried glass vial. The vial was placed in an ultrasonic bath and treated with sonics for 30 minutes. A 10 wt % solution of PMMA in dried and nitrogen-sparged DCM was mixed for ˜12 h at which time 0.923 g of this solution was transferred to a flame-dried glass vial. To this PMMA solution was added 46 μL of Si 6 H 12 and 46 μL of the sonicated Ag/DCM mixture and the entire contents were stirred for 10 minutes using a Teflon-coated magnetic stir bar. The solution volume was then doubled by diluting with additional DCM.
[0135] Fused silica and quartz substrates (1 cm×1 cm×1 mm) were cleaned as described above. Thin films were prepared by spun-coating as described above using 30 μL of the four-component ink (Si 6 H 12 /PMMA/Ag). After spin-coating, thermal treatment of samples deposited on fused silica and quartz was conducted in a nitrogen ambient (<1 ppm O 2 and H 2 O). The samples were placed on a room temperature aluminum hotplate and covered with an aluminum heat shield to improve temperature uniformity. The hotplate was ramped to 350° C. at 250° C./h at which time the thermal treatment was quenched by removing the sample from the hotplate to an aluminum plate at ambient temperature. Raman characterization of these films showed the existence of crystalline silicon after melting with the Raman laser.
Example 16
[0136] In some instances a liquid that serves as a solvent for the polymer may react with Si 6 H 12 . A coaxial electrospinning approach can be employed to circumvent the deleterious interaction of Si 6 H 12 with some solvents. The product formed by coaxial electrospinning where neat Si 6 H 12 and a poly(acrylonitrile) (PAN) in dimethylformamide (DMF) solution were expelled from the inner and outer tubes, respectively was heat treated to 350° C. in nitrogen ambient for one hour, in air at 350° C. for one hour, and in nitrogen at 800° C. for one hour.
[0137] The PAN in DMF solution was prepared by placing 2.465 g of dried DCM into a flame-dried vial and adding a total of 548 mg PAN while stirring with a PTFE-coated magnetic stir bar for 24 h at 500 rpm. A 7.62 cm×7.62 cm×0.762 mm copper foil substrate was cleaned as previously mentioned and moved into the electrospinning glovebox before being mounted and connected to the apparatus. Electrospinning was performed with a 20 cm stand-off distance, 0.5 mL/h flow rate of both the inner and outer fluids and a 10 to 19 kV excitation.
[0138] After spinning for one hour, the sample was removed and subjected to thermal treatment at 350° C. for one hour on a hotplate in nitrogen ambient (<1 ppm O 2 and H 2 O) with a ramp rate of 200° C./h, followed by tube furnace treatment in air at 350° C. for one hour and nitrogen ambient at 800° C. for one hour. Optical microscopy of the annealed coaxial electrospun sample confirms the presence of wire-like deposits with diameter ˜1 μm. Raman analysis of this same sample shows the presence of silicon, as evidenced by a ˜480 cm −1 and 520 cm −1 bands corresponding to a-Si and c-Si, respectively.
[0139] A description of this phenomenon can be envisioned by consideration of the thermal properties of each of the constituents of this three-component ink. Firstly, Si 6 H 12 shows that evaporation begins at around 225° C. with some polymerization that gives 32.9% residual mass after heating to 350° C. Secondly, PAN crosslinks around 350° C. in air and thermalizes to carbon around 800° C. in nitrogen. Therefore, when the coaxial electrospun wires formed from the three-component Si 6 H 12 /PAN ink were thermally-treated, the silicon component converts to a-Si and/or c-Si and the polymer component carbonizes to form structurally stable and conductive carbon.
Example 17
[0140] Polyhydropolysilanes with linear, branched, and cyclic structures accelerate the polymerization of CHS when one or more of these compounds are added to CHS and the resulting mixture is exposed to energy from thermal, electromagnetic, or mechanical sources.
[0141] For example, polyhydropolysilanes of formula Si n H n+2 , linear or branched, individually, or in combination, have been shown to accelerate the polymerization of CHS when added to CHS.
[0142] Linear and branched polyhydropolysilanes of formula Si n H n+2 , where n ranges from 2-10,000, when mixed with CHS, accelerates polymerization to form films that can be placed in a variety of devices that respond to light, e.g., solar cells.
[0143] Polyhydropolysilanes composed of one or more polyhydrocyclopolysilane rings attached to another polyhydrocyclopolysilane, with or without substituent's on the ring, were also been shown to accelerate the polymerization of CHS when added to CHS.
[0144] Polyhydropolysilanes composed of one or more cyclopolysilane rings, with or without substituents on the ring, will also accelerate the polymerization of CHS when added to CHS.
Example 18
[0145] Samples comprised of 1%-50% (by volume) of a linear silane such as Si 3 H 8 , dissolved in CHS showed accelerated polymerization rates of 10%-200% compared to polymerization of pure CHS when exposed to energy from thermal, electromagnetic, or mechanical sources.
Example 19
[0146] Samples comprised of 1%-50% (by volume) of a branched polysilane such as neopentasilane, (H 3 Si) 4 Si, dissolved in CHS showed accelerated polymerization rates of 10%-200% compared to polymerization of pure CHS when exposed to energy from thermal, electromagnetic, or mechanical
Example 20
[0147] CPS (cyclopentasilane, Si 8 H 10 ), when mixed with CHS, was shown to accelerate the polymerization of CHS when added to CHS. Samples comprised of 1% to 50% (by volume) CPS dissolved in CHS have accelerated polymerization rates of 10% to 200% compared to polymerization of pure CHS when exposed to light in the ultraviolet range or temperatures in excess of 80 deg C.
[0148] Derivatives of CPS with one or more silyl groups attached to the ring, when mixed with CHS, were also shown to accelerate polymerization of CHS. Experiments were also conducted on samples sizes of 10 mg to 10 g. It was discovered that H 3 Si—Si 5 H 9 , where the Si 5 H 9 represents a cyclopentasilane structure, absorbs light efficiently in the 200 nm to 210 nm range and that exposure of mixtures of this compound with CHS could be readily polymerized at these wavelengths. This observation is expected to be the same for all compounds containing five silicon atoms in a ring. Pure CHS and pure CPS do not have significant absorptions of light at wavelengths greater than 200 nm. The fact that the H 3 Si—Si 5 H 9 , where the Si 5 H 9 represents a cyclopentasilane structure, is responsive to lower energy light was unexpected. Therefore, CHS can be polymerized with lower energy light using these accelerants. These technologies represent potentially significant cost savings in the production of many silicon containing materials.
Example 21
[0149] Silylcyclopentasilane was shown to accelerate polymerization and film formation of CHS and other liquid silanes. This structure has the formula of Si 6 H 12 , but is comprised of a five membered ring of silicon atoms with the 6 th silicon attached to the ring. Samples comprised of 1% to 50% (by volume) of silylcyclopentasilane dissolved in CHS showed accelerated polymerization rates of 10% to 200% compared to polymerization of pure CHS when exposed to energy from thermal, electromagnetic, or mechanical sources. In one example, the addition of silylcyclopentasilane to CHS, allows more efficient absorption of wavelengths above 200 nm than a sample of pure CHS. The light used for this compound is of lower energy than is needed for both CPS and CHS.
Example 22
[0150] Additionally, derivatives of CHS with one or more linear or branched silyl groups attached to the ring, when mixed with CHS, accelerate polymerization of CHS. It was also observed that partially or fully halogenated silanes and polysilanes accelerate polymerization of CPS and CHS.
[0151] It can be seen that many different novel four-component or five-component inks can be devised to commercially produce silicon based nanowires and similar materials in electrospinning reactors, and the accelerants can be selected to accelerate polymerization and reduce the energy input necessary to produce the silicon based materials.
[0152] From the discussion above it will be appreciated that the invention can be embodied in various ways, including the following:
[0153] 1. A method for synthesizing silicon nanofibers, comprising combining a liquid silane, a polymer, an accelerant and a solvent to form a viscous solution, passing a stream of viscous solution through a high electric field to form fibers, depositing the formed fibers onto a substrate, and transforming the deposited fibers into a silicon nanostructure.
[0154] 2. A method for synthesizing silicon nanofibers, comprising: combining a liquid silane, a polymer, an accelerant, a solid phase and a solvent to form a viscous solution, passing a stream of viscous solution through a high electric field to form fibers, depositing the formed fibers onto a substrate, and transforming the deposited fibers into an silicon nanostructure.
[0155] 3. The method as recited in embodiment 1 or 2, wherein the accelerant comprises cyclopentasilane and the liquid silane comprises cyclohexasilane.
[0156] 4. The method as recited in embodiment 1 or 2, wherein the accelerant comprises a Si substituted cyclopentasilane of the formula H 3 Si—Si 5 H 9 (n-silylcyclopentasilane).
[0157] 5. The method as recited in any of the proceeding embodiments, wherein the transformation of the deposited fibers comprises exposure of the formed fibers to light with a wavelength within the range of 200 nm to 210 nm.
[0158] 6. The method as recited in embodiment 1 or 2, wherein the accelerant comprises a polyhydropolysilane of formula Si n H n+2 where n ranges from 2-10,000.
[0159] 7. The method as recited in embodiment 1 or 2, wherein the accelerant is selected from the group of accelerants consisting of: a linear silane of formula Si 3 H 8 , a cyclohexasilane derivative with one or more linear or branched silyl groups attached to the ring, a halogenated silane, a polyhydrocyclopolysilane ring attached to another polyhydrocyclopolysilane and neopentasilane of formula (H 3 Si) 4 Si.
[0160] 8. The method as recited in any of the preceding embodiments, wherein the polymer is selected from the group of polymers consisting essentially of poly(methyl methacrylate), polycarbonate, poly(vinylidene fluoride-co-hexafluoropropylene), and polyvinyl butryal.
[0161] 9. The method as recited in any of the preceding embodiments, wherein the solvent is selected from the group of solvents consisting essentially of toluene, xylene, cyclooctane, 1,2,4-trichlorobenzene, dichloromethane or mixtures thereof.
[0162] 10. The method as recited in any of the preceding embodiments, further comprising coating the transformed fibers with a coherent, conductive coating selected from the group of coatings consisting essentially of graphite, carbon black, KB Carbon, carbon nanotubes and graphene.
[0163] 11. An electrospinning ink composition, comprising a liquid silane of the formula Si n H 2n , an accelerant, a polymer, and a solvent.
[0164] 12. An electrospinning ink composition, comprising: a liquid silane of the formula Si n H 2n , an accelerant, a polymer, a solid phase, and a solvent.
[0165] 13. The ink composition as recited in embodiment 11 or 12, wherein the liquid silane comprises a liquid silane is a cyclosilane selected from the group of cyclosilanes consisting essentially of cyclopentasilane, cyclohexasilane and 1-silylcyclopentasilane.
[0166] 14. The ink composition as recited in any of the preceding embodiments, wherein the liquid silane comprises a liquid silane of the formula Si n H 2n+2 .
[0167] 15. The ink composition as recited in embodiment 11 or 12, wherein the accelerant comprises cyclopentasilane.
[0168] 16. The ink composition as recited in embodiment 11 or 12, wherein the accelerant comprises a Si substituted cyclopentasilane of the formula H 3 Si—Si 5 H 9 (n-silylcyclopentasilane).
[0169] 17. The ink composition as recited in embodiment 11 or 12, wherein the accelerant comprises a polyhydropolysilane of formula Si n H n+2 where n ranges from 2-10,000.
[0170] 18. The ink composition as recited in embodiment 11 or 12, wherein the accelerant is selected from the group of accelerants consisting of: a linear silane of formula Si 3 H 8 , a cyclohexasilane derivative with one or more linear or branched silyl groups attached to the ring, a halogenated silane, a polyhydrocyclopolysilane ring attached to another polyhydrocyclopolysilane and neopentasilane of formula (H 3 Si) 4 Si.
[0171] 19. The ink composition as recited in embodiment 12, wherein the solid phase is a metallic particle selected from the group of metal particles consisting essentially of metallic particles of Al, Au, Ag, Cu, In—Sn—O, fluorine-doped tin oxide and carbon black.
[0172] 20. The ink composition as recited in embodiment 12, wherein the solid phase is a semiconducting particle selected from the group of semiconducting particles consisting essentially of carbon nanotubes, silicon nanowires, polydihydrosilane (Si n H 2 ) n , CdSe, CdTe, PbS, PbSe, ZnO and Si.
[0173] 21. The ink composition as recited in embodiment 12, wherein the solid phase is a metal reagent selected from the group of metal reagents consisting essentially of CaH 2 , CaBr 2 , Cp 2 Ti(CO) 2 , TiCl 4 , V(CO) 6 , Cr(CO) 6 , Cp 2 Cr, Mn 2 (CO) 10 , CpMn(CO) 3 , Fe(CO) 5 , Fe 2 (CO) 9 , Co 2 (CO) 8 , CO 4 (CO) 12 , Cp 2 Co, Cp 2 Ni, Ni(COD) 2 , BaH 2 , [Ru(CO) 4 ] ∞ , Os 3 (CO) 12 , Ru 3 (CO) 12 , HFeCo 3 (CO) 12 , and H 2 FeRu 3 (CO) 13 .
[0174] 22. An ink composition as recited in embodiment 12, wherein the solid phase is a photoactive particle selected from the group of photoactive particles consisting essentially of a carbon fullerene, a quantum dot of CdSe, PbS, Si or Ge, and a core-shell quantum dot of ZnSe/CdSe or Si/Ge.
[0175] Although the description above contains many details, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.” | Described herein are synthesis schemes and methods for producing silicon based nanostructures and materials, including compositions and methods for synthesis of silicon-based nanowires and composites from four-component inks of a liquid silane, a polymer, an accelerant and a solvent, or from five-component inks of a liquid silane, a polymer, an accelerant, a solid phase and a solvent. The methods can be used for producing silicon based microfibers and nanofibers that can be used in a variety of applications including material composites, electronic devices, sensors, photodetectors, batteries, ultracapacitors, and photosensitive substrates. | 3 |
BACKGROUND OF THE INVENTION
[0001] AAV vectors offer unique advantages over other vector systems in gene therapy applications. Studies have shown that these replication deficient parvovirus vectors can deliver DNA to specific tissues and confer long-term transgene expression in a variety of systems. Although many studies have looked at the tissue-specific expression elicited by each of the AAV serotypes, a true understanding of how AAV transduces these tissues is still unclear. Of the large AAV family, only a few receptors or co-receptors have been identified for any of the parvoviruses. The ability to better target transduction to specific tissues on the basis of the receptors that each serotype uses for entry, is essential to enable users to pick a serotype given the receptor expression in specific tissue, or to exploit altered receptor expression under disease conditions.
[0002] AAV6 has been reported to effectively transduce muscle, lung, brain, and multiple types of tumors, including gliomas and lung adenocarcinomas, and to elicit lower serum-neutralizing antibody concentrations when compared with AAV2. As such, there exists a need for improving the treatment of patients suffering from diseases such as cancer, which could be treated by AAV6 vector based gene therapy.
BRIEF SUMMARY OF THE INVENTION
[0003] In accordance with the present invention, it was found that the epidermal growth factor receptor (EGFR) is a co-receptor for AAV6 infection in mammalian cells, and is necessary for efficient vector internalization.
[0004] In an embodiment, the invention provides a method for introducing a heterologous nucleic acid into a host cell expressing EGFR comprising providing a pharmaceutical composition comprising a recombinant adeno-associated virus (AAV) vector comprising the AAV subtype 6 (AAV6) viral genome, or a functional portion thereof, and containing a heterologous nucleic acid sequence capable of being expressed by the host cell, under conditions which allow transduction of the host cell; and transducing the host cell with the recombinant AAV6 vector.
[0005] In a further embodiment, the host cell is a mammalian cell. In addition, in another embodiment, the host cell is a cancer cell. In yet another embodiment, the cancer cell is derived from a tumor of the head or neck.
[0006] In an embodiment of the present invention, the heterologous nucleic acid sequence can be either DNA or RNA, and can encode for a polypeptide.
[0007] In a further embodiment of the present invention, the heterologous nucleic acid encodes a gene that increases the host cell's susceptibility to a prodrug or cytotoxic agent. For example, in an embodiment, the heterologous nucleic acid can encode an enzyme that when expressed in the cell in the presence of an agent or prodrug, causes modification of the agent into a cytotoxin, which then kills the host cell.
[0008] In another embodiment, the method includes a period of time between the administration of a therapeutically effective amount of a pharmaceutical composition comprising a recombinant AAV6 vector which encodes a gene that increases the host cell's susceptibility to a prodrug or cytotoxic agent, and the administration of a therapeutically effective amount of a pharmaceutical composition comprising the specific prodrug or cytotoxic agent. In an embodiment, the method of the present invention includes administration of one or more additional chemotherapeutic agents either concurrently with, or, after administration of the pharmaceutical composition comprising a recombinant AAV6 vector and the administration of a therapeutically effective amount of a pharmaceutical composition comprising the specific prodrug or cytotoxic agent.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0009] FIG. 1 is a pie chart illustrating that of the top 1000 genes returned by the program COMPARE, 760 genes were associated with identifiable gene names, of which 226 genes had established pathway interactions. Of these genes with known pathway interactions, 169 (75%) were found to be involved in EGFR signaling, with 21 (9%) having a direct interaction with, or regulation of, the EGF receptor (ERBB1).
[0010] FIG. 2 is a graph showing the quantification of FACS analysis of 32D-EGFR cells 96 hours after transduction with AAV2, AAV5, AAV1 or AAV6-CMV-EGFP. ***P<0.0001, n=3.
[0011] FIG. 3 shows two graphs that depict HEK293T and HN13 cells that were transfected with EGFR and siRNA against EGFR. Expression levels were quantified by western blotting, and the results are expressed as the percentage which are positive for GFP relative to controls. Cells were transduced by AAV2 or AAV6-CMV-eGFP (***P<0.0001, n=3).
[0012] FIG. 4 is a FACS analysis of HEK293T cells preincubated with one of the EGFR-specific inhibitors, AG1478 (Tyrphostin) or gefitinib (Iressa®, 4-(3-Chloro-4-fluorophenylamine)-7-methoxy-6(3-(4-morpholinyl)quinazoline), and subsequently incubated with AAV6-CMV-eGFP, to evaluate the impact of EGFR function on AAV6 mediated transduction. AAV2 transduction was not significantly influenced by EGFR inhibition. ***P<0.0001, n=3.
[0013] FIG. 5A is a graph showing internalization of AAV6 in 32D-EGFR cells. Internalization was measured in the presence or absence of gefitinib to evaluate the impact of function EGFR on AAV6 internalization. *P<0.01, n=3.
[0014] FIG. 5B is a graph depicting immunoprecipitation of AAV after incubating AAV2, AAV5, or AAV6 with protein A-sepharose beads alone, or with beads precoated with rhEGFR-Fc, or rhFGFR-Fc. ***P<0.0001, n=3.
[0015] FIG. 6 shows that AAV6 transduces tumor cells with functional EGFR expression. In vitro transduction of HEp-2 and HN12 cells with AAV2 and AAV6 in the presence or absence of the EGFR inhibitor, AG1478, was studied. A statistically significant increase in AAV6-mediated transduction was found in HN12 cells compared to HEp-2 cells (**p<0.001, n=3). Transduction of HN12 cells in the presence of AG1478 was reduced by 77% (***p<0.0005, n=3). An increase in AAV2-mediated transduction in HEp-2 cells compared to HN12 cells was noted (**p<0.001, n=3). There was no significant (NS) difference in AAV2-mediated transduction of HEp-2 or HN12 cells in the presence or absence of AG1478.
[0016] FIG. 7 depicts photographs showing evidence of AAV6 mediated transduction of EGFR expressing tumors and delivery of the cytotoxic transgene, HSVtk, followed by ganciclovir treatment, results in a significant reduction in tumor growth. Head and neck tumor cell lines, HN12 and HEp-2, were injected subcutaneously into the right and left flank of female nude mice. After tumors were established, AAV6-CMV-luciferase was introduced by direct intratumoral injection to the right flank tumors, with the vehicle control injected into the left flank tumors. Ten days after AAV administration, in vivo luciferase activity was measured by bioluminescence after intraperitoneal injection of luciferin (representative images, n=5).
[0017] FIG. 8 shows that AAV6 is able to deliver transgene to HNSCC xenograft tumors with high expression of EGFR. To further verify AAV-mediated transduction of the HNSCC tumors in the xenograft model, HN12 and HEp-2 tumor tissue was isolated and presence of transgene was quantified. Total DNA was isolated from tumors that received AAV6-CMVLuciferase (AAV6-CMV-Luc), or vehicle control, and the number of copies of vector genome/mg tissue were quantified by QPCR. HN12 tumors injected with AAV6-CMV-luciferase contained 4.6×10 4 ±0.1×10 4 copied vector genome/mg tissue. In contrast, AAV6-CMV-luciferase vector in HEp-2 cells was at background. ***p<0.0001, n=3.
[0018] FIG. 9 is a graph depicting the percentage growth of HN12 tumors injected with AAV6-CMV-HSVtk, followed by ganciclovir (GCV) treatment, and HN12 tumors treated with GCV alone. The HN12 xenograft tumors received intratumoral injections of AAV6-CMV-HSVtk. One week after AAV6 transduction, mice were started on daily GCV injections. Arrow indicates day GCV treatment was started. *P<0.05, **P<0.001, n=9.
DETAILED DESCRIPTION OF THE INVENTION
[0019] In accordance with the present invention, it was found that the epidermal growth factor receptor (EGFR) is a co-receptor for AAV6 infection in mammalian cells, and is necessary for efficient vector internalization.
[0020] In an embodiment, the invention provides a method for introducing a heterologous nucleic acid into a host cell expressing EGFR comprising providing a pharmaceutical composition comprising a recombinant adeno-associated virus (AAV) vector comprising the AAV subtype 6 (AAV6) viral genome, or a functional portion thereof, and containing a heterologous nucleic acid sequence capable of being expressed by the host cell, under conditions which allow transduction of the host cell; and transducing the host cell with the recombinant AAV6 vector.
[0021] In an embodiment of the present invention, the transduction of the host cell can be either in vivo or in vitro.
[0022] In a further embodiment, the host cell is a mammalian cell. In addition, in another embodiment, the host cell is a cancer cell. In yet another embodiment, the cancer cell is derived from a tumor of the head or neck.
[0023] In an embodiment of the present invention, the heterologous nucleic acid sequence can be either DNA or RNA, and can encode for a polypeptide.
[0024] In another embodiment, the heterologous nucleic acid encodes proteins or polypeptides that replace missing or defective proteins required by the cell or subject into which the vector is transferred, or encodes a gene for a missing or defective protein, or can encode a cytotoxic polypeptide that can be directed, e.g., to cancer cells or other cells whose death would be beneficial to the subject.
[0025] In a further embodiment of the present invention, the heterologous nucleic acid encodes a polypeptide or protein that increases the host cell's susceptibility to a prodrug or cytotoxic agent, or encodes for a gene for said polypeptide or protein. For example, in an embodiment, the heterologous nucleic acid can encode a gene for an enzyme that when expressed in the cell in the presence of an agent or prodrug, causes modification of the agent into a cytotoxin, which then kills the host cell. For example, in an embodiment, the heterologous nucleic acid can encode at least one of the following enzymes selected from the group consisting of: E. coli nitroreductase, cytosine deaminase, Varicella Zoster-tk, Cytochrome P450 B1 (CYP2B1), carboxypeptidase G2 (CPG2) and E. coli purine nucleoside phosphorylase (ePNP), and the cells are then exposed to an agent or prodrug selected from the group consisting of: CB1954 (5-[aziridin-1-yl]-2,4-dinitrobenzamide), 5-FC (5-Fluorocytosine), araM (6-methoxy purine arabinoside), CPA (cyclophosphamide), benzoic acid mustard glutamates, and 6-methylpurine 2′-deoxyriboside (MePdR) respectively. In another embodiment, the heterologous nucleic acid encodes Herpes Simplex Virus thymidine kinase enzyme (HSV-tk), and the agent is an antiviral agent in the class of nucleotide analogs, such as acyclovir or ganciclovir.
[0026] In yet another embodiment of the present invention, the heterologous nucleic acid can also encode EGFR.
[0027] In an embodiment, the method includes a period of time between the administration of a therapeutically effective amount of a pharmaceutical composition comprising a recombinant AAV6 vector which encodes a gene that increases the host cell's susceptibility to a prodrug or cytotoxic agent, and the administration of a therapeutically effective amount of a pharmaceutical composition comprising the specific prodrug or cytotoxic agent. In another embodiment, the method of the present invention includes administration of one or more additional chemotherapeutic agents either concurrently with, or, after administration of the pharmaceutical composition comprising a recombinant AAV6 vector and the administration of a therapeutically effective amount of a pharmaceutical composition comprising the specific prodrug or cytotoxic agent.
[0028] By “nucleic acid” as used herein includes “polynucleotide,” “oligonucleotide,” and “nucleic acid molecule,” and generally means a polymer of DNA or RNA, which can be single-stranded or double-stranded, synthesized or obtained (e.g., isolated and/or purified) from natural sources, which can contain natural, non-natural or altered nucleotides, and which can contain a natural, non-natural or altered internucleotide linkage, such as a phosphoroamidate linkage or a phosphorothioate linkage, instead of the phosphodiester found between the nucleotides of an unmodified oligonucleotide. It is generally preferred that the nucleic acid does not comprise any insertions, deletions, inversions, and/or substitutions. However, it may be suitable in some instances, as discussed herein, for the nucleic acid to comprise one or more insertions, deletions, inversions, and/or substitutions.
[0029] In an embodiment, the nucleic acids of the invention are recombinant. As used herein, the term “recombinant” refers to (i) molecules that are constructed outside living cells by joining natural or synthetic nucleic acid segments to nucleic acid molecules that can replicate in a living cell, or (ii) molecules that result from the replication of those described in (i) above. For purposes herein, the replication can be in vitro replication or in vivo replication.
[0030] The nucleic acids can be constructed based on chemical synthesis and/or enzymatic ligation reactions using procedures known in the art. See, for example, Sambrook et al. (eds.), Molecular Cloning, A Laboratory Manual, 3 rd Edition, Cold Spring Harbor Laboratory Press, New York (2001) and Ausubel et al., Current Protocols in Molecular Biology , Greene Publishing Associates and John Wiley & Sons, NY (2007). For example, a nucleic acid can be chemically synthesized using naturally occurring nucleotides or variously modified nucleotides designed to increase the biological stability of the molecules or to increase the physical stability of the duplex formed upon hybridization (e.g., phosphorothioate derivatives and acridine substituted nucleotides). Examples of modified nucleotides that can be used to generate the nucleic acids include, but are not limited to, 5-fluorouracil, 5-bromouracil, 5-chlorouracil, 5-iodouracil, hypoxanthine, xanthine, 4-acetylcytosine, 5-(carboxyhydroxymethyl) uracil, 5-carboxymethylaminomethyl-2-thiouridine, 5-carboxymethylaminomethyluracil, dihydrouracil, beta-D-galactosylqueosine, inosine, N 6 -isopentenyladenine, 1-methylguanine, 1-methylinosine, 2,2-dimethylguanine, 2-methyladenine, 2-methylguanine, 3-methylcytosine, 5-methylcytosine, N 6 -substituted adenine, 7-methylguanine, 5-methylaminomethyluracil, 5-methoxyaminomethyl-2-thiouracil, beta-D-mannosylqueosine, 5′-methoxycarboxymethyluracil, 5-methoxyuracil, 2-methylthio-N 6 -isopentenyladenine, uracil-5-oxyacetic acid (v), wybutoxosine, pseudouracil, queosine, 2-thiocytosine, 5-methyl-2-thiouracil, 2-thiouracil, 4-thiouracil, 5-methyluracil, uracil-5-oxyacetic acid methylester, 3-(3-amino-3-N-2-carboxypropyl) uracil, and 2,6-diaminopurine. Alternatively, one or more of the nucleic acids of the invention can be purchased from companies, such as Macromolecular Resources (Fort Collins, Colo.) and Synthegen (Houston, Tex.).
[0031] The nucleic acid can comprise a recombinant adeno-associated virus (AAV) vector comprising the AAV subtype 6 (AAV6) viral genome, and containing a heterologous nucleic acid sequence capable of being expressed by the host cell.
[0032] The nucleic acids of the invention can be incorporated into a recombinant expression vector. In this regard, the invention provides recombinant expression vectors comprising any of the nucleic acids of the invention. For purposes herein, the term “recombinant expression vector” means a genetically-modified oligonucleotide or polynucleotide construct that permits the expression of an mRNA, protein, polypeptide, or peptide by a host cell, when the construct comprises a nucleotide sequence encoding the mRNA, protein, polypeptide, or peptide, and the vector is contacted with the cell under conditions sufficient to have the mRNA, protein, polypeptide, or peptide expressed within the cell. The vectors of the invention are not naturally-occurring as a whole. However, parts of the vectors can be naturally-occurring. The inventive recombinant expression vectors can comprise any type of nucleotides, including, but not limited to DNA and RNA, which can be single-stranded or double-stranded, synthesized or obtained in part from natural sources, and which can contain natural, non-natural or altered nucleotides. The recombinant expression vectors can comprise naturally-occurring, non-naturally-occurring internucleotide linkages, or both types of linkages. Preferably, the non-naturally occurring or altered nucleotides or internucleotide linkages do not hinder the transcription or replication of the vector.
[0033] The recombinant expression vectors of the invention can be prepared using standard recombinant DNA techniques described in, for example, Sambrook et al., supra, and Ausubel et al., supra. Constructs of expression vectors, which are circular or linear, can be prepared to contain a replication system functional in a prokaryotic or eukaryotic host cell. Replication systems can be derived, e.g., from ColEl, 2μ plasmid, λ, SV40, bovine papilloma virus, and the like.
[0034] Desirably, the recombinant expression vector comprises regulatory sequences, such as transcription and translation initiation and termination codons, which are specific to the type of host (e.g., bacterium, fungus, plant, or animal) into which the vector is to be introduced, as appropriate and taking into consideration whether the vector is DNA or RNA based.
[0035] The recombinant expression vector can include one or more marker genes, which allow for selection of transformed or transfected hosts. Marker genes include biocide resistance, e.g., resistance to antibiotics, heavy metals, etc., complementation in an auxotrophic host to provide prototrophy, and the like. Suitable marker genes for the inventive expression vectors include, for instance, LacZ, green fluorescent protein (GFP), luciferase, neomycin/G418 resistance genes, hygromycin resistance genes, histidinol resistance genes, tetracycline resistance genes, and ampicillin resistance genes.
[0036] The term “heterologous nucleic acid sequence” means one or more nucleic acid sequences encoding polypeptides for one or more proteins or enzymes which are not native to AAV6, and which are capable of being expressed when transduced in a host cell, or sequences encoding genes for said one or more proteins or enzymes. In an embodiment of the present invention, the heterologous nucleic acid sequence encodes a gene for an enzyme that is expressed within the host cell, and wherein the enzyme's activity within the host cell, increases the host cell's susceptibility to a particular prodrug or cytotoxic agent. This type of enzyme is also called a “suicide gene.” See, for example, Suicide Gene Therapy: Methods and Reviews , Springer, Caroline J. (Cancer Research UK Centre for Cancer Therapeutics at the Institute of Cancer Research, Sutton, Surrey, UK), Humana Press, 2004). Examples of combinations of enzyme and prodrug that are capable of being used in the present invention include, for example, HSV-tk and ganciclovir, E. coli nitroreductase and CB1954 (5-[aziridin-1-yl]-2,4-dinitrobenzamide), cytosine deaminase and 5-FC (5-Fluorocytosine), Varicella Zoster-tk and araM (6-methoxy purine arabinoside), Cytochrome P450 B1 (CYP2B1) and CPA (cyclophosphamide), carboxypeptidase G2 (CPG2) and benzoic acid mustard glutamates, E. coli purine nucleoside phosphorylase (ePNP) and 6-methylpurine 2′-deoxyriboside (MePdR).
[0037] The heterologous nucleic acid can be a nucleic acid not normally found in the target cell, or it can be an extra copy or copies of a nucleic acid normally found in the target cell. The terms “exogenous” and “heterologous” are used herein interchangeably.
[0038] By “functionally linked” is meant that the promoter can promote expression of the heterologous nucleic acid, as is known in the art, and can include the appropriate orientation of the promoter relative to the exogenous nucleic acid. Furthermore, the heterologous nucleic acid preferably has all appropriate sequences for expression of the nucleic acid. The nucleic acid can include, for example, expression control sequences, such as an enhancer, and necessary information processing sites, such as ribosome binding sites, RNA splice sites, polyadenylation sites, and transcriptional terminator sequences.
[0039] The heterologous nucleic acid can encode beneficial proteins or polypeptides (e.g., “beneficial” proteins or polypeptides) that replace missing or defective proteins required by the cell or subject into which the vector is transferred, or can encode a cytotoxic polypeptide that can be directed, e.g., to cancer cells or other cells whose death would be beneficial to the subject. The heterologous nucleic acid can also encode antisense RNAs that can bind to, and thereby inactivate, mRNAs made by the subject that encode harmful proteins. The heterologous nucleic acid can also encode ribozymes that can effect the sequence-specific inhibition of gene expression by the cleavage of mRNAs. In one aspect, antisense polynucleotides can be produced from an heterologous expression cassette in an AAV6 vector construct where the expression cassette contains a sequence that promotes cell-type specific expression (Wirak et al., EMBO 10:289 (1991)). For general methods relating to antisense polynucleotides, see Antisense RNA and DNA , D. A. Melton, Ed., Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y. (1988). Other examples of heterologous nucleic acids which can be administered to a cell or subject as part of the recombinant AAV6 vector of the present invention can include, but are not limited to, the following: nucleic acids encoding secretory and nonsecretory proteins, nucleic acids encoding therapeutic agents.
[0040] In addition, other therapeutic agents may be encoded by heterologous nucleic acids, such as tumor necrosis factors (TNFs), as TNF-α; interferons, such as interferon-α, interferon-β, and interferon-γ, interleukins, such as IL-1, IL-1B, and ILs-2 through -14; GM-CSF; adenosine deaminase; cellular growth factors, such as lymphokines; soluble CD4; Factor VIII; Factor IX; T-cell receptors; LDL receptor; ApoE; ApoC; alpha-1 antitrypsin; ornithine transcarbamylase (OTC); cystic fibrosis transmembrane receptor (CFTR); insulin; Fc receptors for antigen binding domains of antibodies, such as immunoglobulins; anti-HIV decoy tar elements; and antisense sequences which inhibit viral replication, such as antisense sequences which inhibit replication of hepatitis B or hepatitis non-A, non-B virus. The nucleic acid is chosen considering several factors, including the cell to be transfected. Where the target cell is a blood cell, for example, particularly useful nucleic acids to use are those which allow the blood cells to exert a therapeutic effect, such as a gene encoding a clotting factor for use in treatment of hemophilia. Another target cell is the lung airway cell, which can be used to administer nucleic acids, such as those coding for the cystic fibrosis transmembrane receptor, which could provide a gene therapeutic treatment for cystic fibrosis. Other target cells include muscle cells where useful nucleic acids, such as those encoding cytokines and growth factors, can be transduced and the protein the nucleic acid encodes can be expressed and secreted to exert its effects on other cells, tissues and organs, such as the liver. In addition, cancer cells corresponding or derived from lung, muscle, brain and other tissues can be target tissues. Furthermore, the nucleic acid can encode more than one gene product, limited only, if the nucleic acid is to be packaged in a capsid, by the size of nucleic acid that can be packaged.
[0041] The provided viral particles can be administered to cells, as described herein, with a Multiplicity of Infection (MOI) of 10. The MOI is the ratio of infectious virus particles to the number of cells being infected. Thus, an MOI of 0.1 results in the average inoculation of 1 virus particle for every 10 cells. The general theory behind MOI is to introduce one infectious virus particle to every host cell that is present in the culture. However, more than one virus may infect the same cell which leaves a percentage of cells uninfected. This occurrence can be reduced by using a higher MOI to ensure that every cell is infected. The provided viral particles can therefore be administered to cells, as described herein, with a MOI of 0.01 to 100, such as for example 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 30, 40, 50, 60, 70, 80, 90, 100.
[0042] The recombinant AAV vector is produced by recombinant methods utilizing multiple plasmids. In one example, the AAV1, AAV2, AAV5 or AAV6 recombinant viruses are produced using a three plasmid procedure previously described (Alisky et al., Neuroreport, 11: 2669-2673 (2000)). Briefly, semiconfluent HEK293T cells are transfected by calcium phosphate with three plasmids: an Ad helper plasmid containing the VA RNA, E2, and E4; an AAV helper plasmid containing the Rep and Cap genes for the serotype that is to be packaged; and a vector plasmid containing the inverted terminal repeats (ITRs) corresponding to the serotypes flanking a reporter gene of interest. Forty-eight hours posttransduction, the cells are harvested by scraping in TD buffer (140 mM NaCl, 5 mM KCl, 0.7 mM K2HPO4, 25 mM Tris-HCl pH 7.4) and the cell pellet concentrated by low-speed centrifugation. The cells that are efficiently transduced by all three plasmids, exhibit specific integration as well as the ability to produce the particular AAV recombinant virus of the present invention.
[0043] As defined herein, a functional portion or functional variant of the AAV6 vector, includes, for example, nucleotide sequences encoding any of the VA RNA, E2, E4, Rep, and Cap proteins, and fragments thereof.
[0044] The recombinant expression vector of the present invention comprises a native or normative promoter operably linked to the nucleotide sequence encoding a recombinant AAV6 viral genome and contains a heterologous nucleic acid sequence capable of being expressed by the host cell, or to the nucleotide sequence which is complementary to or which hybridizes to the nucleotide sequence encoding a recombinant AAV6 viral genome and containing a heterologous nucleic acid sequence capable of being expressed by the host cell, discussed above.
[0045] The selection of promoters, e.g., strong, weak, inducible, tissue-specific and developmental-specific, is within the ordinary skill of the artisan. Similarly, the combining of a nucleotide sequence with a promoter is also within the skill of the artisan. The promoter can be a non-viral promoter or a viral promoter, e.g., a cytomegalovirus (CMV) promoter, an SV40 promoter, an RSV promoter, and a promoter found in the long-terminal repeat of the murine stem cell virus.
[0046] The invention further provides a host cell comprising any of the recombinant expression vectors described herein. As used herein, the term “host cell” refers to any type of cell that can contain the inventive recombinant expression vector. The host cell can be an animal cell. Preferably, in an embodiment, the host cell is a mammalian cell. The host cell can be a cultured cell or a primary cell, i.e., isolated directly from an organism, e.g., a human. The host cell can be an adherent cell or a suspended cell, i.e., a cell that grows in suspension. Most preferably, the host cell is a human cell. The host cell can be of any cell type, can originate from any type of tissue, and can be of any developmental stage. Most preferably the host cells can include, for instance, muscle, lung, and brain cells, and the like.
[0047] The host referred to in the inventive methods can be any host. Preferably, the host is a mammal. As used herein, the term “mammal” refers to any mammal, including, but not limited to, mammals of the order Rodentia, such as mice and hamsters, and mammals of the order Logomorpha, such as rabbits. It is preferred that the mammals are from the order Carnivora, including Felines (cats) and Canines (dogs). It is more preferred that the mammals are from the order Artiodactyla, including Bovines (cows) and Swines (pigs) or of the order Perssodactyla, including Equines (horses). It is most preferred that the mammals are of the order Primates, Ceboids, or Simoids (monkeys) or of the order Anthropoids (humans and apes). An especially preferred mammal is the human.
[0048] In addition, the host cell can be a cancer cell. For example, in an embodiment, the host cell of the present can be a tumor cell, such as a tumor derived from the head or neck of a mammal, or a cell line derived from the head or neck of a mammal. With respect to the inventive methods, the cancer can be any cancer which expresses EGFR, including any of acute lymphocytic cancer, acute myeloid leukemia, alveolar rhabdomyosarcoma, bone cancer, brain cancer, breast cancer, cancer of the anus, anal canal, or anorectum, cancer of the eye, cancer of the intrahepatic bile duct, cancer of the joints, cancer of the neck, gallbladder, or pleura, cancer of the nose, nasal cavity, or middle ear, cancer of the oral cavity, cancer of the vulva, chronic lymphocytic leukemia, chronic myeloid cancer, colon cancer, esophageal cancer, cervical cancer, gastrointestinal carcinoid tumor. Hodgkin lymphoma, hypopharynx cancer, kidney cancer, larynx cancer, liver cancer, lung cancer, malignant mesothelioma, melanoma, multiple myeloma, nasopharynx cancer, non-Hodgkin lymphoma, ovarian cancer, pancreatic cancer, peritoneum, omentum, and mesentery cancer, pharynx cancer, prostate cancer, rectal cancer, renal cancer (e.g., renal cell carcinoma (RCC)), small intestine cancer, soft tissue cancer, stomach cancer, testicular cancer, thyroid cancer, ureter cancer, and urinary bladder cancer. Preferably, the cancer is head or neck cancer.
[0049] Also provided by the invention is a population of cells comprising at least one host cell described herein. The population of cells can be a heterogeneous population comprising the host cell comprising any of the recombinant expression vectors described, in addition to at least one other cell, e.g., a host cell (e.g., a lung cell), which does not comprise any of the recombinant expression vectors, or a cell other than a lung cell, e.g., a skin cell, a neutrophil, an erythrocyte, a hepatocyte, an endothelial cell, an epithelial cell, a muscle cell, a brain cell, etc. Alternatively, the population of cells can be a substantially homogeneous population, in which the population comprises mainly of host cells (e.g., consisting essentially of) comprising the recombinant expression vector. The population also can be a clonal population of cells, in which all cells of the population are clones of a single host cell comprising a recombinant expression vector, such that all cells of the population comprise the recombinant expression vector. In one embodiment of the invention, the population of cells is a clonal population comprising host cells comprising a recombinant expression vector as described herein.
[0050] The recombinant vectors comprising the AAV6 viral genome and containing a heterologous nucleic acids sequence capable of being expressed by the host cell to be used for in vivo administration must be sterile. This is readily accomplished by, for example, filtration through sterile filtration membranes, prior to, or following reconstitution.
[0051] Therapeutic compositions generally are placed into a container having a sterile access port, for example, an intravenous solution bag or vial having a stopper pierceable by a hypodermic injection needle. The route of administration of the recombinant AAV vectors, in accordance with the present invention, is in accord with known methods, e.g., injection or infusion by intravenous, intraperitoneal, intramuscular, intraarterial, subcutaneous, intralesional routes, by aerosol or intranasal routes, or by sustained release systems as noted below. The recombinant AAV vectors, are administered continuously by infusion or by bolus injection.
[0052] An effective amount of recombinant AAV vector to be employed therapeutically will depend, for example, upon the therapeutic and treatment objectives, the route of administration, the age, condition, and body mass of the patient undergoing treatment or therapy, and auxiliary or adjuvant therapies being provided to the patient. Accordingly, it will be necessary and routine for the practitioner to titer the dosage and modify the route of administration, as required, to obtain the optimal therapeutic effect. A typical daily dosage might range from about 1×10 4 genomic particles/dose to about 1×10 9 genomic particles/dose or more, preferably from about 1×10 6 to about 1×10 8 genomic particles/dose, depending on the above-mentioned factors. Typically, the clinician will administer antibody until a dosage is reached that achieves the desired effect. The progress of this therapy is easily monitored by conventional assays.
[0053] The recombinant adeno-associated virus (AAV) vectors used in the context of the present invention can, themselves, be linked to a detectable label. Such a detectable label allows for the presence of or the amount of the viral titer to be determined.
[0054] Alternative methods of vector delivery such as convection may enhance AAV6 distribution and, thus, more widespread tumor killing than the simple intratumoral injection. For example, an alternative method for efficient and widespread delivery of macromolecules and particles to tumors is convection-enhanced infusion, which is used to supplement simple diffusion and to improve vector distribution by bulk flow inside and outside the tumor. Stereotactic injection and subsequent infusion by maintaining a positive pressure gradient is able to improve the distribution of large molecules in animal models (Lieberman D. M., et al., J. Neurosurg. 82: 1021-1029 (1985)). In an embodiment, the present invention provides a method of treating a tumor which expresses EGFR in a mammal comprising administering to the mammal via convection-enhanced infusion, a therapeutically effective amount of a pharmaceutical composition comprising a recombinant AAV6 vector which encodes a gene that increases the host cell's susceptibility to a prodrug or cytotoxic agent, and administering to the mammal a therapeutically effective amount of a pharmaceutical composition comprising the specific prodrug or cytotoxic agent.
[0055] When applied, for example, to rat brain tumors, this convection-enhanced infusion technique was able to mediate delivery of virus particles to tumors with an approximate volume of 100 mm 3 , and also beyond the tumor borders into the surrounding brain tissue (Nilaver et al., Proc. Natl. Acad. Sci. USA 92: 9829-9833 (1995)).
[0056] Other methods of vector application include, for example, intravascular methods. Intravascular methods of vector application make use of a natural and ubiquitously distributed network of arteries, veins and capillaries, which is present in every normal tissue and is even denser in malignant tumors. Intravascular applications, such as intra-arterial injection of virus vectors, are capable of delivering a vector to the largest proportion of tumor cells and surrounding tissues without afflicting mechanical injury to normal brain tissue or having other toxic consequences (Spear et al., J. Neurovirol. 4: 133-147 (1998); Muldoon et al., “Delivery of therapeutic genes to brain and intracerebral tumors; in Chiocca E. A., and Breakefield X. O. (eds.), “Gene Therapy for Neurological Disorders and Brain Tumors,” Boston: Humana Press, pp 128-139 (1997)). In an embodiment, the present invention provides a method of treating a tumor which expresses EGFR in a mammal, comprising administering to the mammal, via intravascular methods of vector application, a therapeutically effective amount of a pharmaceutical composition comprising a recombinant AAV6 vector which encodes a gene that increases the host cell's susceptibility to a prodrug or cytotoxic agent, and administering to the mammal a therapeutically effective amount of a pharmaceutical composition comprising the specific prodrug or cytotoxic agent.
[0057] Alternatively, in an embodiment, the present invention provides a method of treating a tumor which expresses EGFR in a mammal comprising administering to the mammal via intravascular methods of vector application, a therapeutically effective amount of a pharmaceutical composition comprising a recombinant AAV6 vector which encodes a gene that increases the host cell's susceptibility to a prodrug or cytotoxic agent, and administering to the mammal a therapeutically effective amount of a pharmaceutical composition comprising the specific prodrug or cytotoxic agent, in combination with one or more other pharmaceutically active agents or drugs, such as a chemotherapeutic agents, e.g., asparaginase, busulfan, carboplatin, cisplatin, daunorubicin, doxorubicin, fluorouracil, gemcitabine, hydroxyurea, methotrexate, paclitaxel, rituximab, vinblastine, vincristine, etc.
[0058] The terms “treat,” and “prevent” as well as words stemming therefrom, as used herein, do not necessarily imply 100% or complete treatment or prevention. Rather, there are varying degrees of treatment or prevention of which one of ordinary skill in the art recognizes as having a potential benefit or therapeutic effect. In this respect, the inventive methods can provide any amount of any level of treatment or prevention of a disease in a mammal. Furthermore, the treatment or prevention provided by the inventive method can include treatment or prevention of one or more conditions or symptoms of the disease being treated or prevented. Also, for purposes herein, “prevention” can encompass delaying the onset of the disease, or a symptom or condition thereof.
[0059] The following examples further illustrate the invention but, of course, should not be construed as in any way limiting its scope.
EXAMPLES
[0060] Cell Cultures, rAAV production and transduction. The NCI60 cell line panel, and mouse IL-3-dependent myeloid cell line 32D, were maintained under standard culture conditions and cultured in RPMI media, 10% heat-inactivated fetal bovine serum (FBS), and 100 U/ml penicillin/streptomycin/amphotericin B (Invitrogen, Carlsbad Calif.). The 32D cells were further supplemented with 10 μg/ml IL-3 (Sigma, St. Louis Mo.). 32D cells were transfected with lipofectamine 2000 (Invitrogen) to deliver EGFR (ERBB1), ERBB2, ERBB3, or ERBB4 expression plasmids. Stably transfected 32D cells were selected for neomycin resistance, single cell populations were expanded and validated for specific isoform expression by western blot analysis. HN12, HN13 and HEp-2 cells were maintained under standard culture conditions and cultured in DMEM media, 10% heat-inactivated FBS, 100 U/ml penicillin/streptomycin/amphotericin B (Invitrogen).
[0061] Recombinant AAV1, AAV2, AAV5 and AAV6 were produced using a three plasmid expression system (See, Schmidt, M., et al., “Adeno-associated virus type 12 (AAV 12): a novel AAV serotype with sialic acid- and heparan sulfate proteoglycan-independent transduction activity,” J. Virol. 82: 1399-1406 (2008)). AAV was produced carrying either the Rous sarcoma virus long terminal repeat promoter driving expression of the nuclear localized beta-galactosidase reporter gene (RSV-NLS-LacZ), or nuclear-localized enhanced green fluorescent protein (NLS-eGFP), luciferase, or the herpes simplex virus 1 thymidine kinase transgene (HSVtk), driven by the cytomegalovirus early-immediate promoter, the driving protein promoter (CMV) and flanked by AAV2 inverted terminal repeats (ITR). In developing the seed data for COMPARE, the NCI60 cell line panel was transduced over a serial dilution with AAV6-RSV-NLS-LacZ. Transduction efficiency was measured by staining for beta-galactosidase expression in the transduced cells 60 hours post-transduction.
[0062] Comparative Gene Analysis. AAV6 transduction efficiency was measured in 48 cell lines within the NCI60 cell panel. Cells were transduced with AAV6-RSV-NLSLacZ vector over a serial dilution, and the averaged transduction efficiency was used as seed data for COMPARE as previously described (Di Pasquale, G., et al. Identification of PDGFR as a receptor for AAV-5 transduction. Nat. Med., 9: 1306-1312 (2003)). The full AAV6 transduction profile data is available in the DTP database (http://dtp.nci.nih.gov/mtargets/mt_index.html) (See, Zaharevitz, D. W., Holbeck, S. L., Bowerman, C. & Svetlik, P. A., “COMPARE: a web accessible tool for investigating mechanisms of cell growth inhibition,” J. Mol. Graph. Model. 20: 297-303 (2002)). COMPARE is a publicly available web-based data-mining tool offered by the Developmental Therapeutics Program (DTP), at the National Cancer Institute (NCI) (http://dtp.nci.nih.gov/compare/). The cDNA microarray data for the NCI60 cell line panel was used to identify genes with an expression pattern that highly correlated with the AAV6 transduction profile. A second software program, Microarray Analysis Program Package (MAPP) (Wilson, P. A., Microarray Analysis Perl Program (2007)), was used to further detail potential genes of interest by identifying alternative gene descriptors, subcellular location, and function specific for the COMPARE output format. The MAPP detailed gene data was then input into two pathway analysis software packages, Pathway Architect (Stratagene, La Jolla Calif.) and ExPlain (Biobase International, Wolfenbüttel, Germany), to visualize connectivity of genes that positively correlate with AAV6 transduction. The use of multiple pathway mapping software packages compensated for the variability in mapping algorithms and coverage of signal transduction pathway of each program.
[0063] AAV transduction and pharmacological inhibition. The 32D and 32D-EGFR cells were transduced with 1.0E4 genomic particle (gp)/cell with each of the AAV serotypes tested. Cells were analyzed for GFP expression by FACS analysis at 96 hours post-transduction. The HEK293T, HN12 and HEp-2 cells, shown to be permissive to AAV2 and/or AAV6, were used to evaluate the specific role of EGFR in AAV-mediated transduction. Cells were incubated at 37° C. in the presence or absence of AG1478 (10 μm) or gefitnib (10 μm) for 30 minutes prior to addition of AAV. AAV2 and AAV6 containing the CMV-NLS-eGFP construct were added at a concentration of 1.0×10 4 gp/ml for 90 minutes. Cells were gently washed to remove excess, non-bound virus, and GFP expression was analyzed by FACS 48 hours post transduction for HEK293T cells, or 96 hours post transduction for HN12 and HEp-2 cell lines.
[0064] siRNA knockdown of EGFR expression. siRNA against EGFR was used to knockdown EGFR expression in HEK293T and HN13 cells. The EGFR siRNA (Qiagen, Valencia Calif.; #S100074053) and the Allstars negative siRNA control (Qiagen, #1027280), were added to cells as per manufacturer's protocol. Cultures were incubated for 48 hours prior to transduction with AAV6 containing the CMV-NLS-eGFP construct at a concentration of 1.0E4 gp/cell. Cells were analyzed for transgene expression 48 hours post transduction by FACS analysis.
[0065] AAV Internalization. 32D-EGFR cells were incubated with either AAV2 or AAV6-CMV-NLS-eGFP in the presence or absence of 10 m AG1478 for 90 minutes at 37° C. Cells were gently washed to remove excess, non-bound virus and incubated with 0.5% trypsin to removed remaining extracellular virus. Intracellular DNA was isolated and copies of vector genome/cell population were quantified by QPCR as described previously (Di Pasquale, G., et al.).
[0066] Specific Co-precipitation of AAV6 and EGFR. The rhEGFR-Fc or rhFGFRFc chimeric soluble proteins (R&D Systems, Minneapolis, Minn.; 5 g protein) were coupled with a 10% solution of protein-A sepharose beads (Sigma) in PBS, containing 1% BSA and 0.1% pluronic acid, at 4° C. for 4 hours with gentle agitation. AAV was added (1.0×10 9 gp) to the soluble receptor-sepharose bead complex solution and incubated at 4° C. with gentle agitation for 90 minutes. Beads were centrifuged and extensively washed to remove excess, non-bound protein and AAV. Viral DNA was isolated and copies of vector genome were quantified by QPCR (Di Pasquale, G., et al.). As a measure of non-specific AAV binding, sepharose beads and AAV were incubated for similar durations and conditions, in the absence of rhEGFR-Fc, or rhFGFR-Fc.
[0067] Animal Studies. All animal studies were carried out according to NIH-approved protocols, in compliance with the Guide for the Care and Use of Laboratory Animals. Female athymic (nu/nu) nude mice (Harlan Sprague-Dawley), 5 to 6 weeks old and weighing 18 to 20 g, were used in the study, housed in appropriate sterile filter-capped cages, and fed and given water ad libitum. Head and neck tumor cell lines, HN12 and HEp-2 (2.0×10 6 cells/injection), were injected subcutaneously into both the right and left flank of nude mice to establish xenograft tumors. After tumors were established (7-10 days), AAV6-CMV-luciferase or AAV6-CMV-HSVtk (4.0×10 9 gp/40 ul) was injected into the flank tumors. Luciferase transgene expression was measured 10 days post AAV6 treatment by intraparatoneal injection of luciferin (4 mg/100 ml in PBS). Bioluminescence was imaged using the IVIS Xenogen imaging system (Xenogen, Alemeda Calif.) to measure luciferase expression in vivo. Regions of interest were quantified as mean average radiance (photons/s/cm 2 /sr) using Living Image software tools (Xenogen). To quantify copies of vector genome/mg tumor tissue, DNA was isolated from 25-35 mg samples of tumor tissue and copies vector genome were quantified by QPCR17. Copies vector genome/mg tissue of HN12 or HEp-2 tumors that only received vehicle control was used a background control and subtracted from vector genome/mg tumor tissue calculated for tumors that received intratumoral AAV6-CMV-luciferase injections.
[0068] For the gene-directed enzyme prodrug therapy (GDEPT) study, tumors were injected with AAV6-CMV-HSVtk (4.0E9 genomic particles/400) or equal volume of vehicle (0.9% saline). Ganciclovir (Sigma) (50 mg/kg/day) was delivered via intraparatoneal injections daily. Tumor volume was measured as previously described (See, Amornphimoltham, P., et al., “Mammalian target of rapamycin, a molecular target in squamous cell carcinomas of the head and neck,” Cancer Res. 65: 9953-9961 (2005)). Length (L) and width (W) of tumor were determined and volume was calculated using the following equation: (L*W 2 )/2. Percent tumor growth was calculated as tumor volume at each time point per volume prior to start of ganciclovir treatment. Tumors were measured until day 20 at which time the size of the untreated tumors required ethical termination of the study.
[0069] There was no significant difference in tumor volume noted between tumors that received AAV6 and those that did not prior to starting ganciclovir treatment (data not shown). Additionally, there was no significant difference in percent tumor growth of tumors that received AAV6-CVM-HSVtk and no ganciclovir treatment and those tumors that were not transduced by AAV6 but did receive ganciclovir treatment (data not shown).
[0070] Statistical Analysis. We analyzed the statistical significance of the linear relationship between AAV6 transduction and gene expression patterns using Pearson correlation coefficient (PCC) calculated through the COMPARE program, and verified statistical significance of EGFR (GC16216) using correlation analysis with Prism software (Graphpad, La Jolla Calif.). All data is presented as means+/−s.e.m. Statistical significance was calculated using unpaired Student's t-test.
Example 1
[0071] This example discloses how CGA was used to identify correlations between viral transduction profiles and gene expression profiles across the NCI60 cell panel.
[0072] Building upon the established CGA method, additional bioinformatics-based software and pathway visualization packages were added, to further prioritize potential AAV cell surface receptors. The expression data and Pearson correlation coefficient (PCC) values were obtained from the Developmental Therapeutics Program online database and web-accessible COMPARE program. Of the top 1000 genes returned by COMPARE, 760 genes were associated with identifiable gene names, of which 226 genes had established pathway interactions. Of these genes with known pathway interactions, 169 (75%) were found to be involved in EGFR signaling with 21 (9%) having a direct interaction with or regulation of the EGF receptor (ERBB1) ( FIG. 1 ).
[0073] A positive correlation between EGFR expression (DTP microarray pattern identification number GC16212) and cells permissive to AAV6 (PCC value of 0.421, P=0.003) was identified. Our discovery of extensive clustering of positive PCC genes connected to the EGFR signaling pathway provided the basis for further studies on the involvement of EGFR or its downstream signaling pathways in AAV6 transduction.
Example 2
[0074] To confirm whether the in silico findings would translate to activity in vivo, the influence of EGFR expression on AAV6 transduction was studied.
[0075] Initially, 32D cells, an IL-3-dependent hematopoietic progenitor cell line, which lack EGFR expression to stably express EGFR (32D-EGFR), were transduced with multiple AAV serotypes. Wild-type 32D cells were not permissive for any of the serotypes tested. In the presence of EGFR, AAV6 was able to efficiently transduce about 54.1±0.3% of the 32D-EGFR cells ( FIG. 2 ). Like AAV6, AAV1 was able to transduce the 32D-EGFR cells, but to a lesser extent suggesting additional molecules may be necessary for optimal transduction activity with this vector. The lack of transduction by AAV2 or AAV5 in the presence or absence of EGFR suggests EGFR specificity for AAV6-like viruses.
Example 3
[0076] In this example, EGFR-specific siRNA was used to knock down EGFR expression, and evaluate the impact on AAV transduction in two cell lines, HEK293T cells and HN13 cells, human embryonic kidney and head-and-neck tumor cell lines, respectively.
[0077] Expression levels were quantified by western blotting, and the results are expressed as the percentage which are positive for GFP relative to controls. Cells were transduced by AAV2 or AAV6-CMV-eGFP (***P<0.0001, n=3). In HEK293T and HN13 cells, EGFR expression was knocked down by 37% and 58%, respectively, with EGFR-specific siRNA and, in accordance, corresponded with a 40% and 70% decrease in transduction, respectively ( FIG. 3 ).
Example 4
[0078] To better understand the role of EGFR in AAV6 transduction, AAV6 vector transduction was measured in the presence or absence of the EGFR inhibitors AG1478 or gefitinib.
[0079] HEK293T cells were preincubated with one of the EGFR-specific inhibitors, AG1478 (Tyrphostin) or gefitinib (Iressa®, 4-(3-Chloro-4-fluorophenylamine)-7-methoxy-6(3-(4-morpholinyl)quinazoline), and subsequently incubated with AAV6-CMV-eGFP, to evaluate the impact of EGFR function on AAV6 mediated transduction. AAV2 transduction was not significantly influenced by EGFR inhibition. ***P<0.0001, n=3.AAV6 transduction of HEK293T cells was inhibited by 50% in the presence of either inhibitor. Under the same conditions, AAV2 transduction was unchanged ( FIG. 4 ).
Example 5
[0080] This example shows that EGFR is necessary for AAV6 internalization.
[0081] Internalization was measured in the presence or absence of gefitinib to evaluate the impact of function EGFR on AAV6 internalization. *P<0.01, n=3. Further analysis suggested that EGFR is involved in vector entry, as AAV internalization was decreased by over 500% in the presence of gefitinib ( FIG. 5A ). These results suggest that functional signaling through EGFR is required for AAV6 transduction and vector internalization.
Example 6
[0082] Although the above data suggest a direct interaction between EGFR and AAV6, EGFR could be functioning as a part of a complex, or AAV6 could be using the same trafficking pathway as EGFR.
[0083] To measure direct EGFR-AAV6 interaction, soluble recombinant human EGFR-Fc fusion protein (rhEGFR-Fc) or soluble FGFR (rhFGFR-Fc) was prebound to protein A-sepharose beads, and then they were incubated with AAV2, AAV5 or AAV6. Of the three serotypes used, AAV6 binding increased approximately sevenfold in the presence of rhEGFR-Fc ( FIG. 5B ). No significant increase in EGFRspecific binding with AAV2 or AAV5 was observed. Furthermore, AAV6 did not bind to rhFGFR-Fc-coated beads ( FIG. 5B ), suggesting a specific AAV6-EGFR interaction.
Example 7
[0084] Increased expression of EGFR correlates with aggressive head and neck squamous cell carcinoma (HNSCC) tumor growth and resistance to treatment (Thariat, J., et al., Int. J. Clin. Oncol., 12: 99-110 (2007)). The utility of AAV6 to transduce and ablate specific HNSCCs presenting with elevated EGFR expression was assessed by gene-directed enzyme prodrug therapy. Two HNSCC cell lines, HN12 and HEp-2 were selected to represent polarities of EGFR expression. HN12 cells express a higher level of membrane-localized EGFR compared with HEp-2 cells, which express a lower, more diffuse pattern of EGFR expression (Magné, N., et al., Br. J. Cancer, 86: 1518-1523 (2002). In preliminary in vitro studies, HN12 cells showed an EGFR-dependent AAV6 transduction, whereas HEp-2 cells were markedly less permissive to AAV6. Transduction of HEp-2 cells was not altered in the presence of AG1478 ( FIG. 6 ).
Example 8
[0085] In this example, in order to evaluate the AAV6-EGFR interaction in vivo, xenograft tumor models of these two cell lines were developed in female athymic (nu/nu) nude mice.
[0086] The mouse tumors were intratumorally injected with AAV6 containing a luciferase transgene under control of a cytomegalovirus immediate early promoter (AAV6-CMV-Luciferase). Upon receiving an intraperitoneal injection of solution containing luciferin (the chemical substrate for luciferase protein), the HN12 tumors that received AAV6-CMV-luciferase showed a significantly elevated (15-fold) average radiance of 1.01×104±0.31×104 photons s−1 cm−2 sr−1, after subtraction of average background radiance, compared with the Hep-2 tumors (0.69×103±0.48×103 photons s−1 cm−2 sr−1) ( FIG. 7 ). This difference in transduction activity was also confirmed by quantification of vector genomes isolated from the tumors ( FIG. 8 ). The ability of AAV6 to efficiently transduce EGFR-expressing tumors in vivo presented an opportunity to target and deliver cytotoxic transgenes to HN12 tumors highly expressing membrane-localized EGFR.
Example 9
[0087] This example tests whether the specificity and tropism of AAV6 for EGFR expressing HN12 cells was sufficient to ablate tumor growth without damaging the surrounding EGFR-expressing muscle.
[0088] HN12 xenograft tumors were injected with AAV6 vectors encoding herpes simplex virus thymidine kinase (HSVtk) followed 7 days later by treatment with ganciclovir. At the culmination of the study (day 20), we observed a 65% reduction in tumor growth between tumors transduced with AAV6-CMV-HSVtk vector and treated with ganciclovir and tumors that received only ganciclovir treatment ( FIG. 9 ).
[0089] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
[0090] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0091] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. | Comparative gene analysis (CGA) was combined with pathway visualization software to identify a positive correlation between AAV6 transduction and epidermal growth factor receptor (EGFR) expression. It was found that EGFR is necessary for vector internalization and functions as a co-receptor for AAV6. The identification and characterization of AAV6's requirement of EGFR expression for high transduction activity has allowed construction of recombinant AAV6 vectors which are capable of targeting and killing specific types of head and neck tumors that because of this high EGFR activity, were until now, refractory to current therapies. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of co-pending U.S. patent application Ser. No. 12/031,843, filed Feb. 15, 2008, which is a divisional of U.S. patent application Ser. No. 09/851,848, filed May 9, 2001 now U.S. Pat. No. 7,392,217, which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to electronic trading markets. More particularly, this invention relates to ways to control the extent to which traders can manipulate electronic trading markets.
As electronic trading becomes more popular, there is an increasing need to control the extent to which traders can manipulate and abuse electronic trading markets. Currently, the trading of fixed-income securities, such as United States Treasuries, United Kingdom Gilts, European Government Bonds, and Emerging Market debts, and non-fixed income securities, such as stocks, is possible through electronic trading systems.
In one method of electronic trading, bids and offers are submitted by traders to a trading system. A bid indicates a desire to buy while an offer indicates a desire to sell. These bids and offers are then displayed by the trading system to other traders. The other traders may respond to these bids and offers by submitting sell (or hit) or buy (or lift or take) commands to the trading system. Once a bid or offer has been responded to by a sell or buy command, a trade has been executed.
Electronic trading can be conducted over any suitable communication system. For example, networked computers can be used to implement a trading system. Traders can submit bid, offer, hit, or lift commands via any suitable input device, such as a mouse, keyboard, or any other suitable device.
Electronic timers are sometimes used in electronic trading systems. In certain systems, a “trade-state” timer may be used to provide a period of exclusivity for two traders (called “current workers”) who are “working-up” a trade—i.e., adding size to a pending series of trades. This trade-state timer may be set to a predetermined time period. For example, for U.S. Treasuries, the trade-state timer may be set to twelve seconds. During a work-up trade, the current workers may have a right of first refusal to trade at a certain level. A current worker may submit a bid or an offer anytime during this trade state. However, during this period, no other trader may submit a bid or offer, or respond with a sell or buy command.
In some systems, “bid-offer” timers may be used to prevent traders from prematurely canceling bids and offers entered by the traders. The timers may give other traders an opportunity to respond to the bids and offers before they can be cancelled by the traders that submitted them. The timers may be set to a predetermined period. For example, in U.S. Treasuries, the bid-offer timer may be preferably set to four seconds. The bid-offer timer may begin when a trader has submitted a bid or offer to the trading system.
When these timers are used together in an electronic trading system, a bid-offer timer may begin when a current worker submits a bid or offer during a work-up trade. The submission of the bid or offer may be timed so that the bid-offer timer expires just prior to the time that the trade-state timer expires. Immediately upon expiration of the trade-state timer, the former current worker may then replace the current bid or offer with a lower bid or offer. At the same time, another trader may submit a sell or buy command in response to the current worker's first bid or offer. Since the current worker has replaced the first bid or offer, the new trader may unintentionally end up selling or buying at a different level than was expected. By canceling the earlier bid or offer and submitting a new bid or offer in order to deceive the new trader, the current worker is said to be “gaming” the market.
Many current trading markets allow traders to “game” the market. As explained above, one form of gaming is done by submitting a bid or offer to the market only to quickly replace it with a new bid or offer. This can be accomplished by manipulating the market timers.
The bids or offers may be any trade type. These may include all-or-none (AON), limit order (LMT), market order (MKT), market-if-touched (MIT), stop-order (STP), etc. More common in gaming is submitting a market order as a first bid or offer and then canceling and replacing the market order with a limit order. A market order buys or sells at the current trading price while a limit order buys or sells at a stated price or better off the current market.
In view of the foregoing, it would be desirable to provide systems and methods for controlling a trader's ability to manipulate electronic trading markets.
SUMMARY OF THE INVENTION
It is an object of this invention to provide systems and methods for controlling a trader's ability to manipulate electronic trading markets.
For background purposes only, a trading interface for an electronic trading system that may be used in accordance with the present invention is illustrated in Kirwin et al. U.S. patent application Ser. No. 09/745,651, filed Dec. 22, 2000, which is hereby incorporated by reference herein in its entirety.
In accordance with this invention, a variety of approaches to control gaming during electronic trading may be used. One approach compares a price difference between two bids or offers. A second approach manipulates the bid-offer and trade-state timers.
More particularly, the price approach may compare the prices of the new and old bids or offers by a trader upon receiving a request to replace a bid or offer. If the change in price is greater than some predetermined value set by the trading system, the trading system may only permit the bid or offer to be replaced by first entering a “cooling off” period. During this cooling off period, any attempt to sell or buy in response to the bid or offer may be suspended. In this way, a new trader has an opportunity to see the price change before submitting a sell or buy command. As an alternative, if the change in price is too great, the new bid or offer may be automatically removed from the market.
The time approach links the timeout of the bid-offer timer to the end of the trade-state timer, rather than the time when a bid or offer was submitted. In this approach, the bid-offer timer may be programmed to count down upon completion of the trade-state timer if a current worker submitted a bid or offer during the trade state. During this time, a new trader (seller or buyer) may respond to the bid or offer, and the current worker cannot cancel or replace the bid or offer during the trade-state timer or during the bid-offer timer.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the 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:
FIG. 1 is a hardware implementation of an exemplary embodiment of an electronic trading system in accordance with the present invention;
FIG. 2 illustrates a detached trading view of a market cell containing a bid in accordance with the present invention;
FIG. 3 illustrates a detached trading view of a market cell when a trader has gamed the market in trading systems prior to the present invention;
FIG. 4 illustrates a detached trading view of a market cell when a seller responds to a bid in accordance with the present invention;
FIG. 5 is a flow diagram of an exemplary embodiment of a price approach in accordance with the present invention; and
FIG. 6 is a flow diagram of an exemplary embodiment of a timing approach in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides systems and methods for controlling gaming in electronic trading systems. One approach involves detecting a change in price between two bids or offers by the same trader and suspending trading for a predetermined amount of time if the price difference is too large, or removing the new bid or offer from the trading system. Another approach involves preventing a trader from canceling or replacing a bid or offer for a predetermined amount of time by linking the timers associated with entry and modifications of bid, offer, sell, and buy commands.
FIG. 1 illustrates one embodiment of an electronic trading system 10 according to the present invention. As shown, system 10 may include one or more user computers 12 , each of which may include a mouse 22 , that are connected by one or more communication links 14 and a computer network 16 to a trading server 18 .
In system 10 , trading server 18 may be a processor, a computer, a data processing device, or any other suitable server. User computer 12 may be a computer, processor, personal computer, computer terminal, personal digital assistant, a combination of such devices, or any other suitable data processing device. Mouse 22 may be any suitable pointing device capable of receiving user input. Computer network 16 may be any suitable network, including the Internet, an intranet, a wide area network (WAN), a local area network (LAN), a wireless network, a digital subscriber line (DSL) network, a frame relay network, an asynchronous transfer mode network (ATM), a virtual private network (VPN), etc. Communication links 14 may be any suitable communication links for communicating data between user computers 12 and trading server 18 , such as network links, dial-up links, wireless links, hard-wired links, etc.
All trading interactions between user computers 12 preferably occur via computer network 16 , trading server 18 , and communication links 14 . Traders at user computers 12 may conduct trading transactions using mice 22 , keyboards, or any other suitable devices.
FIGS. 2-4 illustrate market cells that may be displayed on a user computer 12 in accordance with the present invention. A market cell may include indications of the item to be traded, pending bids and/or offers for the item, the last trading price, and a field for entering trade commands. For ease of description, FIGS. 2-4 will be described in terms of bids although the same applies for offers as well.
FIG. 2 illustrates a detached trading view of a market cell 50 containing a market order bid entered by a trader for an item. As shown, a symbol 52 for the item to be traded (e.g., usg-5y) may be indicated. As also shown, the trader may have entered a market order bid 56 having a price of 98.21 for $10 million in 5 year bonds as well as a limit order bid 58 having a price of 98.14 for the same amount. The last trading price 60 for the item (e.g., 98.222) may also be indicated. “Command Line” 64 may be used by a trader to enter a bid, offer, sell, buy, cancel, or replace command, or any other suitable command. These commands may be entered using text, using dedicated buttons, or using any other suitable approach to execute trade commands.
FIG. 3 illustrates a detaching trading view of market cell 100 after a trader has gamed the market. Using the existing electronic trading system, a trader can manipulate the timers to replace market order bid 56 in FIG. 2 with the limit order bid 102 (bid 58 in FIG. 2 ) having a price of 98.15. Unaware of this change, a seller thinks he or she is responding to the 98.21 bid when he or she is actually responding to the 98.15 bid. The new price is indicated in last price column 106 .
FIG. 4 illustrates a detached trading view of a market cell 150 when a trader tries to cancel or replace bid 56 prior to a seller responding to the bid. Under the present invention, a trader who tries to cancel or replace a bid will either be prevented from changing the bid for a predetermined time period or trading for the item will be suspended, giving a potential seller notice of the new bid.
If a bid cannot be canceled for a predetermined time period, a seller may hit the bid as indicated by indicator 152 . As shown, the seller has sold $ 10 million of usg-5Y at a price of 98.21. The new trading price is reflected in the last price column 156 .
FIG. 5 is a flow diagram of a price approach to prevent gaming in accordance with the present invention. Process 200 begins at step 202 with one or more bids or offers already entered in the trading system. A bid or offer can be a market order, a limit order, any other type of order, or any combination of orders. At step 204 , the trading system may receive a request to cancel or replace a bid or offer. Next, at step 206 , the trading system may determine whether the trader has more than one order for the same item.
If the trader has more than one order, the trading system takes steps to prevent possible gaming. At step 208 , the trading system cancels the first bid or offer and replaces it with the second bid or offer. Next, at step 210 , the trading system compares the price of the canceled bid or offer with the new bid or offer. If the price change in the bids or offers is greater than some delta (e.g., 1/32nd, or any other suitable price difference), process 200 moves to step 212 where a cooling off period timer starts. During this cooling off period, if the trading system receives a request to sell or buy at step 216 , the sell or buy order is suspended at step 218 to give the seller or buyer notice of a change in bid or offer price.
After suspending the sell or buy order, or if the trading system has not received a request to sell or buy, process 200 checks whether the cooling period has ended at step 220 and if not, process 200 moves back to step 216 . The cooling off period may last any suitable amount of time (e.g., 2 seconds). If the cooling period has ended at step 220 , the new bid or offer is updated on the trading system and a seller or buyer can respond with a hit or lift at step 222 . Once a hit or lift is received, a trade occurs and process 200 ends at step 224 .
If the price change in bids or offers at step 210 is not greater than the predetermined delta, process 200 moves to step 226 where the trading system checks for a request to sell or buy. If there is a request to sell or buy (i.e., a seller or buyer responds with a hit or lift response) at step 228 , then a trade occurs and process 200 ends at step 230 . Process 200 may also end at step 230 immediately after step 226 if there is no request to sell or buy.
If the trading system determines that a user does not have more than one bid or offer for the same item at step 206 , process 200 cancels the bid or offer at step 232 . Since the trader no longer has a bid or offer in the market, process 200 ends at step 234 .
FIG. 6 is a flow diagram of a timing approach to control gaming according to the present invention. Process 300 begins at step 302 by starting a trade-state timer. At this point, the trading system for a particular item has entered a trade state. During this trade state several events may occur. One event may be a request to cancel or replace a current bid or offer at step 306 . If this occurs, the trader will be prevented from canceling or replacing the bid or offer, and a pop-up window may be displayed on the trader's screen indicating that he or she cannot cancel or replace the bid or offer until the trade state is over at step 308 . A second event may be a request to submit a hit or take at step 307 . If this occurs, a second trader will be able to submit a hit or take in response to the bid or offer at step 309 . Then at step 311 , the trading system will reset the trade-state timer. A third event may be a request to submit a bid or offer at step 310 . If this occurs, a trader will be able to submit a bid or offer at step 312 . If the trader currently has a bid or offer in the market, submitting a new bid or offer will not replace or cancel the existing bid or offer.
After step 308 , 311 , or 312 , or directly after step 302 (if none of the requests indicated in steps 306 , 307 , and 310 are made), process 300 moves to step 314 where the trading system determines whether the trade-state timer has ended. If the trade-state timer has not ended, process 300 remains in the trade state to wait for a request to cancel or replace an order at step 306 , a request to submit a hit or take at step 307 , a request to submit a bid or offer at step 311 , or for the timer to end at step 314 . If the trade-state timer has ended, process 300 moves to step 316 where the bid-offer timer starts. At this point, process 300 is in a bid-offer state. During the bid-offer state (e.g., 4 seconds or any other suitable time period), one of several things can occur. If process 300 receives a hit or lift response from a seller or buyer, a trade will occur at the bid or offer price made during the trade state at step 324 . Process 300 will then end at step 326 .
During the bid-offer state, process 300 can receive a request to cancel or replace an order at step 320 . If this occurs, similar to the trade state, the trader will be prevented from canceling or replacing the order, and a pop-up window, or any other suitable method, may be used to communicate this message to the trader at step 322 .
After step 322 , or directly after step 316 , process 300 may determine whether the bid-offer timer has ended at step 328 . If the timer has not ended, process 300 may remain in the bid-offer state to wait for a request to cancel or replace a bid or offer at step 320 , for a hit or lift response at step 324 , or for the timer to end at step 328 . If the bid-offer timer has ended, process 300 may then receive a request to cancel or replace an order at step 330 . If such a request is received, the bid or offer will be canceled and will be replaced by a new bid or offer at step 332 . Process 300 may then end at step 334 .
Gaming may be controlled to prevent as well as to promote gaming. Gaming may be promoted by creating liquidity in an illiquid market (e.g., by controlling and encouraging gaming to whatever degree the market will permit). An example for increasing liquidity may be to take an illiquid security, such as an old bond (e.g., 30 year United States Treasury bond), and permit gaming so that trades increase. The permitted sale may be based on a sliding scale of various elements that are controlled. The permitted sale may also occur by permitting the trade to increase until a specific volume is attained, or by generally permitting gaming for specific securities (such as the old bond) in illiquid markets.
Thus it is seen that systems and methods are provided to control gaming in electronic trading systems. One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow. | Systems and methods are provided to control gaming in electronic trading markets. These systems and methods alleviate the problem of a seller or buyer trying to act on a trader's original bid or offer only to trade at an unfavorable level after the trader changes the bid or offer. A pricing method suspends trading for a period of time if a price difference between two bids or offers by the same trader is too great. A timing method prevents a trader from canceling or replacing a bid or offer for a period of time. These methods provide a more fair and efficient way of executing electronic trades. | 6 |
CROSS-REFERENCES
This is a continuation-in-part of application Ser. No. 777,598, filed Mar. 15, 1977, now abandoned, which is a continuation-in-part of application Ser. No. 689,366, filed May 24, 1976, now abandoned.
INTRODUCTION
This invention relates to chemical processes for preparing 2-arylalkanoic acid compounds. More particularly, this invention provides an improved process for preparing 2-aryl-C 2 to C 6 -alkanoic acids. In its preferred aspects this invention is particularly concerned with providing an improved process for preparing 2-aryl-C 2 to C 6 -alkanoic acids which are useful as anti-inflammatory, analgesic and anti-pyretic drug compounds, e.g., 2-(4-isobutyl)-phenyl)propionic acid, now known generally as ibuprofen.
BACKGROUND OF THE INVENTION
2-Arylalkanoic Acids
A variety of arylalkanoic acids are now known to be useful as active anti-inflammatory, analgesic, anti-pyretic, anti-thrombotic pharmaceutical drug products. A few of the better known of these drug compounds include the 2-arylpropionic acid derivatives such as fenoprofen which is 2-(3-phenoxyphenyl)propionic acid and related compounds which are described in Marshall U.S. Pat. No. 3,600,437, ibuprofen which is 2-(4-isobutylphenyl)propionic acid and which is described with other related compounds in Nicholson et al U.S. Pat. No. 3,385,886, naproxen which is 2-(6-methoxy-2-naphthyl)propionic acid which is described with other related compounds in Belgian Pat. No. 747,812 (Derwent Index No. 71729R-B). In addition, a variety of other 2-aryl-C 2 to C 6 -alkanoic acid compounds are described in the medical, pharmaceutical, agricultural and patent literature, including the above patent references as well as Shen U.S. Pat. No. 3,624,142 and Adams et al U.S. Pat. No. 3,793,457 which patents describe some fluoro-substituted biphenylalkanoic acids.
Thus, a large variety of 2-aryl-C 2 to C 6 -alkanoic acids having a variety of practical uses are known and more of such compounds will undoubtedly be discovered and described in the future patent and other technical literature.
Prior Processes
The above patent references also describe a variety of process routes for preparing useful 2-aryl-C 2 to C 6 -alkanoic acids. However, some of the prior processes suffer a variety of disadvantages including expensive starting materials, dangerous by-products, undesired and gross quantities of by-products necessitating substantial expense in destroying or getting rid of such by-products. As a result chemists skilled in chemical process research continue to study and search for improved processes for making the more economically significant 2-aryl-C 2 to C 6 -alkanoic acids, and particularly the 2-arylpropionic acids.
Most of such processes have involved the use of aromatic ring moiety reactants. For example, processes have been described for preparing the 2-(substituted phenyl)propionic acids (a) from aromatic glycidonitriles (see Argentine Pat. Nos. 198,097 and 198,595), (b) from aromatic glycidyl esters (see German Offenlegungsschrift No. 2,404,159, published Aug. 29, 1974), (c) from aromatic alkyl cyanides and by a variety of other process routes, all of which involve the use of an aromatic moiety. See, for example, U.S. Pat. No. 3,600,437 for a description of a number of those processes.
More recently Belgian Pat. No. 820,267 described a process for preparing p-isobutyl-hydratropic acid, also now named 2-(4-isobutylphenyl)propionic acid (ibuprofen) by treating an aliphatic compound of the formula ##STR1## where each R is a C 1 to C 5 -alkyl, with a strong acid aqueous solution at 200° C. to 240° C., or in a dry state with a strong acid salt and an organic base for from 30 minutes to 3 hours. That Belgian patent also indicates that its formula (II) compound need not be isolated before acid treatment but can be obtained in the crude product form by reacting the vinyl-isobutyl-ketone with alkyl α-acetyl-α-methylsuccinate, or by reaction of an acetoacetic acid ester with an alkyl α-halopropionate and then with the vinyl-isobutyl-ketone.
That Belgian patent also refers to prior processes and to some prior patents, including British Pat. No. 1,265,800 which discloses the synthesis of methyl or ethyl 2-(4-isobutyl-2-oxocyclohex-3-enyl)propionate in some undisclosed yield. The Belgian Pat. No. 820,267 indicates that when they repeat the pertinent experiments of the British Pat. No. 1,265,800 they obtained yields of less than 5 percent; and concluded the process for preparing p-isobutyl-hydratropic acid (ibuprofen) as described in British Pat. No. 1,265,800 had no industrial application. The Belgian Patent points out that the advantages of its described process for preparing 2-(4-isobutyl-2-oxo-3-cyclohexenyl)propionic acid intermediate is that it does not require the use of expensive and dangerous reagents such as silver nitrate or cyanide ion. That Belgian patent process for the production of ibuprofen from 2-(4-isobutyl-2-oxo-3-cyclohexenyl)propionic acid is based upon the aromatization which occurs when a dialkyl-α-acetyl-α-[(5-methyl-3-oxo)-hexyl]-α'-methylsuccinate is heated to temperatures of about 200° C. to 240° C. with strong acid, but the Belgian patent process requires temperature over 200° C.
The British Pat. No. 1,265,800 process requires the use of corrosive materials and also requires the use of heating temperatures over 200° C. Persons skilled in this process art are searching for improved processes for making these valuable drug compounds while avoiding the use of polymerizable intermediates, corrosive materials, and the high temperatures described in those references.
OBJECTS OF THE INVENTION
It is an object of this invention to provide an operationally simple, high yielding, one-step process for the manufacture of 2-aryl-C 2 to C 6 -alkanoic acids.
It is a further object of this invention to provide new butenolide derivative compounds which are useful as intermediates in processes for preparing useful 2-aryl-C 2 to C 6 -alkanoic acid compounds.
It is another object of this invention to provide an alternative method for preparing useful 2-aryl-C 2 to C 6 -alkanoic acids via butenolide intermediates.
Other objects, aspects and advantages of this invention will become apparent from reading the remaining specification and claims.
SUMMARY OF THE INVENTION
This invention provides a process for preparing 2-aryl-C 2 to C 6 -alkanoic acids and esters (I) by heating at about 75° C. to 130° C. a mixture containing at least one compound from the group consisting of (A) a 2-(substituted-2-oxo-3-cyclohexenyl)-C 2 to C 6 -alkanoic acid or ester (II), a succinate acid or ester precursor thereof (III), an α-acetyl-α-(substituted-3-oxopropyl)succinic acid or ester derivative (IV), or a butenolide compound (V) and (VI), in the presence of a sulfonic or phosphonic acid while providing a means for removing water from the mixture during the heating operation until the 2-aryl-C 2 to C 6 -alkanoic acid, ester or mixture thereof is formed.
This invention also provides new butenolide compounds (V) and (VI) per se. These compounds can be and are prepared in the reaciton mixture of the above process of this invention.
Another aspect of this invention provides a process for preparing 2-aryl-C 2 to C 6 alkanoic acids (I) through these butenolides by forming a mixture containing the 2-(substituted-2-oxo-3-cyclohexenyl)-C 2 to C 6 -alkanoic acid (II), acetic anhydride and an acid scavenging base; allowing the mixture to stand until an acetate intermediate (XI) is formed, heating the resulting mixture to from about 75° C. to about 130° C. for a time sufficient to form a mixture containing at least one of the butenolide intermediates (V) and (VI), adding a carboxylic acyl halide, e.g., acetyl chloride, and a stoichiometric amount of water to form acetic acid and mineral acid, e.g., hydrochloric acid, in the mixture and then heating the mixture at about 75° C. to about 130° C. for a time sufficient to form the 2-aryl-C 2 to C 6 -alkanoic acid or ester product (I). Alternatively, the buteneloide intermediate (V) and (VI) can be mixed with a sulfonic or phosphonic acid and heated to form about 75° C. to about 130° C. while providing a means for removing water from the mixture for a time sufficient to form a 2-(aryl)-C 2 to C 6 -alkanoic acid or ester product (I) of the process.
DETAILED DESCRIPTION OF THE INVENTION
More specifically, this invention provides an improved process for preparing compounds of the formula ##STR2## wherein R is hydrogen or C 1 to C 4 -alkyl, R 1 is hydrogen, C 1 to C 6 -alkyl or mixtures thereof, and Ar is an aromatic radical containing 6 to 12 carbon atoms in which the aryl ring portion thereof is preferably phenyl bonded to the alkanoic acid carbon atom adjacent to the carboxyl group at an aryl ring carbon atom, which, comprises heating at a temperature of from 75° C. to about 130° C. a mixture containing (A) at least one compound having a formula selected from the group consisting of
(a) a compound of the formula ##STR3## wherein R and R 1 are as defined above; and
Y, taken separately, preferably is C 3 to C 5 -alkyl, or hydrogen;
(b) ##STR4## wherein R, R 1 and Y are as defined above:
(c) ##STR5## wherein R, Y and Z are as defined above, and
(d) a compound of the formula ##STR6## wherein R and Y are as defined above, and (B) a sulfonic acid or a phosphonic acid, preferably in each acid such an acid having from 1 to 12 carbon atoms, while providing a means for removing water from the reaction mixture during the heating operation for a time sufficient to form a formula I compound. The heating of the reaction mixture containing reactants (A) and (B) may be done neat, that is, without added liquid diluent or solvent. However, it has been found that the reaction proceeds more efficiently to produce higher yields if the reaction is diluted with a non-polar organic liquid, preferably one which forms an azeotrope with which in the heated mixture. fWe have found that the product (1) from starting material II, III, or IV in its ester form in the above heating step is usually a mixture of its 2-aryl-C 2 to C 6 -alkanoic acid, and its corresponding ester, so we include such mixtures in the definition of the R 1 moiety. However, this acid/ester mixture is thereafter treated with a hydrolyzing base to remove the ester groups and to form the salt form of the product I. The free acid form of product (I) can be regenerated from the salt by known methods.
Any readily available sulfonic or phosphonic acid can be used in the process. However, as a practical economic matter such acids having from 1 to 12 carbon atoms in the organic group of such acids are of primary interest. Sulfonic and phosphonic acids which have solubility in the non-polar organic liquid diluent for the reactants are preferred. The C 1 to C 12 -alkanesulfonic, C 1 to C 12 -alkanephosphonic, C 6 to C 12 -aryl and the C 7 to C 12 -alkarylsulfonic and -phosphonic acids such as methanesulfonic, ethanesulfonic, dodecanesulfonic, phenylsulfonic, or preferably p-toluenesulfonic acid, or methylphosphonic, ethanephosphonic dodecylphosphonic, phenylphosphonic, p-tolylphosphonic acid, or the like are examples of such acids. These acids may be used in their hydrated form. p-Toluenesulfonic acid monohydrate is our sulfonic acid of choice when ibuprofen is being prepared by this process in toluene. We have found that phenylphosphonic acid also works quite well and would be a preferred phosphonic acid. Other sulfur and phosphorus containing acids such as ortho-phosphoric acid and sulfuric acid have been tried but they do not work nearly as well as do sulfonic and phosphonic acids in the process of this invention.
A preferred embodiment of this invention is to use this process to prepare ibuprofen by heating to from about 100° C. to about 130° C. in a non-polar organic liquid solvent or diluent which azeotropes with water, preferably at reflux in a toluene containing diluent medium (about 110° C.), a mixture containing (A) at least one compound of the formulas:
(a) ##STR7## wherein each formula R 1 is hydrogen, a C 1 to C 6 -alkyl or mixtures thereof in the particular batch used, and (B) a substantially equimolar amount, relative to the total current of starting materials IIa, IIIa and IVa, of p-toluenesulfonic acid or its hydrate or phenylphosphonic acid, for a time sufficient to form an ibuprofen compound of the formula ##STR8## wherein R 1 is as defined above. Thereafter, the preferred process includes the step of adding water after the heating step in an amount sufficient to hydrate the p-toluenesulfonic acid so that the hydrated acid separates from the liquid phase of the mixture. The reaction mixture containing the crude ibuprofen product can then be treated with an alkali metal hydroxide, carbonate or bicarbonate preferably in aqueous solution form, to form ibuprofen alkali metal salt. Any alkali metal basic compound could be used in this step but as a practical, economic matter only sodium, potassium or lithium hydroxide bicarbonate or carbonate would be used.
As an added embodiment of this invention it has been found that addition of acetone or an equivalent ketone, but preferably acetone, to an aqueous alkali metal ibuprofen or other 2-aryl-C 2 to C 6 alkanoate salt solution is very effective to precipitate the alkali metal ibuprofen salt from the liquid phase and this property of acetone in these mixtures provides a simple, effective means for separating the ibuprofen or other 2-aryl-C 2 to C 6 -alkanoic acid, as its salt, from its reaction mixture. The amount of acetone added can be any amount which will cause the salt to precipitate but can range from say equimolar amounts relative to the salt content of the mixture to volume excesses of acetone relative to the aqueous phases, depending on agitation conditions and the amount of time one allows for the salt to separate.
The crude alkali metal ibuprofen or other 2-aryl-C 2 to C 6 alkanoate salt can be then converted to its corresponding acid by acidification with an acid strong enough to convert the ibuprofen or other 2-aryl-C 2 to C 6 -alkanoate salt to its free acid form followed by extraction, drying and evaporation procedures. For example, the ibuprofen or other 2-aryl-C 2 to C 6 -alkanoate alkali metal salt in aqueous medium can be acidified with an economical mineral acid such as 6 N sulfuric or hydrochloric acid to form the acid and the reaction mixture can be extracted one or more times with non-polar, organic liquid solvent such as Skelly-solve® B. The combined organic phases containing the acid can be separated from the aqueous phase and dried over a chemical drying agent such as sodium sulfate and then evaporated to leave as residue the crystalline ibuprofen or other acid product, which can be collected and readied for its ultimate use in pharmaceutical formulations or agricultural or other practical compositions as known in the art.
As indiated by the above listed starting materials this invention provides a low temperature, high yielding process for the manufacture of ibuprofen and related 2-aryl-C 2 -C 6 -alkanoic acids from α-acetylsuccinate ester derivatives of formula IV above. Such α-acetylsuccinate ester derivative starting materials can be prepared by Michael condensation reaction analogous to the procedures described in British Pat. No. 1,265,800, cited above. Thus, it is not necessary according to this invention to isolate and separatly start this process with the 2-(substituted-2-oxo-3-cyclohexenyl)C 2 to C 6 -alkanoic acid or ester (II) per se. Such compounds (II) are formed in situ in the process of this invention when the starting reaction mixture contains the α-acetylsuccinate ester (IV).
During the heating step of the process of this invention, water production, ester hydrolysis, and decarboxylation are noted. Water can be continuously removed by attaching a Dean-Start trap or equivalent apparatus to the reaction vessel. Optionally, the reaction mixture may be switched from reflux to partial takeoff of distillate, or it can be distilled through molecular sieves, e.g., 4 A molecular sieves, which absorb both water and alcohol. Because of the efficient azeotrope formation of toluene/ethanol/water (about 57/37/12 v/v/v, respectively) it is preferred to use toluene as the non-polar diluent when ibuprofen is being prepared. This removal of alcohol and water shifts the equilibrium of any α-acetylsuccinate derivative (IV) containing reaction mixture toward the production of a 2-(substituted-2-oxo-3-cyclohexenyl)-propionic acid (II). Further reflux of the reaction mixture under water separating conditions, e.g., with a Dean-Stark trap attached to the reaction vessel, converts the 2-(substituted-2-oxo-3-cyclohexenyl)propionic acid to butenolides V and VI above, which aromatize at different reaction rates to the 2-aryl-C 2 to C 6 -alkanoid acid or ester product (I).
It has also been found according to this invention that the process of this invention produces butenolide derivative compounds of formulas V and VI above. These butenolide compounds can be isolated if desired, but they need not be isolated since they are useful as chemical intermediates in the process of this invention to prepare the 2-aryl-C 2 to C 6 -alkanoic acid and ester products (I). Preferred examples of such compounds are those of formulas (V) and (VI) wherein Y is isobutyl and R is methyl.
These preferred butenolide intermediates (V) and (VI) are useful as intermediates for preparing the known drug compound ibuprofen in the process of this invention.
If desired, the conditions of this process of this invention can be adjusted to produce larger quantities of these butenolide intermediate compounds (V) and (VI). For example, the 2-(substituted-2-oxo-3-cyclohexenyl)-alkanoic acid or esters (II) reaction mixture can be treated with only catalytic amounts, say 1 to 10 percent, of the sulfonic or phosphonic acid in a non-polar, azeotroping solvent to form a mixture containing mostly that of butenolide (VI) and a minor amount of butenolide (V). Treatment of the 2-(substituted-2-oxo-3-cyclohexenyl)alkanoic acid (II) with acetic anhydride in the presence of an acid scavenging base which does not destroy the reactants, e.g., with potassium carbonate or pyridine, at room temperature for a time sufficient to form the unstable intermediate XI of the formula: ##STR9## wherein R and Y are as defined above, and -OAc denotes acetoxy, and then followed by heating of that mixture to 75° C. to 110° C. yields a mixture in which the butenolide intermediate content contains a major amount of structures V and minor amounts of butenolide structure VI.
Treatment of these butenolides with a mineral acid such as sulfuric acid or hydrochloric acid in acetic acid (or acetyl chloride and water) aromatizes butenolide to its 2-aryl-C 2 to C 6 -alkanoic acid (I). Treatment of butenolide VI with p-toluenesulfonic acid according to this invention converts to its 2-aryl-C 2 -alkanoic acid (I) product.
Although the detailed examples hereinbelow are drawn for the most part to describe the process for the preparation of the preferred product ibuprofen, the process of this invention can also be adapted to the production of other similar 2-aryl-C 2 to C 6 -alkanoic acid products.
During the heating step water in the reaction mixture is removed by any conventional chemical, physical or mechanical means. To insure complete and efficient reaction it is preferred that the sulfonic or phosphonic acid be used in approximately molar equivalent amounts relative to the starting material (A) which is actually or theoretically in the reaction mixture, although such stoichiometric proportions of sulfonic or phosphonic acid are not required. It is just that the preferred sulfonic or phosphonic acid can be essentially quantitatively recovered for reuse in the process so that it is not necessary to economize on its use.
Any non-polar organic liquid diluent which is a stable liquid and preferably dissolves the reactants in the heating temperature range can be used in the process of this invention. Preferably this organic liquid also boils in this temperature range and forms an azeotrope with water and any alcohol which may be generated during the heating step. Toluene is our preferred solvent which ibuprofen is being prepared but other organic liquids such as xylene, mesitylene, heptane, octane, and commerical mixtures of such organic liquids having boiling points ranges within the ranges of the heating step of the process of this invention including Skellysolve® C and D (See Merck Index, Eighth Edition, page 951) can be used. Mixtures of organic liquid which contain polar ingredients as well as one or more of the above non-polar ingredients and having boiling boint ranges within the heating range may also be used.
The means for removing or inactivating water in the reaction mixture during the heating operation can be provided by chemical or physical procedures known in the art, or by combinations of both chemical and physical means.
Preferably, however, we have obtained our best yields of 2-(aryl)C 2 to C 6 -alkanoic acid or ester product (I) when the reaction mixture includes a liquid or mixture of liquids which form an azeotrope with water, which water containing azeotrope is distilled out of the reaction mixture during the heating operation. Numerous types of chemicals are known to form binary or tertiary water-containing azeotropes having boiling points sufficient for distllation during the heating operations. Such chemicals include C 5 to C 8 alkanes, and C 6 to C 8 -aromatic hydrocarbons, halogenated hydrocarbons, particularly those containing from 1 to 6 carbon atoms and from 1 to 4 chlorine or bromine atoms, ethers, esters, organic acids, ketones, aldehydes, and the like, as set forth in various chemical handbooks, e.g., Handbook of Chemistry, edited by N. A. Lange, ninth edition (1956) published by Handbook Publishers Inc., Sandusky, Ohio, pp. 1484 to 1486 and 1493 and in Chemical Rubber Co., Handbook of Chemistry and Physics, 45th Edition, pp. D-1 to C-18 (1964-65). We prefer that the liquid that is used to form a water containing azeotrope in the reaction mixture be a readily available, economical, inert organic liquid which may or may not be a solvent for the reaction mixture. Examples of suitable water-azeotrope forming liquids that are heavier than water which may be used include 1,2-dichloroethane, chloroform, methylene chloride and carbon tetrachloride. Examples of suitable water-azeotrope forming liquids that are lighter than water which may be used include benzene, toluene, xylene, pentane, hexane, heptane, and the like.
We have found that the 2-(substituted-2-oxo-3-cyclohexenyl)C 2 to C 6 -alkanoic acids (II) can be converted to the corresponding 2-(aryl)C 2 to C 6 -alkanoic acids (I) by heating them neat in molten p-toluene-sulfonic acid monohydrate or an equivalent sulfonic or phosphonic acid at about 120° C. for 5 to 20 hours, but the yield of the desired 2-(aryl)C 2 to C 6 -alkanoic acid is not as high as when a solvent for the reaction mixture is used.
The invention is exemplified in more detail by the following examples which are not intended to limit the scope of the invention but only to illustrate its operability under various conditions. All temperatures are in degrees centigrade unless otherwise indicated.
EXAMPLE 1
Process using toluene solvent.
In a 10 ml. flask there was placed about 1.01 gm. (4.52×10 -3 mole) of crystalline 2-(4-isobutyl-2-oxo-3-cyclohexenyl)propionic acid, 0.8596 gm. of p-toluene-sulfonic acid monohydrate (4.52×10 -3 mole), and 5 ml. of toluene.
The flask was then fitted with a Dean-Stark trap and a condenser under a nitrogen atmosphere. The flask and its contents was then heated to reflux (b.p. toluene=110° C.) in an oil bath collecting water in the Dean-Stark trap.
After a total of about 1 hour and twenty minutes, a thin layer chromatographic (TLC) analysis of a sample of the reaction mixture indicated that almost all of the 2-(4-isobutyl-2-oxo-3-cyclohexenyl)propionic acid had been consumed. The reaction mixture was heated for another 4.5 hours at reflux to insure complete reaction. (Total of about 6 hours reaction time). The mixture was then allowed to cool to room temperature, and a TLC analysis of the reaction mixture showed that the reaction was complete.
To recover the ibuprofen product from the reaction mixture, the flask and its contents were treated as follows:
About 50 μl. of water was added to the reaction mixture flask precipitating p-toluenesulfonic acid monohydrate. The mixture was cooled in an ice bath and filtered. The filtered material was washed with toluene and the filtrate and the toluene washings were combined.
The ibuprofen was recovered from the toluene mixture by extracting the toluene phase with 0.2062 gm. of sodium hydroxide (1.805 gm.=4.52×10 -3 mole) dissolved in about 20 ml. of water. The toluene phase was extracted a second time with a 5 percent sodium bicarbonate solution. The combined aqueous basic fractions were back extracted with Skellysolve® B to remove any neutrals (organic soluble materials). The combined Skellysolve B and toluene fractions were combined, dried over sodium sulfate and evaporated to a gold residue weighing 89.3 mg. (96 percent).
The aqueous basic fraction containing sodium ibuprofen salt was acidified with 6N sulfuric acid, sodium chloride was added, and then extracted twice with Skellysolve B to take up the ibuprofen acid product therein. The Skellysolve B phase was dried over sodium sulfate and evaporated to leave as residue 867.7 mg. (93.2 percent yield) of ibuprofen which was 99.9 percent pure by gas liquid chromatographic (GLC) analysis.
A 0.7895 gm. portion of the ibuprofen product was re-dissolved in 3 ml. of hot Skellysolve B and after cooling the solution the ibuprofen re-crystallized to yield 0.6982 gm. of white crystalline ibuprofen, M.P. 74.5° C. to 75° C.
EXAMPLE 2
Process using molten p-toluenesulfonic acid.
A 0.9756 gm. portion of 2-(4-isobutyl-2-oxo-3-cyclohexenyl)propionic acid (4.265×10 -3 mole) and 1.0046 gm. of p-toluensulfonic acid monohydrate (m. p. 104° C. to 106° C.) were added to a 15 ml. flask under nitrogen, the flask was fitted with a condenser and a magnetic stirring bar. The flask and its contents were heated in an oil bath for a total of about 14 hours, after which an additional 0.2009 gm. of p-toluenesulfonic acid was added, and heating was continued until a total heating time of 23 hours was completed.
The resulting reaction mixture was dissolved in toluene and crystals of p-toluenesulfonic acid precipitated and were filtered after addition of one mole equivalent of water. The toluene phase was extracted with 5 percent sodium bicarbonate solution, dried over sodium sulfate and evaporated to a brown oil weighing 0.0739 gm. (8.2 percent of theoretical ibuprofen yield).
The aqueous sodium bicarbonate phase was acidified and extracted three times with Skellysolve B which was dried over sodium sulfate, and evaporated to leave crude ibuprofen product weighing 0.7065 gm. (78.8 percent of theoretical ibuprofen yield). This yield was obtained despite spillage of the reaction mixture.
A 272.3 mg. portion of this crude ibuprofen was crystallized from Skellysolve B yielding 251.2 mg. of ibuprofen (92.3 percent yield).
EXAMPLE 3
Process using catalytic amounts of acid catalyst.
To a 15 ml. one-necked flask equipped with Dean-Stark trap and condenser, was added 0.0937 gm. of p-toluensulfonic acid monohydrate, 0.9935 gm. of crystalline 2-(4-isobutyl-2-oxo-3-cyclohexenyl)propionic acid, and 4 ml. toluene. The mixture was heated to reflux under nitrogen. After 5 hours of heating, TLC and GLC analysis of the reaction mixture showed minor amounts of ibuprofen product and 2-(4-isobutyl-2-oxo-3-cyclohexyl)propionic acid, and a major amount of two butenolide intermediates VA and VIA, which have been identified as being: ##STR10## where ibu denotes an isobutyl group.
Isolation of Va and VIa can be accomplished by extracting this cooled reaction mixture with 5 percent aqueous sodium bicarbonate, washing the toluene phase with water, drying it over sodium sulfate and evaporation of the toluene. The residual oil containing mostly (VIa) and a minor amount of (Va) is chromatographed over silica gel giving as oils pure Va and VIa having the following physical properties:
Va:
60 MHz (CDCl 3 ) 0.87 sextet (6H); 1.83 doublet (5H) resolves into a 2H singlet and 3H triplet on addition of Eu(FOD) 3 ; 5.22 singlet 1H, 5.64 ppm singlet (1H). 1R (CHCl 3 ) 1750, 1700 cm -1 .
λ max MeOH 213 (7,500); 278 mμ sh (ε 674)
mass spectrum: 206 (m+), 177, 149.
VIa:
60 MHz NMR (CDCl 3 ) 0.90 (6H), 1.80 (5H), 4.96 quartet (1H) 5.45 quartet (1H)
IR 1750, 1695 cm. -1
λ max MeOH 220 mμ (ε 5850)
mass spectrum: 206 (m+), 177, 163, 149.
Subjecting each of the intermediates, Va and VIa to p-toluene sulfonic acid in refluxing toluene as before, produces ibuprofen.
EXAMPLE 4
Preparing ibuprofen from diethyl α-acetyl-α-(5-methyl-3-oxo-hexyl)-β-methylsuccinate containing mixture.
To a 110 ml., round-bottomed flask fitted with condenser and Dean-Stark trop there was added 4.339 gm. of a mixture containing:
(A) diethyl α-acetyl-α-(5-methyl-3-oxo-hexyl)-β-methylsuccinate. (IVa),
a compound of the formula: ##STR11## a compound of the formula: ##STR12## and (B) 2.443 gm. of p-toluenesulfonic acid monohydrate and 17 ml. of toluene.
Under an inert atmosphere of nitrogen, the flask and its contents were refluxed for 6.5 hours with water removal. Water (115 μl.) was then added to reaction mixture, momentarily cooled, and reflux was continued for another 16 hours. TLC analysis showed the reaction to be complete to a mixture of ibuprofen and its ethyl ester.
To the cooled reaction mixture was added 0.23 ml. of water, and the resulting precipitate of p-toluene-sulfonic acid monohydrate was filtered, washed with toluene, and dried.
The toluene filtrate under nitrogen was treated with 4.8 ml. of 33 percent aqueous sodium hydroxide at 60° C. for 22 hours. The upper organic layer was separated from the cooled reaction mixture by decantation, 5 ml. of acetone was added to the remaining basic aqueous layer and the resulting slurry of ibuprofen sodium salt was cooled at 0° C. for 2 hours, filtered and washed with cold acetone.
This ibuprofen sodium salt in 5 ml. of water was acidified with 6N H 2 SO 4 , and extracted twice with Skellysolve B. The combined organic phases were dried over sodium sulfate and evaporated to give 2.03 gm. of crystalline ibuprofen. The yield was 79 percent.
EXAMPLE 5
Process using a phosphonic acid.
A mixture containing 1.00 gm. (4.46 mmole) of 2-(4-isobutyl-2-oxo-3-cyclohexenyl)propionic acid and 0.70 gm. (4.46 mmole) of phenylphosphonic acid in 5 ml. of toluene is refluxed at about 110° for about 20 hours. The water formed is removed during the course of the reaction with an appropriate trap.
The phenylphosphonic acid is recovered by filtering it out of the reaction mixture. The ibuprofen [2-(4-isobutylphenyl)propionic acid] is then separated from neutral biproducts by extracting the filtered reaction mixture with 20 ml. of 10 percent sodium hydroxide in water solution. The basic phase containing dissolved sodium 2-(4-isobutylphenyl)propionate is then re-acidified with 6N sulfuric acid and the ibuprofen content is extracted from the acidified mixture with Skellysolve B from which solution ibuprofen crystallizes on cooling.
EXAMPLE 6
Process using molten p-toluenesulfonic acid with acetic anhydride as water scavenger.
To a melt of 1.216 g. of p-toluenesulfonic acid monohydrate (6.31 mmole) and 0.60 ml. of acetic anhydride (6.31 mmole) at 94° C. was added 1.01 g. of 2-(4-isobutyl-2-oxo-3-cyclohexenyl)propionic acid. This mixture was heated under nitrogen for 35 hours at 115° C. A 5 ml. quantity of heptane was added to the hot reaction mixture and decanted. This operation was carried out four times. The decantate was concentrated, extracted with 5 percent sodium bicarbonate aqueous solution, and the aqueous phase obtained was acidified to pH 2 and extracted with Skellysolve B. Drying over sodium sulfate and evaporation of this Skellysolve B phase yielded 0.855 g. (92.3 percent yield) of crystalline ibuprofen assaying 97.5 percent pure by gas liquid chromatography (GLC).
EXAMPLE 7
Preparation of ibuprofen from Michael adduct mixture.
A crude mixture (about 400 g.) of compound IIa, above, where R 1 is ethyl (ethyl 2-(4-isobutyl-2-oxocyclohex-3-enyl propionate), compound IIIa, above, where R 1 is ethyl (diethyl α-methylα'-(4-isobutyl-2-oxocycylohex-3-enyl) succinate, and compound IVa above, where R 1 is ethyl (diethyl α-methyl-α'-acetyl-α'-(5-methyl-3-oxohexyl)succinate, (containing approximately 0.6 mole of ibuprofen-making starting materials and 403 g. (2.12 mole) of p-toluenesulfonic acid monohydrate) are stirred under nitrogen at 80° C. for two hours. Water is added to the reaction mixture in three portions (3×86 ml.) and an equivalent volume of each portion of water is distilled from the reaction mixture at about 120° C. (before the next portion of water was added). The time required for these distillations is about 4 hours. Toluene (695 ml.) is added and the mixture is distilled (at reflux) over 6.5 hours to aromatize the ene-one acids (IIa, IIIa and IVa) to form ibuprofen acid, 2-( 4-isobutylphenyl)propionic acid, and to azeotrope away the water with a Dean-Stark trap.
The resulting solution is cooled to 35° C. and water is added to precipitate p-toluenesulfonic acid monohydrate. The resulting slurry is cooled to 0° C. to 5° C., stirred over 1 hour and filtered and washed with about 50 ml. of toluene. The p-toluenesulfonic acid monohydrate precipitate solid (filtered material) is suitable for recycling and reuse. About 80 percent, 323 g., of the p-toluene sulfonic acid monohydrate was recovered.
The toluene filtrate and wash are mixed with 10 percent aqueous sodium hydroxide (412.5 g.) and the resulting organic phase is re-extracted with 135 ml. of water, and the phases separated again. The combined aqueous phases are diluted with 200 g. of 50 percent sodium hydroxide solution after which 99.75 of solid hydroxide and 428 ml. of acetone are added. Upon cooling this aqueous base treated mixture to 0° C. to 5° C. and stirring for about 1.5 hours, sodium 2-(4-isobutylphenyl)propionate (sodium ibuprofen) crystallizes out. This crystalline precipitate is collected by filtration and washed twice with 0° C. acetone portions (2×175 ml.) to purify the sodium ibuprofen salt cake. The sodium ibuprofen salt cake is added to 352 ml. of water and Skellysolve B (mixed hexanes) or hexane, 630 ml., is added. Concentrated sulfuric acid (80 ml.) is added to bring the pH of the mixture to about 0.6 and the resulting mixture is warmed to about 42° C. to dissolve the ibuprofen acid in the mixture. The aqueous and organic phase are allowed to separate. The aqueous phase is discarded and the organic phase is washed with water, e.g., two 1200 ml. portions of water. The organic phase containing the dissolved ibuprofen acid is separated from the water phase and cooled to 0° C. to 5° C. and stirred for about 0.5 hours until crystallization of the ibuprofen acid is completed. The ibuprofen crystals are filtered and washed with hexane and dried to give 90 to 100 g. of ibuprofen acid. | 2-Aryl-C 2 to C 5 -alkanoic acids and esters thereof are prepared by heating a 2-(2-oxo-3-cyclohexenyl)-alkanoic acid or ester derivative in the presence of a sulfonic acid or a phosphonic acid at 75° C. to 130° C. while providing a means for removing water from the reaction mixture. In the process new butenolide derivative intermediates have been discovered. Alternatively, the 2-aryl-C 2 to C 6 -alkanoic acids can be prepared from the butenolides by forming a mixture of the 2-(2-oxo-3-cyclohexenyl)-alkanoic acid with acetic anhydride in the presence of an acid scavenging base, allowing the mixture to stand for a time sufficient to form an acetate intermediate, heating the resulting mixture to about 75° C. to about 130° C. to form the betenolide intermediates. Thereafter these intermediates can be heated with sulfonic or phosphonic acid as above while removing water to form the 2-aryl-C 2 to C 6 -alkanoic acid or adding a carboxylic acyl halide and water to form acetic acid and mineral acid in the mixture, and this resulting mixture can be heated to 75° C. to 130° C. for a time sufficient to form 2-aryl-C 2 to C 6 -alkanoic acid products which have a variety of uses. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to hydrotherapy jets.
2. Description of the Related Art
Various hydrotherapy jets have been developed for use in spas, hot tubs, pools and bath tubs that discharge a stream of water that can be aerated through a variety of discharge nozzles. Designs of these hydrotherapy jets provide different flow characteristics that result in different massage effects being experienced by the body. Such jets have been found to produce a pleasing massage effect for many users, and have become quite popular. In the design of single or multi-use spas or tubs, it is common to use a variety of different jet nozzles to provide a variety of different massaging effects.
Early jets simply discharged a stream of warm water along the longitudinal axis of the jet body, with later jets providing aeration of the water stream. Since then numerous jets have been developed in which the direction of the stream can be adjusted. For example, U.S. Pat. No. 5,269,029 to Spears, et al. (assigned to the same assignee as the present invention) discloses a jet that provides an off axis stream of water and has an axial push-pull mechanism used to control the flow of water. The mechanism can also be rotated to rotate a stream of water around the jet axis, thus providing directional control over the stream.
Jets have also been developed having a rotating outlet or eyeball that automatically rotates in response to water flowing through the outlet. As an example, see Waterway Plastics, Inc., “1999 product catalog,” page 4, including part nos. 210-6120 and 210-6510. In these jets, the outlet can be adjusted off the jet's longitudinal axis to provide a turning moment in the eyeball in response to the water stream flow.
U.S. Pat. No. 6,178,570 to Denst et al. (assigned to the same assignee as the present invention) discloses a jet having a rotating eyeball with one or more discharge outlets that can be adjusted to vary the direction of the outlet flow stream, as well as the direction and speed of the eyeball's rotation. A high-pressure water stream flows through the outlets and, depending on the orientation of the outlets, the eyeball can rotate clockwise or counter-clockwise at different speeds.
U.S. Pat. No. 5,920,925 to Dongo (assigned to the same assignee as the present invention) discloses a jet having a rotating eyeball and a cap formed with a number of openings positioned at a common radius from the center of the cap. The jet produces a high-pressure water stream that flows through the eyeball, causing it to rotate at a high speed and discharge the jet in a circular pattern that impinges on the openings. Together, the rotational speed and the opening design produce the sensation of a number of simultaneously pulsating water streams that are directed into the spa.
Various hydrotherapy jets have been developed in the past for use with spas, hot tubs, and bath tubs that discharge an aerated stream of water through a variety of discharge nozzles. In general, such jets produce a constant flow stream that provides a good therapeutic effect. However, in an attempt to enhance the therapeutic effect, several systems have been designed that produce a pulsating flow. These systems have met with varying degrees of success as they often require additional or larger components, which increase system cost and add complexity, or generate unwanted pressure losses, thus requiring a larger pump than would otherwise be required.
One prior art approach has been to use mechanical devices to pulse water flowing to an individual jet, or a series of jets. An example of such a system is described in U.S. Pat. No. 4,320,541 to John S. Neenan. In this approach a series of mechanical blocking devices are used to intermittently block and unblock a flow stream. As a flow stream is unblocked, a pulse of water is sent to the jet and ultimately to the user. While this approach does provide a pulsating effect, blocking and unblocking of the flow stream causes abrupt pressure increases imposing a strain on spa systems. Aside from these drawbacks, such systems require additional components that add complexity, cost and weight. In addition, since the pulsation effect is generated away from the jet, the pulsed flow stream experiences a pressure loss, resulting in a decreased pulsation effect being felt at the jet exit.
In an alternate approach, rather than using mechanical devices to generate a pulsed flow, a hydraulic pumping device is used. In such a system, pulsation is produced by a distribution valve which houses a rotor that is rotated by inlet water flow, and distributes the inlet water to a series of outlets which are connected into the individual jets. The rotor is formed with a groove that sequentially aligns the water outlets to the water inlet so that each outlet is periodically connected to, and then disconnected from, the inlet. The water is supplied into each jet in a pulsating or chopping manner. Examples of this system are given in the U.S. Pat. Nos. 5,444,879 and 5,457,825 to Michael D. Holtsnider and assigned to Waterway Plastics, Inc. the assignee of the present invention.
While hydraulic systems do provide a degree of pulsation, they too suffer from many of the same problems as mechanical systems. For example, as the pulsation effect is generated away from the jet, the pulsed flow stream experiences a pressure loss which results in a reduced pulsation effect at the jet, and like the mechanical systems the additional componentry adds complexity, cost and weight to the system. Also, a larger water pump may be required to provide additional energy to rotate the rotor and to compensate for additional pressure losses.
To overcome the drawbacks associated with mechanical and hydraulic pulsed systems, pulsation systems have been designed that do not require mechanical devices or hydraulic distribution systems. Such systems generally have individual pulsation mechanisms located within the individual jets. Examples are shown in the Waterway “1997 product catalog,” page 1, deluxe and octagon series pulsating jet, and in U.S. Pat. No. 5,657,496 to Corb et al., also assigned to Waterway Plastics, Inc. The individual jets contain rotational devices commonly called eyeballs. The eyeballs have water conduits which discharge water flowing through the jet into the spa or tub. The conduits are angled to cause the eyeball to rotate and distribute the flow stream in a circular pattern. The circular distribution provides, to some degree, the sensation of a pulsed flow as the flow stream interacts with a specific point on the body in a periodic fashion. However, this is not truly a pulsed flow since the user actually experiences a continual flow stream, but in a circular pattern.
Attempts have been made to produce a jet that would produce a true pulsed flow. To this end, several designs have been developed in which pulsation is created at the jet itself. In these systems the flow stream at the jet is blocked periodically to create the sensation of a pulsed flow. See Waterway Plastics, Inc. “1997 product catalog” page 1, Standard Poly jets whirly and pulsator jets, and U.S. Pat. No. 4,508,665 to Spinnett. While both the Waterway and Spinnett Jet designs do in fact produce a pulsed flow, the pulsating is created by blocking the flow stream exiting the discharge member as it rotates past a blocking member. When the flow stream comes in contact with the blocking member the flow is temporarily interrupted or halted, thus generating a pulsed flow that is circular or spiral in nature, moving from one zone to another in a sequential manner. The blocking, however, creates an undesirable backflow into the jet, causing strain on the spa system and ultimately lowering efficiency. In addition, the Spinnett design requires multiple deflections of the flow stream as it passes through the jet, causing pressure losses and lowering the system efficiency.
SUMMARY OF THE INVENTION
The invention includes a jet body, a water inlet, a channel within the jet body, a discharge member, and a cap with having a plurality of openings. The jet body produces a high-pressure water stream that flows through the discharge member, causing the discharge member to rotate, and discharges the water stream in a number of concentric patterns. Together the rotation speed and the plurality of openings produce the sensation of a number of concentric rings each having multiple pulsating water streams that are directed into the spa dr tub.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other further features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings, in which:
FIG. 1 is a simplified exploded perspective view of a pulsating hydrotherapy jet unit in accordance with the invention;
FIG. 2 is a sectional view taken along section line 2 — 2 of the double pulsating hydrotherapy jet unit of FIG. 9 ;
FIG. 3 is a top plan view of the discharge member used in the jet of FIG. 1 ;
FIG. 4 is a sectional view taken along section line 4 — 4 of the discharge member of FIG. 3 ;
FIG. 5 is a perspective view of a fully assembled double pulsating hydrotherapy jet unit;
FIG. 6 is a front elevation view of the cap used in the jet of FIG. 5 ;
FIG. 7 is a sectional view taken along section line 7 — 7 of the cap of FIG. 6 ;
FIG. 8 is a sectional view taken along section line 8 — 8 of the cap of FIG. 6 ;
FIG. 9 is a front elevation view of an assembled double pulsating hydrotherapy jet unit;
FIG. 10 is a top plan view of one embodiment of the cap used in the jet of FIG. 2 ;
FIG. 10 a is a bottom plan view of one embodiment of the cap used in the jet of FIG. 2
FIG. 11 is a sectional view of one embodiment of the discharge member used in the jet of FIG. 2 ;
FIG. 12 is an exploded perspective view of a double pulsating hydrotherapy jet unit of FIG. 9 ;
FIG. 13 is a perspective view of a spa/tub system using the present invention; and
FIG. 14 is a flowchart demonstrating one embodiment of the claims.
DETAILED DESCRIPTION OF THE INVENTION
The invention, as shown in FIG. 1 , relates to a low-pressure loss hydrotherapy jet system 40 that uses a single water supply 3 (not shown) and a single air intake 4 (not shown) to produce multiple concentric, rings of simultaneously pulsating water streams in a spa bath. As shown in FIG. 1 aerated water stream 5 enters discharge member 10 , which has a major outlet conduit 17 and a minor outlet conduit 18 . Water stream 5 enters discharge member 10 and splits into subsidiary streams 6 and 7 , which exit discharge member 10 through minor outlet conduit 18 and major outlet conduit 17 respectively. Subsidiary streams 6 and 7 discharge in concentric patterns from discharge member 10 . The subsidiary streams 6 and 7 impinge a concentric arrangement of openings 28 a – 28 g and 27 a – 27 g respectively disposed on cap 20 . Subsidiary stream 7 passing through openings 27 a – 27 g generates a ring of major pulsating streams 8 . Subsidiary stream 6 passing through openings 28 a – 28 g generates a ring of minor pulsating streams 9 .
In one embodiment the upstream contours surrounding the openings creates ridges that divert the rotating discharge member to the respective openings without generating substantial back flow. In one embodiment, when discharge member 10 receives a water supply having a pressure of at least 10 pounds per square inch (psi), discharge member 10 rotates fast enough that the user may have the sensation of major and minor pulsating streams 8 and 9 pulsating simultaneously. Minor pulsating stream 9 may appear to be concentric with major pulsating stream 8 . In one embodiment discharge member 10 may rotate at speeds of at least 500 revolutions per minute (rpm). In one embodiment, the system has the added advantage that its design results in lower pressure losses.
FIG. 1 also shows discharge member 10 has a discharge member sleeve 15 that connects to inner discharge member sleeve 67 (shown in FIG. 12 ). Locking slot 14 on discharge member sleeve 15 allows sleeve attachment tab 66 (shown in FIG. 12 ) to connect inner discharge member sleeve 67 to discharge member 10 . Alignment slot 16 allows alignment of discharge member 10 to inner discharge member sleeve 67 .
As shown in FIG. 2 major outlet conduit 17 diverts aerated water stream 5 away from the longitudinal axis of water stream 5 , and forms subsidiary stream 7 . In one embodiment, subsidiary stream 7 may impart a rotational moment to discharge member 10 . Minor outlet conduit 18 also deflects aerated water stream 5 away from its longitudinal axis forming subsidiary stream 6 , but does not divert it as far away as major outlet conduit 17 . In one embodiment, minor subsidiary stream 6 may impart a rotational moment to discharge member 10 .
Channel 31 , in FIG. 2 , receives water supply 3 flowing from inlet 32 through exit port 33 . Exit port 33 , whose axis is normal to that of Channel 31 , constricts the flow of water supply 3 and provides it to inlet 32 . Attached to exit port 33 , at its upstream end, is a venturi sleeve 30 that houses a venturi 34 . Venturi 34 has an upstream section 35 that tapers down to its smallest diameter at throat 36 . At throat 36 , venturi 34 expands in diameter forming an aft section 37 . Air intake 4 enters through air conduit 45 . Aft of throat 36 , in section 37 , are located a series of air openings 39 used to entrain air supply 4 to aerate the water flowing through venturi 34 . In this manner, air intake 4 is entrained into water supply 3 forming aerated water stream 5 .
In one embodiment, as shown in FIG. 2 , major outlet conduit 17 diverts part of aerated water stream 5 into diverted major outlet conduit aerated water stream 7 . Diverted major outlet conduit aerated water stream 7 leaves discharge member 10 through major outlet conduit 17 . Minor outlet conduit 18 diverts part of aerated water stream 5 into the minor outlet conduit 18 . Subsidiary stream 6 leaves discharge member 10 through minor outlet conduit 18 . Major and minor aerated subsidiary streams 7 and 6 exiting discharge member 10 thru major outlet conduit 17 and minor outlet conduit 18 respectively encounter openings 27 a – 27 g and 28 a – 28 g respectively. In FIG. 2 , aerated water stream 5 exits discharge member 10 as major subsidiary stream 7 thru major ring opening 27 b , and minor subsidiary stream 6 thru minor ring opening 28 e.
Discharge member 10 can be seen just up stream of cap 20 . The cross section of major opening 27 b may be seen in cap 20 . A cross section of minor opening 28 e may also be seen in cap 20 . FIG. 2 shows major outlet conduit 17 lining up with major ring opening 27 b allowing major outlet conduit aerated water stream 7 to exit double pulsating hydrotherapy jet unit 40 . FIG. 2 also shows minor outlet conduit 18 aligning up with minor ring opening 28 e permitting subsidiary stream 6 to exit double pulsating hydrotherapy jet unit 40 .
Washer 52 separates bearing rakes 53 and 51 in FIG. 2 from each other. Bearing rakes 53 and 51 permit discharge member 10 to rotate freely around rotational axis 11 as shown in FIG. 4 . These bearing rakes 53 and 51 fit over inner bearing sleeve 54 and are attached thereto. The combination of inner bearing sleeve 54 , bearings 53 and 51 and washer 52 are then snugly fit inside outer bearing sleeve 55 as is also shown in FIG. 12 . The positioning of bearing rake 51 and bearing rake 53 outside bearing sleeve 54 keeps the bearings separate from aerated water stream 5 , reducing the chance that over time these bearings might seize. Additionally, having two bearing rakes 51 and 53 reduces the wear that would be encountered by a single bearing rake, thus extending the life of the jet.
Washers 56 and 57 , as shown in FIG. 2 , confine air uptake 4 entering thru air conduit 45 allowing it to aerate water stream 3 producing aerated water stream 5 . Conduit 45 has a check valve comprising check valve ball 46 and check valve ball retainer 47 . The check valve prevents water from escaping double pulsating hydrotherapy jet unit 40 back thru air conduit 45 . When water enters air conduit 45 check ball 46 is forced against check ball retainer 47 sealing the conduit closed.
As discharge member 10 rotates around its longitudinal axis, major outlet conduit 17 sweeps consecutively through major openings 27 a to 27 g . As major outlet conduit 17 sweeps through an opening 27 a – 27 g in cap 20 , subsidiary stream 7 passes through said opening creating major pulsating stream 8 (shown in FIG. 1 ).
As discharge member 10 rotates around its longitudinal axis, minor outlet conduit 18 sweeps consecutively through minor openings 28 a – 28 g . As minor outlet conduit 18 sweeps through an opening 28 a – 28 g in cap 20 , subsidiary stream 6 passes through said opening creating minor pulsating stream 9 (shown in FIG. 1 ).
As may be seen in FIG. 2 , in one embodiment major opening 27 b may be aligned with major outlet conduit 17 , and thus does not substantially impede the flow of subsidiary stream 7 through major outlet conduit 17 . In one embodiment, all openings 27 a – 27 g may be aligned with major outlet conduit 17 as opening 27 b is shown here. In one embodiment minor opening 28 e may be aligned with minor outlet conduit 18 , and thus opening 28 e does not interfere substantially with the flow of water out of minor outlet conduit 18 . In one embodiment, all openings 28 a – 28 g may be aligned with minor outlet conduit 18 as opening 28 e is shown here.
In one embodiment, as shown in FIG. 3 major outlet conduit 17 extends further away from the center axis 11 (shown in FIG. 4 ) of discharge member 10 then does minor outlet conduit 18 .
FIG. 4 shows discharge member 10 has an axis of rotation 11 that is collocated with the longitudinal axis of aerated jet 5 (shown in FIG. 2 ). FIG. 4 further demonstrates major outlet conduit 17 extending further away from the centerline then does minor outlet conduit 18 . In one embodiment, conduits 17 and 18 extend up and out from discharge member 10 in a manner that suggests asymmetric bunny ears.
In one embodiment discharge member 10 has a rotational axis 11 with the two linear water outlet conduits 17 and 18 passing through it. Major outlet conduit 17 has a longitudinal axis 13 that is coplanar with axis 11 . Minor outlet conduit 18 has a longitudinal axis 12 that is coplanar with axis 11 . Major outlet conduit's 17 longitudinal axis 13 , and minor outlet conduit's 18 longitudinal axis 12 are orientated at angles α and β respectively to axis 11 of discharge member 10 . In one embodiment α may be greater than 37 degrees, and β may be greater than 21 degrees. In another embodiment one or both of axes 12 and 13 are further offset by an angle γ (as shown in FIG. 3 ) in a direction normal to offsets defined by angles α and β to provide a turning moment to discharge member 10 in response to a jet flow. Subsidiary streams 6 and 7 exiting rotational member 10 trace out concentric patterns, as discharge member 10 rotates, which may be perceived as solid rings of water. In one embodiment angle γ may be approximately 6 degrees.
In one embodiment as shown in FIGS. 2 , 3 and 4 major water outlet conduit 17 and minor water outlet conduit 18 pass through and extend downstream from discharge member 10 , and are spaced approximately 180 degrees apart from one another about axis 11 . Angles α, β and γ are set such that discharge member 10 obtains sufficient rotational speed to provide what may be perceived to be multiple continuous solid concentric bands of water. Interaction of the water bands with cap 20 ultimately may provide the user with the sensation of multiple concentric simultaneously pulsating water streams.
FIG. 5 shows double pulsating hydrotherapy jet unit 40 . Cap 20 may be placed within rotating scallop plate 49 . Scallops 49 a on rotating scallop plate 49 allow the reduction of the flow of water supply 3 to double pulsating hydrotherapy jet unit 40 by rotating discharge member carrier 55 to occlude a portion of water inlet 32 as shown in FIG. 2 .
In one embodiment, as shown in FIG. 6 , cap 20 contains two series of 7 cylindrical openings 27 a – 27 g and 28 a – 28 g . Cap 20 has major ring openings 27 a – 27 g arrayed around the edge of cap 20 at a common radial distance from the center, or longitudinal axis of cap 20 that coincides with longitudinal axis 11 of discharge member 10 when assembled, i.e. in a circle. Also cap 20 has arrayed around its center a circle of minor ring openings 28 a – 28 g that are arrayed at a common radial distance from the longitudinal axis of cap 20 . In one embodiment the radius of major ring openings 27 a – 27 g may be greater than the radius of minor ring openings 28 a – 28 g.
FIG. 7 shows the curve of cap 20 , and cap edge ridge 23 . Cap edge ridge 23 assists in securing cap 20 within scallop ring 49 . This cross section of cap 20 partially exposes minor ring openings 28 e and 28 g.
FIG. 8 cuts directly through the center of major opening 27 b and minor opening 28 e . This specific arrangement of openings is one embodiment of a cap for a double pulsating hydrotherapy jet unit 40 . Other embodiments will be equally effective in providing the double pulsating hydrotherapy jet effect.
FIG. 9 shows an assembled double pulsating hydrotherapy jet unit 40 showing cap 20 and rotating scallop ring 49 . Scallops 49 a can be seen around the periphery of rotating scallop ring 49 . Scallops 49 a allow better finger grip while rotating scallop ring 49 to adjust the rate of flow of water supply 3 . Major ring openings 27 a – 27 g may be seen just inside rotating scallop ring 49 . Cap 20 on which major ring openings 27 a – 27 g are placed is in fact placed over and nestled within rotating scallop plate 49 . In one embodiment, minor ring openings 28 a – 28 g may be seen nested inside and between major ring openings 27 a – 27 g.
In one embodiment, shown in FIG. 10 , cap 20 may have an opening 26 in its center. Center opening 26 may be used to allow discharge of centralized water outlet conduit 19 of FIG. 11 .
As is shown in FIG, 10 a , upstream of openings 27 a through 27 g at the intersection of the openings are a series of raised contours 25 between the openings. In one embodiment the contours 25 form ridges that divert water provided from conduit 17 into one or more of openings 27 a through 27 g . The ridges cut the water, diverting it into the openings. The cutting action allows the water to flow into openings without producing substantial back flow as may be the case if the surfaces between the openings had no ridges. Similar raised contours 24 may be seen between openings 28 a through 28 g that divert water provided from conduit 18 into one or more of bore holes 28 a through 28 g , thus reducing backflow. The contours 24 , 25 can have many different shapes and sizes.
In one embodiment, as shown in FIG. 11 discharge member 10 may contain a centralized water conduit 19 coaxial with the longitudinal axis 11 of discharge member 10 . The centralized water conduit provides a continuous nonpulsating jet to the user in addition to the series of pulsating jets.
FIG. 12 demonstrates how all the individual parts of double pulsating hydrotherapy jet unit 40 relate to one another, and are assembled. Front flange 42 and gasket 41 combine with locking thread ring 48 to grasp the side of a hydrotherapy spa or tub shell 70 (shown in FIG. 13 ). Gasket 41 prevents leakage of water from a hydrotherapy spa or tub shell 70 . Locking thread ring 48 screws down over exterior threading 43 with interior threading 50 . Rotational movement of locking thread ring 48 towards the front of double pulsating hydrotherapy jet unit 40 compresses front flange 42 against gasket 41 and compresses gasket 41 against a wall of hydrotherapy spa or tub shell 70 . Gasket 41 is seated behind front flange 42 . Housing 44 supports stationery and rotating portions of double pulsating hydrotherapy jet unit 40 . This assembly attaches double pulsating hydrotherapy jet unit 40 to the wall of hydrotherapy jet bath.
Mechanical mount retaining ring 60 is placed into Housing 44 to hold outer bearing sleeve 55 in a fixed position. Exit port 33 on outer bearing sleeve 55 permits water from water inlet 32 to enter the interior of double pulsating hydrotherapy jet unit 40 . Discharge member carrier outer sleeve 72 permits attachment to rotating scallop plate 49 . Locking feature 61 locks and makes secure the attachment of discharge member carrier 72 to rotating scallop plate 49 .
Inner bearing sleeve ridge 62 is used as a stop to prevent bearing rakes 53 and 51 from moving too far forward along inner bearing sleeve 54 .
Discharge member 10 slides over and encompasses inner discharge member sleeve 67 . Discharge member 10 is held in place by the interlocking of sleeve attachment tab 66 and discharge member attachment slot 14 (shown in FIG. 1 ). Cap 20 is attached to rotating scallop plate 49 . Cap 20 is stationery compared to, and moves with rotating scallop plate 49 . Discharge member 10 is mounted at the down stream end of venturi sleeve 30 . Venturi sleeve 30 contains aerated water stream 5 . Discharge member 10 is designed so impingement by aerated water stream 5 generates a rotational moment causing discharge member 10 to spin about its axis of rotation 11 . Located down stream of discharge member 10 is cap 20 , which diverts the water flowing from discharge member 10 to produce simultaneous pulsating jets 8 and 9 .
As shown in FIG. 13 , multiple jets can be installed in a spa or tub shell 70 . In this disclosure, spa shell is defined as any bath, pool, reservoir or spa capable of containing a fluid and enabling immersive recreation or therapy. Some or all of the jets can be one of the jets described above, with the jets in this embodiment being jet 40 . The remaining jets 71 may be any other desired type, such as a variety of prior single nozzle jets. Both types of jets are connected to a water pump 78 , used to circulate the water throughout the spa system, by a series of water conduits 73 . Water from shell 70 is provided to pump 78 through the drain 77 , which is connected through return water conduit 74 to pump 78 . Water from pump 78 is provided back to shell 70 by conduits 73 , where it flows into jets 40 and 71 , as the case may be, and in turn into shell 70 , completing the loop. Additionally, an air system 79 may be included that provides air to individual jets 40 and 71 through an air conduit 80 , to aerate the water flowing through the jet. The air system 79 can be pump driven to increase the pressure of the air entering the jet 8 , or can be vacuum based with the venturis located within the jets 40 and 71 drawing air into the jets and water flow stream.
FIG. 14 shows a flow diagram of one embodiment of the claimed invention. A hydrotherapy jet discharge is provided in block 141 . A plurality of water streams is discharged in block 142 . The water streams are rotated in concentric patterns around a common axis in block 143 .
Although the present invention has been described in considerable detail with references to certain preferred configuration thereof, other versions are possible. Therefore, the spirit and scope independent claims should not limited to the preferred version contain therein. | A pulsating hydrotherapy jet is disclosed which has a jet body with a water inlet to allow water to flow into the body. The jet body discharges the water through a discharge member in more than one concentric pattern. A cap mounted on the body to receive the circular water patterns is also disclosed. The cap has a number of openings that form more than one concentric opening ring. Each of the opening rings align with a respective one of the circular water patterns to provide the sensation of a number of circular patterns of multiple pulsating jets. A system for providing a hydrotherapy jet to a reservoir of water is also disclosed. The system includes a reservoir shell capable of holding water with a number of hydrotherapy jets according to the invention that are mounted around the reservoir shell. A water pump system circulates water from the reservoir to the jets. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/618,433, entitled “Anonymous Shopping Transactions On A Network Through Information Broker Services,” filed Nov. 13, 2009, which issued as U.S. Pat. No. 8,001,014 on Aug. 16, 2011 and which is a continuation of U.S. patent application Ser. No. 09/821,040, entitled “Anonymous Shopping Transactions On A Network Through Information Broker Services,” filed Mar. 30, 2001, which issued as U.S. Pat. No. 7,640,187 on Dec. 29, 2009, the contents of which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
This invention relates to a system and method for carrying out anonymous shopping and other on-line transactions over a network through the use of information broker services.
BACKGROUND OF THE INVENTION
The rise in the popularity of interconnected, processor-based networks, such as the Internet, has increased the practice of on-line shopping. The increase of on-line shopping has made it possible for consumers to purchase goods and services with ease. Often, consumers are able to purchase items from the convenience of their own home at any hour of the day.
However, in order to complete an on-line transaction, users are typically required to submit personal, confidential, or otherwise private information over the network to the on-line merchant. Once submitted, the information may be intercepted or otherwise accessed by unintended or unauthorized persons. Obviously, this is an undesirable result. Thus, it is desirable to carry out on-line transactions without needlessly endangering private information.
For example, buyers are typically required to submit a credit card number to the on-line merchant in order to pay for the desired goods or services. However, submitting a credit card number over the network opens the possibility that the credit card number will fall into the wrong hands and unauthorized charges may result.
Buyers are also asked to provide their legal names (usually as it appears on the credit card account). For numerous reasons, buyers may not want to provide their real name over the network. For example, for safety reasons, women living alone may not want to provide their real names. Similarly, buyers may not want to provide their home address when purchasing items on-line.
These and other drawbacks exist.
SUMMARY OF THE INVENTION
One advantage of the invention is that it overcomes these and other drawbacks in existing devices.
Another advantage is that the invention provides a system and method for enabling consumers to shop on-line without having to reveal personal information.
Another advantage is that the invention provides a system and method for using an information broker service to disguise a user's personal information and enable the user to accomplish on-line shopping in an anonymous fashion.
According to one aspect of the invention, there is provided a method for enabling a user to transact an anonymous on-line transaction, wherein a form of on-line payment is requested at a transaction interface. The method may include providing an anonymous user interface that enables a user to initiate an on-line payment, accessing a first profile comprising user data when the user activates the form of on-line payment, generating a second profile linked to the first profile wherein, the second profile comprises anonymous data, and communicating the anonymous data from the second profile to the transaction interface to enable completion of the transaction.
According to another aspect of the invention, there is provided a system for enabling a user to transact an anonymous on-line transaction, wherein a form of on-line payment is requested at a transaction interface. The system may include an anonymous user interface that enables a user to initiate an on-line payment, a profile access initiator that accesses a first profile comprising user data when the user activates the form of on-line payment, a profile generator that generates a second profile linked to the first profile wherein, the second profile comprises anonymous data, and an anonymous data communicator that communicates the anonymous data from the second profile to the transaction interface to enable completion of the transaction.
Other advantages and features of the invention will be apparent to those of skill in the art from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of the overall system according to one embodiment of the invention.
FIG. 2 is a schematic of an anonymous shopping interface according to one embodiment of the invention.
FIG. 3 is a schematic flow diagram illustrating an anonymous shopping method according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Operation of the invention may be described with reference to the following example embodiments. One embodiment applies to, among other things, the situation when a user wants to buy products on the Internet without supplying their credit card number. In this situation, a credit card issuer (e.g., a bank, credit union, or other credit card issuing entity) acts as an information broker and supplies a single-use credit card number for the user to use while conducting an on-line transaction on the Internet site. The Internet site receives and processes the single-use number the same as any other credit card number. The credit card issuer treats the card as a transaction card (i.e., single-use) as long as certain security criteria (explained below) are met.
For example, the above embodiment may be implemented as follows. A user's Internet browser interface may be adapted to include an anonymous shopper interface. The anonymous shopper interface may contain a representation (e.g., graphic image) of a credit card. When the user comes to the purchase point, or other request for a form of on-line payment, during his/her on-line shopping transaction he/she may activate the anonymous shopper interface credit card to complete the purchase. In some embodiments, activating the anonymous shopper card may activate a form fill-in procedure that reads the amount of the transaction (i.e., the amount of the purchase and any shipping, tax or other additional costs) and uses that amount to complete other transaction procedures as described below.
Activation of a form of on-line payment via the anonymous shopping interface may cause a profile access module to initiate access to a stored profile that a user may store containing credit card information corresponding to the credit card account for which the user wants the on-line transaction charges to ultimately be debited. For example, the stored profile may include the user's name, address, credit card account number, account expiration date, and any other information helpful for accomplishing on-line shopping. The profile may be stored at any suitable location. For example, the profile may be stored with the anonymous shopper interface provider, the credit card issuer, the user (e.g., in the user's hard drive), or any other suitable location. Regardless of storage location, upon activation via the anonymous shopper interface, the profile is retrieved for further use in the on-line transaction as described below.
The amount of the transaction and the stored profile information are then communicated through a secured line to the credit card issuer or other information broker. The secured line prevents unauthorized access to the user's private information.
The invention provides a transaction number generator software module for use by the credit card issuer or other information broker processing center. The number generator module generates a single use anonymous transaction number, associated with the user's credit card account, which functions as a “normal” credit card number. The anonymous transaction number is returned over the secured line and filled-in as card credit card number to complete the on-line shopping transaction.
Thus, instead of exposing the user's credit card number, the credit card issuer issues an anonymous per transaction credit card account with a purchase limit based on the transaction amount and an expiration date based on the month/year that the transaction takes place.
This means that the credit card issuer can issue at least one trillion unique credit cards per month. If that limit is hit, some of the numbers in the first four numbers of the user's credit card may be used to create a new limit of one trillion transactions per week.
The user's actual credit card number is never sent over the Internet. The only transmission of the actual credit card number occurs between the anonymous shopper interface and the credit card issuer over a secure private connection. In this manner, the user removes much of the risk of unauthorized use of their credit card. The credit card issuer also reduces their risk of someone stealing the credit card.
Another aspect of the invention applies to the situation when a user wants to conduct a transaction on the Internet without giving out their real name. Currently, users must use their real, or legal, name when supplying their payment and/or shipping information. One embodiment of the invention allows a user to associate an alias or fake name with the selected form of on-line payment (e.g., a single-use credit card).
The alias may be created in any suitable fashion. For example, the alias may be created by the user and stored in a profile. Alternatively, the user may be prompted to submit an alias as part of the request for a single-use transaction number. In any event, the alias name is transmitted to the on-line shopping site (e.g., through auto-form fill) as the name of the credit card account holder. In this manner, the site completes the on-line transaction using the alias name and the user never transmits his/her real name over the Internet.
Another aspect of the invention applies to situations when the customer wants to conduct a transaction anonymously without having to provide a home shipping address. In such a scenario, the invention enables a delivery service (e.g., U.S. Postal Service, UPS, Federal Express, etc.) to act as an information broker for the shipping address.
For example, the above embodiment may be implemented as follows. An anonymous shopper interface may include a representation of a delivery service logo or other identifier. When presented a delivery address request form, the user may select the desired delivery service logo in the anonymous shopper interface. Selecting the delivery service logo sends the delivery address request, along with a user identifier, to the anonymous shopper interface provider.
A user identifier may comprise any identifier that will uniquely correspond to the user. For example, a user identifier may comprise a uniform resource locator (URL), a domain name, an email address, a globally unique identifier (GUID), or other unique identifier.
The anonymous shopper interface provider verifies the user identity (e.g., using a password or other authentication scheme) and retrieves the user's address, billing and other information that the delivery service needs to complete the transaction.
Communication between the anonymous shopper interface and the delivery service is conducted over a private-secure connection. Upon receipt of the request, the delivery service generates an anonymous address. For example, the anonymous address may comprise the address of a delivery service hub station with a special routing code embedded in the address.
The anonymous shopper interface inserts the anonymous address into the on-line shopping site's shipping address form (e.g., through auto-form fill). The on-line shopping site sends the user's items to the anonymous address in the same manner as any other address. When the user's package reaches the delivery service hub station address, the delivery service recognizes the anonymous address and routes delivery to the user's real address. In this manner, the user can shop on-line without fear of revealing private information such as a home address.
The above embodiments are but a few examples of the invention. Other applications and embodiments will be apparent to those of skill in the art upon reading the following detailed description of the figures.
FIG. 1 shows a schematic of the overall system 100 according to an embodiment of the invention. As shown, the various parties involved in on-line shopping interact through the medium provided by the Internet 102 . Those parties may include users 104 , on-line shopping sites 106 , anonymous shopping interface providers 108 , and information brokers 110 .
As described above, users 104 includes persons interested in carrying out an on-line shopping transaction. Users 104 may comprise private individuals, businesses, government entities, or other organizations.
On-line shopping sites 106 may include any Internet site that enables a user 104 to order, purchase, lease, or otherwise obtain, goods or services over the Internet 102 .
Anonymous shopping interface provider 108 represents the entity or entities that provide the anonymous shopping interface 200 described herein. For example, anonymous shopping interface provider 108 may comprise software providers, Internet service providers, or a combination of these and other computer related service providers. As described above, the anonymous shopping interface provider 108 provides the user 104 with an anonymous shopping interface 200 that enables the user to carry out an anonymous on-line shopping transaction.
Information broker 110 represents the entity or entities that provide the information that enables the user to complete an anonymous on-line shopping transaction. For example, for embodiments where a user wishes to shop with an anonymous credit card account, information broker 110 may comprise a bank, credit union, or other financial institution that issues credit card accounts. Similarly, for embodiments where a user wishes to shop with an anonymous address, information broker 110 may comprise a post office, package delivery service, or other delivery service. Of course, for any given transaction information broker 110 may comprise more than one type of entity (e.g., a bank and a delivery service).
As described herein, anonymous shopping interface provider 108 and information broker 110 communicate over a secure communication link 112 . Secure communication link 112 may comprise any suitable communication link having appropriate security guarantees. For example, secure communication link 112 may comprise a credit card authorization network, a secure satellite communication link, a secure telephone communication link, a secure computer network connection, or other secure communication link.
As described above, some embodiments of the invention may comprise a user profile that is stored at a conveniently accessible region. For example, profiles may be stored at storage device 114 . Storage device 114 may comprise any suitable storage device capable of storing user profile information. For example, storage device may comprise a database storage system, a hard drive storage system, or the like.
As indicated by the dashed lines in FIG. 1 , communication between storage device 114 and the rest of system 100 may be accomplished in a number of different fashions. For example, storage device 114 may comprise a hard drive storage system in communication with user 104 , a database storage device in communication with anonymous shopping interface provider 108 , or some other storage scheme may be implemented.
FIG. 2 is a schematic representation of an anonymous shopper interface 200 according to one embodiment of the invention. As shown, a user may browse the Internet using a suitable browser interface 202 . For example, browser interface 202 may comprise a browser such as Netscape Navigator™, Microsoft Internet Explorer™, America On-Line™ browser, or another suitable interface.
Browser 202 operates in a known manner and may comprise a toolbar 204 that allows a user to perform various browsing tasks (e.g., forward, back, print, refresh, home, etc.). As shown, browser 202 enables the user to visit Internet sites and view the various images 206 , links 208 , buttons 209 , and other site features.
One embodiment of the anonymous shopping interface 200 provides an anonymous shopping toolbar 210 that includes the anonymous shopping tools. FIG. 2 shows one embodiment of an anonymous shopping toolbar 210 located as a bar at the bottom of browser 202 . Of course, other configurations are possible. For example, anonymous shopping toolbar 210 may be located at the top or side of the browser 202 . Additionally, the anonymous shopping toolbar 210 may comprise a separate window that overlays the browser 202 and is positionable and sizable according to user preference. Other embodiments of the anonymous shopping toolbar may comprise a separate icon or button on browser toolbar 204 that may activate a menu of anonymous shopping tools. Other configurations are possible.
Anonymous shopping toolbar 210 may comprise various tools to enable the anonymous shopping activities described herein. For example, tools may be provided to enable anonymous credit card accounts (e.g., credit tool 212 ), alias names (e.g., name tool 214 ) and anonymous delivery (e.g., delivery tool 216 ). Other tools may be provided as indicated by other tool 218 .
The tools may take any acceptable form on the anonymous shopping toolbar 210 . For example, tools may comprise buttons that may be activated by clicking with a pointer (e.g., a mouse cursor), pull-down menus, radio buttons, links, or other user selection devices.
FIG. 3 is a schematic flow diagram illustrating a method of anonymous shopping according to one embodiment of the invention. As shown, a user may activate an anonymous shopping tool (e.g., credit tool 212 ) at step 300 . Activation of a tool may be accomplished by user selection of the tool (e.g., by clicking on or otherwise selecting the tool).
Selection of a tool may initiate access to the user's profile as indicated at step 310 . As described herein, the user's profile may be stored at any convenient location and preferably includes user information that assists in completing an on-line shopping transaction.
At step 312 , transaction related information is submitted to an information broker (e.g., information broker 110 ). Transaction related information may comprise purchase price, on-line merchant information (e.g., name, address, etc.), user profile information, and other transaction related information.
At step 314 the information broker 110 generates the anonymous information requested by the user to accomplish the transaction. For example, if information broker 110 is a credit card company, step 314 may comprise generating a single use credit card number for the user to submit to the on-line merchant. Other examples of anonymous information are described above.
At step 316 the anonymous information is returned so that it may be submitted to the on-line merchant. As described herein, in some embodiments the anonymous information may be returned to the user for the user to submit to the on-line merchant. In other embodiments, the anonymous information may be submitted to the on-line merchant directly. Other schemes are possible.
In some embodiments, the anonymous information may be submitted as part of a form fill-in procedure. This is indicated in FIG. 3 as steps 318 A and 318 B. The form fill-in steps may be accomplished at any convenient time in the process. For example, the form fill-in 318 A may be accomplished upon activation (e.g., at 318 A), after the information is returned from the information broker 110 (e.g., at step 318 B), at a combination of the two times (e.g., some information filled at 318 A and some at 318 B) or at some other convenient time.
At step 320 the on-line shopping transaction is completed. For example, the information necessary to complete the on-line transaction, including the anonymous information, is submitted to the merchant.
Other embodiments and uses of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. The specification and examples should be considered exemplary only. The scope of the invention is only limited by the claims appended hereto. | A system and method for enabling a user to transact an anonymous on-line transaction, wherein a form of on-line payment is requested at a transaction interface is disclosed. The method may include providing an anonymous user interface that enables a user to initiate an on-line payment, accessing a first profile comprising user data when the user activates the form of on-line payment, generating a second profile linked to the first profile, wherein the second profile comprises anonymous data, and communicating the anonymous data from the second profile to the transaction interface to enable completion of the transaction. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a process for preparing detergent compositions, in particular compositions suitable for use in automatic dishwashing machines and having relatively low levels of phosphate builders.
Detergent compositions of the above type are conventionally prepared by an agglomeration process wherein a dry mix of solid, hydratable ingredients is formed and is sprayed or otherwise contacted with water or an aqueous solution of other ingredients to form a granular product. Typical processes of this type are described in U.S. Pat. No. 3,598,743, issued Aug. 10, 1971 to K. Coates, U.S. Pat. No. 3,888,781, issued June 10, 1975 to Kingry and Lahrman, and U.S. Pat. No. 3,625,902, issued Dec. 7, 1971 to Summer.
The above patents refer to the desirability of obtaining a product which is free-flowing and resistant to caking. Traditionally, there have been problems in preparing such agglomerated compositions which were non-caking and which had good carton storage stability. While the processes of the above patents provide a product having acceptable caking properties, these patents are generally concerned with products having high levels of hydratable builder salts, especially sodium tripolyphosphate. In recent years, there has been some concern over environmental problems associated with phosphates in detergents, and it is therefore desirable that phosphate levels in detergents of this type be reduced. Unfortunately, it has been found that reduction of the level of hydratable materials such as sodium tripolyphosphate leads to an increase in the severity of the caking problem with agglomerated detergent compositions.
Accordingly, it is an object of the present invention to provide a process for preparing a free-flowing, non-caking detergent composition. It is a further object of the invention to provide a process for preparing an agglomerated detergent composition having a relatively low level of phosphate builder salts.
Another object of the invention is to produce a non-caking automatic dishwashing detergent composition.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a process for preparing a granular detergent composition comprising the steps of:
(a) forming a particulate mixture comprising from about 5% to about 35% by weight of the composition of a substantially anhydrous alkaline condensed phosphate and from about 3% to about 10% by weight of the composition of anhydrous alkali metal silicate having a particle size in the range from about 125 to about 300 mesh; and
(b) with continous mixing, spraying said particulate mixture with from about 10% to about 35% by weight of the composition of an aqueous solution of an alkali metal silicate having an SiO 2 /alkali metal ratio in the range from about 1.0 to about 3.6 to form agglomerated granules.
Other dry ingredients, for example a bleaching agent such as chlorinated trisodium phosphate, and a filler such as sodium sulfate, can be added to the particulate mixture either before or during the agglomerating step. A surfactant, preferably a nonionic surfactant, is normally included in the composition and is preferably sprayed onto the agglomerated granule concurrently with the spraying on of the aqueous silicate solution.
In the present specification, the term "mesh" refers to a Tyler Standard Mesh. A material having a particle size of, for example, 300 mesh consists of particles substantially all of which pass through a Tyler 300 mesh sieve.
DETAILED DESCRIPTION OF THE INVENTION
The first step in the process of the invention consists of the formation of a particulate mixture of dry ingredients of the composition. This dry mix contains two essential ingredients, an alkaline condensed phosphate and an anhydrous alkali metal silicate.
Wherever it appears herein, the term "alkaline condensed phosphate" is used to designate those polyphosphates of the calcium and magnesium ion sequestering type whose Na 2 O/P 2 O 5 ratios range from 1:1 to 1.67:1. A highly preferred condensed phosphate is sodium tripolyphosphate.
Preferably the anhydrous sodium tripolyphosphate is of the so-called "granular" grade, that is having particle size such that not more than 20% passes a 100 mesh U.S. test sieve. Normally at least 15% of sodium tripolyphosphate by weight of the composition is used. If less is used it becomes increasingly difficult to obtain satisfactory agglomerates through in some cases as little as 5% may give an acceptable product. At the other extreme, about 35%, and preferably 30%, of condensed phosphate is the upper limit contemplated in the present invention. While levels higher than 35% can be used in effective compositions, prior art processes, such as those described in the above-cited art, can usually provide compositions having good caking properties.
The essence of the present invention lies in the inclusion of an anhydrous alkali metal, preferably sodium, silicate in the dry particulate mixture formed in the first step of the process. It will be understood that "dry" ingredients are not necessarily anhydrous. Indeed, conventional "dry" silicate, as used, for example, in U.S. Pat. No. 3,598,743, can contain as much as 18.5% water of hydration.
In the present invention, the use of anhydrous silicate of a particular particle size is essential as the silicate component of the dry mix must necessarily absorb part of the moisture from the aqueous phase which is sprayed onto the particulate mixture.
The particulate mixture formed in the process of the present invention must contain from about 3% to about 10% of anhydrous silicate salt, preferably from 4% to 6%. Additionally, this silicate must have a particle size of between about 125 and about 300 mesh, preferably from 190 to 250 mesh.
It has been found that commercial sodium metasilicate, which has a particle size of between about 20 mesh and about 65 mesh is unsuitable for use in the present invention as the relatively large silicate particles are insufficiently soluble to dissolve completely in use of the composition.
Sodium silicate having a ratio of SiO 2 /Na 2 O from about 1.0 to about 3.6 can be used in the invention; preferably the SiO 2 /Na 2 O ratio is about 2.0.
Additional particulate components that can be included with the alkaline builder salts include sodium sulfate, a chlorine-yielding bleach such as chlorinated trisodium phosphate, various known suds suppressors, coloring matter, and dyes.
The term "chlorinated trisodium phosphate" is used to designate a composition consisting of trisodium phosphate and sodium hypochlorite in intimate association in a crystalline form. The chlorinated trisodium phosphate may contain from 1% to 5% available chlorine and may be prepared by the methods of U.S. Letters Patent 1,555,474 or 1,965,304, or modifications thereof. The proportion used in the invention can vary quite widely according to the intended use of the product, for instance from 1% to about 50% by weight, but for most purposes a content of 5% to 35% by weight is preferable.
As the first step of the process of the present invention, the above-described particulate matter is charged to a mixing zone. Any suitable mixing device such as an inclined pan granulator, a rotating drum, or any other vessel with suitable means of agitation may be used. Methods of agitating the particulate components are well-known to those skilled in the art.
The second step in the process of the invention consists of spraying an aqueous solution of alkali metal silicate onto the above-described particulate mixture. In a highly preferred process, the mixture is sprayed with an aqueous solution of sodium silicate having weight ratio of SiO 2 to Na 2 O of from 1:1 to 3.6:1, preferably about 2:1 to 3.3:1. The optimum amout and concentration of the silicate solution depends on a number of factors such as the actual SiO 2 /Na 2 O ratio; the nature of the dry mixture, especially its content of sodium tripolyphosphate; the amount of anhydrous silicate, the type of mixing device; and the like. The amount should be such as to cause the particulate mixture to form a bed of agglomerated granules, but not so great that its particulate nature is destroyed. Usually between about 10% and 35% by weight of the detergent composition, of a solution containing 20-60% (preferably 36-45%) of silicate solids (total of SiO 2 and Na 2 O) gives satisfactory results. The solution to be sprayed on the dry mixture is usually at ambient temperature; i.e., between 50° and 100° F. If desired it may be warmed to as high as 160° F for better atomization.
The process of the invention thus provides agglomerated granules suitable for use as automatic dishwashing machine detergent compositions. Normally, a surfactant, especially a nonionic surfactant, is included in the composition. Nonionic surfactants which meet the above criteria and which are advantageously employed in the composition of this invention include, but are not limited to, the following polyoxyalkylene nonionic detergents: C 8 -C 22 normal fatty alcohol-ethylene oxide condensates, i.e., condensation products of one mole of a fatty alcohol containing from 8 to 22 carbon atoms with from 3 to b 20 moles of ethylene oxide, polyoxypropylenepolyoxyethylene condensates having the formula HO(C 2 H 4 O) x (C 3 H 6 O) y (C 2 H 4 O) x ,H where y equals at least 15 and (C 2 H 4 O) x+x , equals 20-90% of the total weight of the compound; alkyl polyoxypropylenepolyoxyethylene condensates having the formula RO-(C 3 H 6 O) x (C 2 H 4 O) Y H where R is a C 1 -C 15 alkyl group and x and y each represent an integer from 2 to 98; polyoxyalkylene glycols having a plurality of alternating hydrophobic and hydrophilic polyoxyalkylene chains, the hydrophilic chains consisting of linked oxyethylene radicals and the hydrophobic chains consisting of linked oxypropylene radicals, said product having three hydrophobic chains, linked by two hydrophilic chains the central hydrophobic chain constituting 30% to 34% by weight of the product, the terminal hydrophobic chains together constituting 31% to 39% by weight of the product, the linking hydrophilic chains together constituting 31% to 35% by weight of the product, the intrinsic viscosity of the product being from 0.06 to 0.09 and the molecular weight being from about 3,000 to 5,000 (all as described in U.S. Pat. No. 3,048,548); butylene oxide capped alcohol ethoxylates having the formula R(OC 2 H 4 ) y (OC 4 H 9 ) x OH where R is a C 8 -C 18 alkyl group and y is an integer from about 3.5 to 10 and x is an integer from about 0.5 to 1.5; benzyl ethers of polyoxyethylene condensates of alkyl phenols having the formula ##STR1## where R is a C 6 -C 20 alkyl group and x is an integer from 5 to 40; and alkyl phenoxy polyoxyethylene ethanols having the formula ##STR2## where R is a C 8 -C 20 alkyl group and x is an integer from 3 to 20. Other nonionic detergents are suitable for use in the herein-disclosed dishwashing compositions and it is not intended to exclude any detergent possessing the desired attributes.
The nonionic surfactant preferably comprises from about 0.5% to about 35% of the composition and is preferably sprayed onto the agglomerated product prepared by the above-described process. A more preferred range of surfactant level is from 2% to about 15%.
The bleach component previously mentioned that may be part of the particulate matter is a chlorine-yielding bleach. Such bleach is included in the composition at a level sufficient to give the detergent composition an available chlorine content of from 0.5% to 10%, preferably 1% to 5%. As used herein, the term "available chlorine" indicates the amount of chlorine in the composition which is equivalent to elemental chlorine in terms of oxidizing power. "Active chlorine" is oftentimes used instead of "available chlorine". The same type of chlorine is designated by the two terms, but when expressed quantitatively "active chlorine" indicates the chlorine actually present. The numerical value for available chlorine content is twice that for active chlorine. Available chlorine contents below 0.5% fail to give proper cleaning performance, while amounts in excess of 10% do not result in any added cleaning ability. Any of many known chlorine bleaches can be used in the present detergent composition. Examples of such bleach compounds are: chlorinated trisodium phosphate; dichlorocyanuric acid; salts of chlorine substituted cyanuric acid; 1,3-dichloro-5,5-dimethylhydantoin; N,N'-dichlorobenzoylene urea; paratoluene sulfodichloroamide; trichloromelamine; N-chloroammeline; N-chlorosuccinimide; N,N'-dichloroazodicarbonamide; N-chloroacetyl urea; N,N'-dichlorobiurea; chlorinated dicyandiamide; sodium hypochlorite; calcium hypochlorite; and lithium hypochlorite. Depending on the particular bleach utilized, the bleach may be included with the particulate mixture prior to the liquid mixture spray-on or may be admixed with the agglomerated granules of alkaline phosphate, nonionic detergent, and silicate. That is, a bleach that is susceptible to high levels of water and/or heat must be admixed with the agglomerated granules. Similarly a bleach that is not susceptible to water or heat degradation but is of a particle size smaller than desired in the final product must be included with the particulate alkaline builder salt.
The compositions of this invention frequently comprise a suds suppressing agent for the purpose of inhibiting the formation of excessive amounts of foam which can impair the mechanical operation of the dishwashing machine due to a lowering of the pressure at which the washing liquor is impelled against the hard surfaces. Of course, the final selection of the suds suppressing agent depends upon and can be required, in part, because of the qualitative and quantitative characteristics of the particular nonionic surface-active agent which is utilized in the automatic dishwashing compositions herein. In addition, food residues, especially proteinaceous food residues, exhibit suds boosting properties and therefore preferably command the presence of an effective suds regulating agent.
Suds regulating components are normally used in an amount from about 0.001% to about 5%, preferably from about 0.05% to about 3% and especially from about 0.10% to about 1%. The suds suppressing (regulating) agents known to be suitable as suds suppressing agents in detergent context can be used in the compositions herein.
Preferred suds supressing additives are the silicone materials disclosed in U.S. Patent Application Ser. No. 381,659 filed July 23, 1973, inventors Bartolotta et al., incorporated herein by reference. The silicone material can be represented by alkylated polysiloxane materials such as silica aerogels and xerogels and hydrophobic silicas of various types. The silicone material can be described as siloxane having the formula: ##STR3## wherein x is from about 20 to about 2,000, and R and R' are each alkyl or aryl groups, especially methyl, ethyl, propyl, butyl and phenyl. The polydimethylsiloxanes (R and R' are methyl) having a molecular weight within the range of from about 200 to about 200,000, and higher, are all useful as suds controlling agents. Additional suitable silicone materials wherein the side chain groups R and R' are alkyl, aryl, or mixed alkyl and aryl hydrocarbyl groups exhibit useful suds controlling properties. Examples of the like ingredients include diethyl-, dipropyl-, dibutyl-, methylethyl-, phenylmethyl-polysiloxanes and the like. Additional useful silicone suds controlling agents can be represented by a mixture of an alkylated siloxane, as referred to hereinbefore, and solid silica. Such mixtures are prepared by affixing the silicone to the surface of the solid silica. A preferred silicone suds controlling agent is represented by a hydrophobic silanated (most preferably trimethylsilanated) silica having a particle size in the range from about 10 millimicrons to 20 millimicrons and a specific surface area above about 50 m 2 /gm. intimately admixed with dimethyl silicone fluid having a molecular weight in the range from about 500 to about 200,000 at a weight ratio of silicone to silanated silica of from about 19:1 to about 1:2. The silicone suds suppressing agent is advantageously releasably incorporated in a water-soluble or water-dispersible, substantially non-surface-active detergent-impermeable carrier.
Self-emulsifying silicone suds suppressors such as those described in U.S. Patent Application Ser. No. 622,303, filed Oct. 14, 1975 by Gault and Maguire, the disclosure of which is incorporated herein by reference.
Microcrystalline waxes having a melting point in the range from 35° C-115° C and saponification value of less than 100 represent an additional example of a preferred suds regulating component for use in the subject compositions. The microcrystalline waxes are substantially water-insoluble, but are water-dispersible in the presence of organic surfactants. Preferred microcrystalline waxes have a melting point from about 65° C to 100° C, a molecular weight in the range from 400-1,000; and a penetration value of at least 6, measured at 77° F by ASTM-D1321. Suitable examples of the above waxes include: microcrystalline and oxidized microcrystalline petrolatum waxes; Fischer-Tropsch and oxidized Fischer-Tropsch waxes; ozokerite; ceresin; montan wax; beeswax; candelilla; and carnauba wax.
Alkyl phosphate esters represent an additional preferred suds suppressant for use herein. These preferred phosphate esters are predominantly monostearyl phosphate which, in addition thereto, can contain di- and tristearyl phosphates and monooleyl phosphates, which can contain di- and trioleyl phosphates.
The alkyl phosphate esters frequently contain some trialkyl phosphate. Accordingly, a preferred phosphate ester can contain, in addition to the monoalkyl ester, e.g. monostearyl phosphate, up to about 50 mole precent of dialkyl phosphate and up to about 5 mole percent of trialkyl phosphate.
In addition to the components described hereinbefore, the compositions according to this invention can contain additional detergent composition ingredients which are known to be suitable for use in automatic dishwashing compositions in the art-established levels for their known functions. Organic and inorganic detergent builder ingredients, alkali materials, sequestering agents, china protecting agents, corrosion inhibitors, soil suspending ingredients, drainage promoting ingredients, dyes, perfumes, fillers, crystal modifiers and the like ingredients represent examples of functional classes of additional automatic dishwashing composition additives. Suitable inorganic builders include polyphosphates, for example tripolyphosphate, pyrophosphate or metaphosphate, carbonates, bicarbonates and alkali silicates. Examples of water-soluble organic builder components include the alkali metal salts of polyacetates, carboxylates, polycarboxylates and polyhydroxy sulfonates. Additional examples include sodium citrate, sodium oxydisuccinate and sodium mellitate. Normally in granular compositions these builder ingredients can be used in an amount up to 60%, preferably in the range from 10% to 50% by weight.
Suitable examples of sequestering agents include alkali metal salts of ethylenediaminetetraacetic acid and nitrilotriacetic acid.
Examples of china protecting agents include silicates, water-soluble aluminosilicates and aluminates. Carboxymethylcellulose is a well-known soil suspending agent for use in dishwashing compositions whereas fillers for granular compositions are represented by sodium sulfate, sucrose and sucrose esters.
The following examples are illustrative of the present invention.
EXAMPLE I
A dishwashing detergent composition was prepared according to the following procedure. All parts are given by weight.
Anhydrous sodium tripolyphosphate (26.50 parts), sodium sulphate (21.59 parts) and anhydrous sodium silicate (4.60 parts; SiO 2 /Na 2 O ratio of 2.0; particle size about 200 mesh) were mixed together as a dry mix in a pan granulator. During continued agitation of the dry mix, a sodium silicate solution (23.40 parts containing 9.60 parts of silicate solids, average ratios of SiO 2 /Na 2 O of 2.86) was sprayed on to the dry mix. The sodium silicate solution also contained prefume (0.10 parts) and dye solution (0.084 parts).
After approximately half of the silicate solution has been sprayed on, a nonionic surfactant (Pluradot HA 433*; 5.50 parts) was also sprayed on to the dry mix. Concurrently with the spray on of nonionic surfactant, there was added chlorinated trisodium phosphate (22.08 parts containing 10.54 parts of water of crystallization).
Mixing of the composition was continued for 10 minutes to form 100 parts of the detergent composition.
EXAMPLE II
The procedure of Example I was repeated but using 3.73 parts of the anhydrous sodium silicate and 21.1 parts of sodium sulphate in the dry mix, and spraying on 25.74 parts of the silicate solution. Again, 100 parts of a detergent composition was produced.
EXAMPLE III
The procedure of Example II was repeated but using 5.50 parts of the anhydrous sodium silicate and 24.8 parts of sodium sulphate in the dry mix, and spraying on 21.00 parts of the silicate solution. Again, 100 parts of a detergent composition was produced.
The detergent compositions of the above three examples were all effective dishwashing detergent compositions having little tendency towards carton caking and having good solubility in usage. | A granular detergent composition for use in automatic dishwashing machines is prepared by forming a dry mix of an alkali metal condensed phosphate and an anhydrous alkali metal silicate of small particle size and agglomerating the dry mix with a silicate solution. Conventional surfactants can be included in the composition. The process is particularly suited to the preparation of automatic dishwashing machine detergents having relatively low levels of phosphate builders. | 2 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a divisional of prior application Ser. No. 07/945,177, filed Sep. 15, 1992, still pending, which is a continuation-in-part of patent applications Ser. No. 07/745,071, filed Aug. 14, 1991, now abandoned, Ser. No. 07/800,507, filed Nov. 27, 1991, now abandoned Ser. No. 07/805,506 filed Dec. 6, 1991, now U.S. Pat. No. 5,330,432, Ser. No. 07/808,325, filed Dec. 16, 1991, now U.S. Pat. No. 5,324,268, Ser. No. 07/848,838, filed Mar. 10, 1992, now U.S. Pat. No. 5,445,617, Ser. No. 07/868,566 and Ser. No. 07/868,578, both filed Apr. 15, 1992, now U.S. Pat. Nos. 5,320,610 and 5,336,176, and Ser. No. 07/929,338, filed Aug. 14, 1992 now U.S. Pat. No. 5,360,405. The specifications of the above patent applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to safety penetrating instruments and, more particularly, to automatic retractable safety penetrating instruments having sleeves for introduction into anatomical cavities and penetrating members with sharp tips disposed within the sleeves for penetrating cavity walls with automatic retraction of the penetrating members into the sleeves upon penetration to protect tissue and organ structures within the cavities from the sharp tips of the penetrating members.
2. Discussion of the Prior Art
Penetrating instruments are widely used in medical procedures to gain access to anatomical cavities ranging in size from the abdomen to small blood vessels, such as veins and arteries, epidural, plural and subachroniad spaces, heart ventricles and spinal and synovial cavities, with access being established via a sleeve positioned during penetration into the cavity with the penetrating instrument. Use of penetrating instruments has become an extremely popular and important first step in endoscopic, or least invasive, surgical procedures to establish an endoscopic portal for many various procedures with access being established via portal sleeves of the penetrating instruments. Such penetrating instruments typically include a portal sleeve and a penetrating member disposed within the portal sleeve and having a sharp tip or point to pierce or penetrate the tissue forming the cavity wall with the force required to penetrate the cavity wall being dependent upon the type and thickness of the tissue of the wall. Once the wall is penetrated, it is desirable to prevent the sharp tip of the penetrating member from inadvertent contact with or injury to tissue or organ structures in or forming the cavity, and a particular problem exists where substantial force is required to penetrate the cavity wall or the cavity is very small in that, once penetration is achieved, the lack of tissue resistance can result in the sharp tip traveling too far into the cavity and injuring adjacent tissue or organ structures.
Safety trocars having a spring-biased protective shield disposed between an outer sleeve and an inner trocar are marketed by Ethicon, Inc. as the Endopath and by United States Surgical Corp. as the Surgiport. U.S. Pat. No. 4,535,773 to Yoon, No. 4,601,710 to Moll and No. 4,654,030 to Moll et al are illustrative of such safety trocars. A trocar disposed within a portal sleeve and retractable within the sleeve when force from tissue contact is removed from the sharp tip of the trocar is set forth in U.S. Pat. No. 4,535,773 to Yoon.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide improved, simplified automatic retractable safety penetrating instruments capable of use in a wide variety of procedure.
A further object of the present invention is to provide an automatic retractable safety penetrating instrument having a locking and releasing mechanism rotatable or pivotal around an axis in parallel and spaced from a longitudinal axis of the automatic retractable safety penetrating instrument for automatically releasing a retracting mechanism to permit retraction of a penetrating member upon entry of the instrument into an anatomical cavity.
An additional object of the present invention is to position a rotatable locking and releasing mechanism within a shaft of a penetrating member of an automatic retractable safety penetrating instrument to reduce the size of the proximal hub or handle for the penetrating member.
A further object of the present invention is to form a penetrating member of an automatic retractable safety penetrating instrument of telescoping parts such that the distal end can be moved proximally relative to the shaft upon retraction thereby reducing the length of the hub or handle for the penetrating member.
Yet another object of the present invention is to automatically trigger retraction of a penetrating member within a sleeve upon movement of an operating member distally of a rest position after initial movement of the operating member proximally of the rest position during penetration of tissue.
A further object of the present invention is to combine trigger mechanisms in an automatic retractable safety penetrating instrument such that retraction can be triggered by distal movement of an operating member at a position rearward of a rest position of the operating member and/or a position forward of the rest position.
Another object of the present invention is to configure a safety penetrating instrument to allow the safety penetrating instrument to have various optional modes of operation including retraction of the penetrating member, retraction of the penetrating member along with a safety shield or probe, the penetrating member locked against retraction to operate as a standard penetrating instrument, the penetrating member retracts while the shield or probe remains extended, or the penetrating member against retraction while safety shield or probe moves distally.
Some of the advantages of the present invention over prior art are that small or narrow anatomical cavities can be safety penetrated, sleeves can safely be introduced into anatomical cavities of various sizes to expand the use of least invasive procedures in many areas including, for example, cardiac brain, vascular, chest, genitourinary system, breast and spinal fields, safe penetration of cavities can be accomplished with no parts of the safety penetrating instrument other than the sleeve protruding beyond the sharp tip of the penetrating member as is particularly desirable where organ structures adhere to cavity walls, the automatic retractable safety penetrating instrument encourages the use of a smooth, continuous penetration motion by the surgeon thereby reducing trauma, tears and irregular surfaces in the tissue of the cavity wall, the automatic retractable safety penetrating instrument can be used to penetrate anatomical cavities of the type containing organ structures that could be injured by contact with even a blunt instrument part such as a safety shield, the automatic retractable safety penetrating instrument can be economically made of plastic with relatively few components, safe penetration is achieved while permitting injection or evacuation of fluids, a single puncture can be used for both insufflation and forming an endoscopic portal thereby simplifying diagnostic and surgical procedures, trauma and damage to tissue is minimized, tissue jamming and trapping are avoided and automatic retractable safety penetrating instruments according to the present invention can be inexpensively manufactured to be reusable or disposable for universal use.
These and other objects and advantages of the present invention will become apparent from the following description of the preferred embodiments taken in conjunction with the accompanying drawings wherein identical reference numbers indicate identical parts or parts providing identical functions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a broken side view, partly in section of an automatic retractable safety penetrating instrument according to the present invention in a rest state.
FIGS. 2, 3 and 4 are broken side views, partly in section of the automatic retractable safety penetrating instrument of FIG. 1 in various states of operation.
FIG. 5 is a broken perspective view of an end cap release mechanism for use with the automatic retractable safety penetrating instrument of the present invention.
FIG. 5A is a perspective view of an end cap release mechanism carrying a locking and releasing mechanism for use with the automatic retractable safety penetrating instrument of the present invention.
FIG. 5B is a perspective view of an end cap release mechanism carrying a modified locking and releasing mechanism for use with the automatic retractable safety penetrating instrument of the present invention.
FIG. 5C is a section taken along lines 5C--5C of FIG. 5B with the addition of a retraction plate and an operating member.
FIG. 5D is a broken side view, partly in section, of a modified locking and releasing mechanism for use with the automatic retractable safety penetrating instrument of the present invention wherein the trigger is formed by an angled flat spring member.
FIG. 6 is a broken side view, partly in section, of an automatic retractable safety penetrating instrument according to the present invention having a modified locking and releasing mechanism.
FIGS. 6A, 6B and 6C are broken side views, partly in section, showing a modified locking and releasing mechanism for use with the instrument of FIG. 6.
FIG. 7 is a broken side view, partly in section of an automatic retractable safety penetrating instrument according to the present invention having a safety shield.
FIG. 8 is a broken view, partly in section, showing interconnection of the shield and penetrating member of FIG. 7 to allow retraction of the shield and penetrating member together or the penetrating member alone.
FIG. 9 is a side view, partly in section, of another embodiment of an automatic retractable safety penetrating instrument according to the present invention in a rest state utilizing a probe for triggering retraction.
FIGS. 10, 11, 12 and 13 show operating states for the instrument of FIG. 9.
FIGS. 14, 15, 16 and 17 are end views of the trocar penetrating member of the instrument of FIG. 9 showing various positions of the probe.
FIG. 18 is a side view, partly in section, of a modification of the automatic retractable safety penetrating instrument of FIG. 9 wherein the penetrating member triggers retraction.
FIG. 19 is a broken perspective of the locking and releasing mechanism of the instrument of FIG. 18.
FIG. 20 is a broken side view, partly in section, of another embodiment of an automatic retractable safety penetrating instrument according to the present invention having a safety shield for triggering retraction.
FIGS. 21 and 22 are broken perspective views of distal ends for the instrument of FIG. 20.
FIG. 23 is a broken perspective view of the locking and releasing mechanism of the instrument of FIG. 20.
FIG. 24 is a broken side view, partly in section, of the instrument of FIG. 20 in the operative position.
FIGS. 25 and 26 are a broken side view, partly in section, and a broken top view, respectively, of the hub of the instrument of FIG. 20.
FIG. 27 is a broken side view, partly in section, of a modified distal end for an automatic retractable safety penetrating instrument according to the present invention.
FIG. 28 is a broken side view, partly in section, of the distal end of an automatic retractable safety penetrating instrument according to the present invention having a cannulated penetrating member.
FIGS. 29 and 30 are exploded views of the distal ends of automatic retractable safety penetrating instruments according to the present invention having cannulated penetrating members.
FIG. 31 is a side view of the distal ends of FIGS. 29 and 30 with the safety probe in the extended position.
FIG. 32 is a perspective view of the cannulated penetrating members of FIGS. 29 and 30 with the probe in a retracted position.
FIG. 33 is a side view of a trocar-like cannulated penetrating member for use with the automatic retractable safety penetrating instrument of the present invention.
FIGS. 34, 35 and 36 are perspective top and bottom views of the penetrating member of FIG. 33 with the probe in a retracted position.
FIG. 37 is a broken side view, partly in section, of an automatic retractable safety penetrating instrument according to the present invention wherein retraction is triggered by a shield.
FIG. 38 is a broken side view, partly in section, of an automatic retractable safety penetrating instrument according to the present invention having a modified locking and releasing mechanism.
FIGS. 39 and 39a are side and perspective views of locking and releasing members for use with the instrument of FIG. 38.
FIG. 40 is an end view of the locking and releasing member for use with the instrument of FIG. 38.
FIGS. 41, 42 and 43 are broken views showing operation of the locking and releasing mechanism of the instrument of FIG. 38.
FIG. 44 is a broken view, partly in section, of a modification of the locking and releasing mechanism of FIG. 38.
FIG. 45 is a broken side view, partly in section, of the locking and releasing mechanism of FIG. 38 triggered by a safety shield.
FIG. 46 is a broken side view of a modified locking and releasing member of the type illustrated in FIG. 38.
FIG. 47 is a side view, partly in section, of an automatic retractable safety penetrating instrument according to the present invention having a penetrating member formed of a distal end telescoping with respect to a shaft.
FIGS. 48 and 49 are perspective views of retracting springs for the instrument of FIG. 47.
FIGS. 50 and 51 are broken side views, partly in section, of modifications of the instrument of FIG. 47.
FIG. 52 is a broken side view, partly in section, of an automatic retractable safety penetrating instrument according to the present invention in combination with a multi-lumenal member in the portal sleeve housing.
FIG. 53 is a broken side view, partly in section, of an automatic retractable safety penetrating instrument according to the present invention wherein the locking and releasing mechanism is disposed within a control tube.
FIG. 54 is a side view, partly in section, of an automatic retractable safety penetrating instrument according to the present invention wherein the distal end of a penetrating member telescopes with respect the shaft and is triggered for retraction by a safety shield for a probe.
FIG. 55 is a broken side view, partly in section, of an automatic retractable safety penetrating instrument according to the present invention wherein the locking and releasing mechanism is located partly in the hub and partly in the shaft of the penetrating member.
FIGS. 56, 57, 58, 59 and 60 are broken side views, partly in section, of modifications of the automatic retractable safety penetrating instrument according to the present invention with various locking and releasing mechanisms.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An automatic retractable safety penetrating instrument 60 according to the present invention is illustrated in FIG. 1 and includes an elongate penetrating member 62, an outer sleeve or cannula, such as portal sleeve 64, concentrically disposed around the penetrating member, a hub 66 mounting penetrating member 62 and a valve housing 68 mounting portal sleeve 64. The hub 66 can be latched to housing 68 with the use of any suitable releasable mechanism, such as detents operated by buttons, allowing the hub to be removed from the housing withdrawing the penetrating member from the portal sleeve. Accordingly, the automatic retractable safety penetrating instrument 60 can be considered to be formed of a portal unit and a penetrating unit, the portal unit including portal sleeve 64 and housing 68 and the penetrating unit including penetrating member 62 and hub 66.
The penetrating member 62 is preferably made of a medical grade material, such as stainless steel, and has an outer diameter or size dependent upon the surgical procedure to be performed and the anatomical cavity to be penetrated. The penetrating member 62 is made up of a distal part 70 and a tubular end part 72 concentrically disposed around the distal part with the distal part mounted for longitudinal telescoping movement relative to the end part. Distal part 70 includes an elongate body 74 which can be cylindrical or have any desired configuration in cross-section terminating distally at a distal end 76 of the penetrating member. Distal end 76 terminates distally at a tip 78 for penetrating anatomical tissue and proximally at an end wall or shoulder 80 Joining the distal end to body 74. The distal end 76 can have various solid or hollow geometric configurations including various trocar, blade and needle distal end configurations such as conical and pyramidal, and the tip 78 can be sharp or blunt and provided with an external thread. As shown in FIG. 1, distal end 76 is formed as a trocar having a pyramidal configuration with equally spaced end surfaces or facets 82 tapering distally to a sharp tip 78 and proximally joined at a junction 84 to a cylindrical neck 86 terminating proximally at shoulder 80. Body 74 terminates proximally at an operating member or flange 88 at a proximal end of the penetrating member, the proximal end being disposed in hub 66 with body 74 passing through an opening in a front wall of the hub. The distal end 76 can be formed integrally, unitarily with body 74 or the distal end can be formed separately from body 74 and removably mounted thereon, such as with threads 90, allowing various distal ends of diverse configurations to be interchangeably mounted on body 74. Body 74 has an outer diameter or size that is less than the outer diameter of neck 86 with end part 72 having an inner diameter sized to closely receive the outer diameter or size of body 74. End part 72 has an outer diameter that is the same as the outer diameter of neck 86 such that the neck and end part are closely received by the inner diameter of the portal sleeve 64. End part 72 terminates distally at a stop or abutment 92 proximally spaced from shoulder 80 with the instrument in an extended position as shown in FIG. 1 and proximally at a retraction member including a retraction plate or flange 94 disposed in hub 66 with the end part passing through the opening in the front wall of the hub and body 74 passing through an opening in the retraction plate. Body 74 can be hollow or tubular along the length thereof, or the body can be partly hollow or tubular to receive a control tube 96 extending distally from a rear wall of hub 66 and into the proximal end of the penetrating member. Where body 74 is hollow or tubular or formed with an internal passage along the length thereof communicating with the lumen of the control tube, a channel (not shown) can be disposed in distal end 76 in communication with the lumen or passage of the body to provide fluid communication entirely through the instrument 60. A valve (not shown), which can be of any conventional design, can be mounted in communication with the lumen of the control tube, such as along the rear wall of hub 66, to control fluid flow through the instrument. A cautery attachment can be provided on the penetrating member for electric cautery procedures. A helical coil operating spring 98 is disposed concentrically around the control tube and connected between operating flange 88 and the rear wall of the hub to bias the penetrating member in a distal direction. A helical coil balancing, cushion or positioning spring 100 is disposed concentrically around body 74 and connected between retraction plate 94 and the operating flange 88 to bias the penetrating member in a proximal direction such that the operating flange is maintained at an initial, rest or balanced position with the instrument in the extended position as shown in FIG. 1. A retracting mechanism engages the proximal end of the penetrating member and includes the retraction member, retraction plate 94 in FIG. 1, and a helical coil retracting spring 102 connected between retraction plate 94 and the rear wall of the hub. If required, a guide rod 104 can extend from the rear wall of the hub to the front wall thereof passing through the retraction plate with the retracting spring concentrically disposed around the guide rod to provide a guide to maintain the retracting spring in axial alignment.
Hub 66 can be made of any suitable material to be disposable or reusable and has an external configuration to cooperate with housing 68 to facilitate grasping by a surgeon with one hand for use in penetrating tissue. Hub 66 can have any desired configuration in cross-section and is shown in FIG. 1 as being substantially rectangular. An end cap 106 of hub 66 has a skirt 108 extending distally through an opening in the hub rear wall, the end cap being mounted for longitudinal movement relative to the hub by a mounting member including a helical coil mounting spring 110 connected between the hub rear wall and a rear wall of the end cap rear wall to bias the end cap in a proximal direction. If needed, various mechanisms can be provided in the hub or end cap to limit proximal movement of the end cap relative to the hub.
A locking and releasing or trigger mechanism 112 actuates the retracting mechanism and includes a latch or locking spring having a substantially flat base 114 secured to an inner surface of skirt 108 to extend through the opening in the hub rear wall and a U-shaped bend 116 disposed in the end cap and proximally joining base 114 to an arm 118. Arm 118 extends distally from bend 116 through a slot 120 in the rear wall of the hub, the arm extending in the direction of the retraction plate 94 substantially parallel with a longitudinal axis of the instrument. A bent locking finger or member 122 is carried on a distal end of the arm to engage the retraction plate 94 when the locking spring is in its normal condition as illustrated in FIG. 1. A trigger or releasing member 124 including a cam or bend in arm 118 is disposed distally of the operating flange 88 in the initial position the trigger member 124 being angled in a distal direction from the arm to cause bending or flexing of the arm in a direction outwardly from the instrument longitudinal axis when the operating flange is moved distally of the initial position as will be explained further below. One or more than one additional trigger or releasing members 126 are disposed on arm 128 proximally of the operating flange 88 in the initial position; and where a plurality of trigger members 126 are provided, it is preferred that the trigger members be closely spaced to extend longitudinally along the arm as shown in FIG. 1. The trigger members 126 are angled in a proximal direction from arm 118 to allow movement of the operating flange thereby in a proximal direction to a set position without causing bending or flexing of arm 118 and to cause bending or flexing of arm 118 in a direction outwardly from the instrument longitudinal axis when the operating flange is moved distally from the set position toward the initial position. A detent including a bump, protrusion or cam 128 is provided on arm 118 distally of bend 116 and proximally of the trigger members 126. Protrusion 128 has a forward portion angled from arm 118 in a proximal direction to permit distal movement of the protrusion through slot 120 and a transverse rear portion joined to the forward portion to prevent proximal movement of the protrusion through the slot to lock the end cap relative to the hub when the instrument is in the extended position. An end cap release mechanism for releasing the detent from the hub is provided in instrument 60 and includes an actuating device made up of a pair of actuating buttons 130 externally mounted on end cap 106 at diametrically opposing locations with release arms 132 extending from buttons 130 through skirt 108 in a direction transverse to the instrument axis to be disposed on opposite sides of bend 116. Buttons 130 can have various configurations to move the release arms to squeeze, flatten or compress bend 116 inwardly to align protrusion 128 with slot 120, the release arms being moved in a direction aligned with the direction of squeezing of bend 116 when the buttons are pressed inwardly in the direction of the instrument axis as will be explained further below. As shown in FIG. 1, buttons 130 are in the nature of springs 131 made of resilient strips of metal, plastic or other spring material forming lobes having a bulging configuration in a direction outwardly from the instrument axis with the release arms extending therefrom to be moved by the lobes when the lobes are flattened or collapsed. One or more than one button 130 can be provided on end cap 106; and, where two buttons are provided at diametrically opposing locations, bilateral actuation of the end cap release mechanism is facilitated. The release arms 132 can be arranged in many ways to be aligned with or offset from one another; and, where only a single button and release arm are provided, the bend can be compressed between the release arm and the skirt.
Sleeve 64 can be a portal sleeve or cannula as shown in FIG. 1 or any other tubular structure, such as a catheter for intravenous use, designed to establish communication with an anatomical cavity. Sleeve 64 is preferably made of a substantially cylindrical length of rigid or flexible and transparent or opaque material, such as stainless steel or other suitable, medically acceptable, plastic or metal material; and, where the sleeve is made of a flexible material, the penetrating member can also be made of a flexible material. The sleeve has an outer diameter dependent upon the size of the penetrating member and the surgical procedure to be performed, the sleeve typically ranging in size from portal sleeve size to intravenous tube size, with an inner diameter sized to closely receive the outer diameters of neck 86 and end part 72. Portal sleeve 64 has a distal end 134 with a configuration to produce a smooth profile with the distal end 70 of the penetrating member when the instrument is in an operative position to penetrate tissue as will be explained further below, a proximal end mounted in or formed with a front wall of valve housing 68 and a lumen extending between the distal and proximal ends.
Housing 68 can be made of any suitable material to be disposable or reusable and has a configuration in cross-section corresponding to the cross-sectional configuration of hub 66. A wall 136 extends inwardly from housing 68 at a position distally spaced from the rear end thereof to produce a recess suitable for receiving detents (not shown) releasably securing the hub and housing, the wall 136 having a central passage for receiving a valve assembly. The valve assembly can have any conventional configuration to produce a closed or sealed condition upon removal of the penetrating unit. As shown in FIG. 1, the valve assembly is formed as a unitary, one-piece integral construction of rubber or soft plastic to facilitate sealing to prevent fluid flow through the instrument when the penetrating unit is removed. The valve assembly is formed of a valve body 138 having a passage therethrough and a proximal flange extending outwardly therefrom to be received in the recess at the rear end of the housing. The valve body 138 has a peripheral configuration to fit snugly within the passage through wall 136, and a valve member extends distally from valve body 138 and has a normally sealed position with a hemispherical bulging end received in a valve seat formed at an end of the passage to produce a normally closed, sealed configuration. To provide assisted bias toward the sealed configuration, a spring member 140 can be imbedded within the valve assembly to bias the valve member toward the valve seat. While the face of the valve seat is illustrated as being transverse to the longitudinal axis of the automatic retractable safety penetrating instrument 60, the valve seat can be angularly oriented.
In use, the automatic retractable safety penetrating instrument 60 is normally provided in a rest state wherein the distal end 76 of penetrating member 62 is retracted within portal sleeve 64 to be in a safe, protected position, the rest state coinciding with the retracted position for the penetrating member. In the rest state, retracting spring 102 is in a relaxed, unbiased or unloaded state causing retraction plate 94 to be moved proximally carrying with it penetrating member 62. Springs 131 are in relaxed states forming lobes extending in a direction outwardly from the instrument axis. Operating spring 98 and cushion spring 100 are also in relaxed, unloaded or unbiased states; and, accordingly, with the automatic retractable safety penetrating instrument 60 initially provided in a rest state, no loading of the springs 98, 100, 102 and 131 exists such that the strength of the springs is not weakened and shelf life is increased. Where it is desired to supply the instrument 60 in as small a configuration as possible, end cap 106 can be supplied in a locked position with protrusion 128 locked within the hub and locking and releasing mechanism 112 disengaged from the retracting mechanism in the rest position for the instrument. Where the instrument 60 can be supplied in a ready position with end cap 106 biased proximally relative to the hub as illustrated in FIG. 2, mounting spring 110 can be in an unloaded or relaxed state with protrusion 128 disposed proximally of the hub rear wall, and the locking and releasing mechanism 112 can be in a relaxed state with the locking spring in the normal condition with locking member 122 engaged with retraction plate 94. Where the instrument is supplied with the end cap locked within the hub, buttons 130 are depressed causing release arms 132 to move toward each other squeezing bend 116 to align the rear portion of protrusion 128 with slot 120 such that mounting spring 110 automatically moves the end cap proximally, and the instrument will be in the ready position shown in FIG. 2. When it is desired to utilize the instrument 60 to penetrate tissue and enter an anatomical cavity, the hub and housing are grasped by a surgeon, and the end cap 106 is squeezed causing movement of the end cap distally relative to the hub such that arm 118 functions as a push member to move the retraction plate 94 and with it end part 72 distally carrying distal part 70 in the distal direction. Continued squeezing of the end cap causes the forward portion of protrusion 128 to be engaged by the hub rear wall such that arm 118 is bent or flexed a small amount allowing the protrusion 128 to pass through the slot 120 and into the hub while the retraction plate 94 remains held by the locking member 122. Once protrusion 128 has entered the hub, arm 118 returns to the normal condition, and the rear portion of the protrusion engages the rear wall of the hub to lock the end cap against proximal movement at which time the end part 72 will be locked against proximal movement with the retraction plate 94 locked in place adjacent the front wall of the hub as shown in FIG. 1. With the instrument 60 in the extended position shown in FIG. 1, the operating flange 88 will be in the initial position disposed proximally of trigger member 124 and distally of trigger members 126 and the distal end junction 84 of the penetrating member will be spaced from the distal end 134 of the portal sleeve by a distance that is the same as the spacing between shoulder 80 and abutment 92.
The instrument can now be utilized to penetrate tissue and enter an anatomical cavity. The hub and housing are grasped by the surgeon, and the instrument is forced against tissue, such as tissue T forming a wall of an anatomical cavity, causing distal part 70 of penetrating member 62 to move proximally relative to end part 72 against the bias of operating spring 98. Abutment of shoulder 80 with stop 92 limits proximal movement of the distal part at which time the instrument will be in an operative position illustrated in FIG. 3 with the distal end junction 84 aligned with the distal end 134 of the portal sleeve to form a substantially smooth profile. As distal part 70 moves proximally, operating flange 88 moves proximally deflecting trigger members 126 in the proximal direction such that the operating flange moves proximally therepast to a set position without disengaging the locking member 122 from the retraction plate 94. Once the distal end 134 of the portal sleeve has passed through the tissue T and entered the anatomical cavity, operating spring 98 will move distal part 70 distally relative to end part 72 causing the operating member 88 to be moved distally from the set position toward the initial position to engage a trigger member 126 distally closest thereto such that arm 118 is flexed or bent in a direction outwardly from the instrument axis causing locking member 122 to be moved out of engagement with retraction plate 94. Accordingly, retracting spring 102 will automatically move the retraction member 94 and with it the end and distal parts of the penetrating member to the retracted position with the distal tip 78 of the penetrating member in a safe, protected position within the portal sleeve as shown in FIG. 4. By providing a plurality of closely spaced trigger members 126, the distance that the operating member must be moved distally from the set position prior to retraction can be minimized. Where the operating member is moved to a set position that is not proximal of a trigger member 126 due to the resistance of the tissue being small or where trigger members 126 are not provided, operating spring 98 will move the distal part of the penetrating member distally from the set position upon the portal sleeve distal end entering the anatomical cavity, and the momentum of the operating spring will override the bias of the cushion spring 100 such that the operating member 88 will be moved distally of the initial position to engage trigger member 124 and flex arm 118 in a direction outwardly from the instrument axis such that the locking member 122 is moved out of abutment with retraction plate 94. By providing both trigger members 124 and 126, redundant protection is provided for the automatic retractable safety penetrating instrument 60 in that triggering can be obtained via either distal movement of the operating member from the set position toward the initial position or distal movement of the operating member past the initial position.
Once the distal end of the instrument 60 has entered the anatomical cavity and the penetrating member has moved to the retracted position, the portal sleeve will have been introduced into the cavity such that the penetrating unit can be withdrawn from the portal unit. When the penetrating unit is withdrawn, the valve member will return to the biased position such that the bulging end will engage the valve seat to seal the portal unit from fluid flow therethrough from insufflation pressure. Additionally, the axial length of the passage produces an elongated seal with penetrating member 62 minimizing escape of fluid during cavity penetration; and, if an instrument of a different size than the penetrating member is to be introduced after withdrawal of the penetrating unit, the valve assembly can be easily interchanged to install a valve assembly having a passage of a diameter to seal along the different size instrument.
The instrument 60 can be reusable or disposable for single patient use; and, where reusable, instrument 60 can be moved from the retracted position to the ready position by pushing or depressing buttons 130 causing release arms 132 to move toward each other. Accordingly, bend 116 will be compressed or flattened such that the rear portion of protrusion 128 is aligned with the slot 120 in the hub rear wall causing mounting spring 110 to automatically move the end cap 10 proximally relative to the hub. The locking spring will return to the normal condition with locking member 112 engaged with retraction plate 94, and the instrument will be in the ready position to be reset in the extended position via squeezing operation of the end cap.
Various mechanisms can be utilized in the automatic retractable safety penetrating instrument in place of or in addition to the end cap for use in setting the instrument in the extended position. As one example, a pin and slot arrangement can be used as the resetting mechanism with a pin provided on the penetrating member or the retracting mechanism, such as in the periphery of the retraction plate, to extend through a longitudinal slot in the hub allowing the retracting mechanism to be moved via manual movement of the pin along the slot when setting the instrument in the extended position.
While coiled springs are shown in the instrument 60 for the operating, retracting, cushion and mounting springs, many different arrangements and types of springs or other bias devices can be utilized with the present invention, and the bias devices can be arranged in instrument 60 in many various ways. Where springs are utilized, the springs can be tension, compression or torsion springs. When the operating member is proximally spaced from the trigger member 124 in the initial position, the cushion and operating springs can be of equal strength, and where the operating member is engaged with the trigger member 124 in the initial position, the cushion spring can be of lesser strength than the operating spring due to the increased resistance provided by the trigger member 124. The cushion spring can be disposed at various locations in the instrument including within the shaft of the penetrating member to position the operating member in the initial position. Various single or multiple piece devices can be utilized as the locking and releasing mechanism to lock the retracting mechanism against movement and to be released in response to distal movement of an operating member. The locking and releasing mechanism can be mounted for movement around an axis transverse to the instrument axis as shown in FIG. 1, parallel with the instrument axis, aligned with the instrument axis and in many other ways. Various types of trigger members including cams, springs with bumps or springs cut to provide extending leaves or triggers, linkages and many other types of devices can be utilized to trigger retraction in response to distal movement of the operating member, and the trigger members can be provided at any suitable location including on the locking member or the operating member. Where provided on the locking member, the trigger members can be formed integrally, unitarily with the locking spring or separately therefrom. As shown in FIG. 1, locking member 122 and trigger members 124 and 126 are unitarily, integrally formed of a single strip of resilient, spring material such as metal or plastic. In addition to the penetrating member, various other parts of the instrument including the sleeve can be utilized to trigger retraction; and, where the instrument is supplied with a safety shield or probe, movement of the probe or shield trigger release of the retracting mechanism. Where movement of the shield or probe is utilized to trigger retraction, retraction can be triggered via movement of an operating member from the set position toward the initial position or distally of the initial position. The locking and releasing mechanism can be arranged in the instrument 60 in many ways; and, depending on the size of the instrument, the locking and releasing mechanism can be mounted within or externally of the penetrating member, within the control tube, the hub or the housing. Where disposed within the penetrating member, the locking and releasing mechanism can be mounted at any location along the shaft of the penetrating member including the penetrating member distal end to be disposed entirely or partially within the penetrating member. The end cap can be mounted on the hub in many ways with the skirt disposed within or externally of the hub, and various bias members can be utilized to bias the end cap. Where secured to the end cap, the locking and releasing mechanism can be provided as a module facilitating assembly of the automatic retractable safety penetrating instrument. The locking and releasing mechanism can be utilized as the push member or the push member can be a separate device. Various release mechanisms can be utilized in the instrument 60 to be manually actuated to release the end cap from the hub, and the release mechanisms can be mounted on the instrument in many various ways in accordance with the structure of the locking and releasing mechanism or push member with the release mechanism of FIG. 1 being particularly advantageous for bilateral operation with right and left hand compatibility. The distance that the end cap must be moved proximally in the ready position will be in accordance with the distance that the push member must be moved proximally to be in a position to move the retracting mechanism distally. Accordingly, the length of skirt 108 will depend upon the distance that the end cap must be moved proximally, and various devices such as a bellows can be provided in the instrument to bridge any longitudinal gap or space between the skirt and the hub where the skirt is moved outside of the hub in the ready position. Instrument 60 can be provided with or without a control tube, although a control tube is desirable to allow fluid flow through the instrument. Control tube 96 can be rotatably mounted and can extend through the end cap to terminate at the end cap rear wall. A valve can be disposed along the rear wall of the end cap in communication with the lumen of the control tube to control fluid flow through the instrument where the inner member is hollow or formed with an internal passage.
A modified locking and releasing mechanism and end cap release arm for the automatic retractable safety penetrating instrument according to the present invention are illustrated in FIG. 5 at 160 wherein the locking and releasing mechanism 212 is shown without a trigger member. Locking and releasing mechanism 212 is similar to locking and releasing mechanism 112 and includes a latch or locking spring having a base 214 for being secured to the end cap of the automatic retractable safety penetrating instrument, a U-shaped bend 216 and an arm 218 joined to base 214 by bend 216. Arm 218 has a locking member 222 at a distal end thereof to engage the retracting member for locking the retraction mechanism of the automatic retractable safety penetrating instrument against movement; and, if desired, arm 218 can be used as the push member for use in setting the automatic retractable safety penetrating instrument in the extended position via squeezing operation of the end cap. A detent or protrusion 228 is disposed on arm 218 distally of bend 216 for locking the end cap relative to the hub of the automatic retractable safety penetrating instrument in the extended position. Various trigger members can be provided on the locking spring to be actuated by the operating member to trigger retraction, or the locking spring can be designed to cooperate with a trigger member provided on the operating member as will be explained further below. Release arm 218 extends into the end cap to terminate at a tapered end 219 for compressing or squeezing bend 216 when the release arm is moved toward the locking spring by an actuating device, such as buttons 130, in a direction transverse to the direction of squeezing. Accordingly, by moving the release arm 218 into the end cap in a direction transverse to the desired direction of flattening or squeezing of the bend, the tapered configuration of the release arm will progressively flatten or compress the bend allowing protrusion 228 to move through the slot in the hub rear wall thusly releasing the end cap.
A modification of the locking and releasing mechanism for the instrument 60 is illustrated in FIG. 5A wherein triggers 124 and 126 are mounted on a substrate 121 laminated to arm 118 with triggers 126 and 127 cut from substrate 121 as indicated by apertures 127 to be bent upwardly therefrom. Accordingly, triggers 126 will flex distally and downwardly looking at FIG. 5 during proximal movement of the operating member; and, during distal movement of the operating member, the triggers 126 will cause the arm 118 to flex to release the retracting mechanism, the substrate providing additional strength to allow repetitive operation of the triggers 126.
In the modified locking and releasing mechanism illustrated in FIGS. 5B and 5C, the arm 118 is cut at 119 to allow triggers 124 and 126 to extend therethrough angled proximally to allow operating member 88 to pass thereby while flexing the triggers 126 without flexing the arm 118, the operating member having a beveled ends 89 to facilitate proximal movement thereof. The triggers 124 and 126 extend from a member 123 disposed below arm 118 and having a lip 125 engaging the edge of arm 118 such that member 123 can flex downwardly looking at FIG. 5C without movement of arm 118 with proximal movement of operating member 88. Upward movement of member 123 is prevented during distal movement of operating member 88 such that the arm 118 is caused to deflect downwardly moving lock 122 from the locked position to a release position actuating the retraction mechanism.
In the modified locking and releasing mechanism illustrated in FIG. 5D, no trigger members 126 are utilized and the trigger 124 is formed of an angled portion of arm 118. The rest position is illustrated in FIG. 5D; and, after movement of operating member 88 rearwardly from the rest position, the operating member will be subsequently moved distally past the rest position due to the force from operating spring 98 compressing spring 100. As the operating member 88 moves forwardly of the rest position, the peripheral edge of the operating member, which is preferably angled at the same angle as the trigger 124, engages the trigger 124 to move the lock 122 to the release position allowing retraction.
A modification of the automatic retractable safety penetrating instrument according to the present invention is illustrated at 360 in FIG. 6, only the penetrating unit of the instrument 360 being shown. The automatic retractable safety penetrating instrument 360 is similar to automatic retractable safety penetrating instrument 60; however, the operating member or flange 388 for the automatic retractable safety penetrating instrument 360 has a trigger member 326 extending from the periphery thereof, the trigger member 326 being angled outwardly from the operating member in a distal direction. The locking and releasing mechanism 312 for the automatic retractable safety penetrating instrument 360 includes a latch or locking spring similar to that described for locking and releasing mechanism 112; however, arm 318 for locking and releasing mechanism 312 has a plurality of spaced barbs, ratchet teeth or serrations 321 extending longitudinally therealong for being successively engaged by trigger member 326.
Operation of automatic retractable safety penetrating instrument 360 is similar to that described for automatic retractable safety penetrating instrument 60 in that the operating flange is positioned by the operating and balancing springs 398 and 400 in an initial position with trigger 326 disposed distally of some of the barbs 321. Where the initial position for the trigger member is such that at least one barb is disposed distally of the trigger member, the trigger member can be maintained in engagement with the nearest distal barb as illustrated in FIG. 6 allowing the cushion spring to be of lesser strength than the operating spring and for further stability in the initial position. During penetration of anatomical tissue, operating member 388 will be moved proximally causing trigger member 326 to move proximally past and engage successive barbs 321 such that the penetrating member moves incrementally in a controlled manner until the operating member has moved to the set position with the trigger engaged with a distally closest barb. Once the distal end of the portal sleeve has entered the anatomical cavity, operating spring 398 will move operating flange 388 distally from the set position such that trigger member 326, via engagement with the distally nearest barb, causes arm 318 to be pivoted and locking member 382 to be released from engagement with retraction plate 394 for immediate retraction upon penetration with minimal distal movement of the operating flange. By providing a plurality of closely spaced barbs, trigger member 326 will be engaged with a nearest distal barb for various set positions ensuring immediate retraction upon distal movement of the operating member. Where momentum triggering is desired, one or more barbs 321 can be disposed distally of the initial position to be utilized to pivot the arm 318 upon distal movement of the operating member distally of the initial position. Where momentum triggering is utilized, one barb disposed distally of the initial position should be sufficient to trigger retraction; however, more than onebarb can be provided for increased safety. The automatic retractable safety penetrating instrument 360 can be used with or without momentum triggering; and, where momentum triggering is provided in addition to triggering by distal movement of the operating member from the set position toward the initial position, redundant protection is provided.
A modification of the instrument 360 is shown in FIG. 6A wherein teeth or barbs 321 are formed of flexible members while operating member 388 has a beveled end 389 whereby the configuration of the teeth 321 and the operating member 388 allows flexing of the teeth as the operating member moves proximally thereby but, during distal movement of the operating member upon entry into an anatomical cavity, the arm 318 will be flexed to release lock 322 and actuate retraction.
In the modification of FIGS. 6B and 6C for use with instrument 360, the trigger 326 is replaced with a pivotal member 327 having an angled surface to facilitate movement past teeth 321. The pivotal member 327 shown in FIG. 6B is mounted on a pivot 329 on the peripheral edge of operating member 388 and the pivotal member has a triangular shape such that the member can pivot only counterclockwise looking at FIG. 6B. Accordingly, the pivotal member 328 can pivot to allow proximal movement of the operating member 388 but, upon distal movement of the operating member, will cause the arm 318 to flex to actuate the retraction mechanism. In FIG. 6C, pivotal member 327' is mounted on a pivot 331 to form a transversely extending operating member which can pivot only counterclockwise looking at FIG. 6C due to a protrusion 333 preventing clockwise pivoting. Accordingly, member 327' will pivot during proximal movement but will cause arm 318 to deflect to actuate the retracting mechanism upon distal movement.
Another modification of the automatic retractable safety penetrating instrument according to the present invention is illustrated at 460 in FIG. 7, only the penetrating unit of the instrument 460 being shown. The automatic retractable safety penetrating instrument 460 is similar to automatic retractable safety penetrating instrument 60 except that a safety shield 463 is concentrically disposed around the penetrating member 462 with the penetrating member including a body 474 terminating proximally at retraction plate or flange 494 disposed in hub 466. Safety shield 463 has a distal end 467 disposed beyond the tip 478 of the penetrating member when the instrument is in an extended position as shown in FIG. 7 and a proximal end terminating at an operating member or flange 488 disposed in hub 466. A helical coil operating spring 498 is concentrically disposed around the penetrating member and connected between operating flange 488 and retraction plate 494 to bias the safety shield in a distal direction. A helical coil cushion spring 500 is disposed concentrically around the safety shield and connected between the front wall of the hub and the operating flange 488 to bias the safety shield in a proximal direction such that the operating flange is maintained at an initial position with the instrument in the extended position as shown in FIG. 7. A helical coil retracting spring 502 disposed around guide rod 504 is connected between retraction plate 494 and the front wall of the hub. Hub 466 and end cap 506 are similar to hub 66 and end cap 106 with end cap 506 being mounted for longitudinal movement relative to the hub and biased in a proximal direction by a bias member including a mounting spring 510. A locking and releasing or trigger mechanism 512 for actuating the retracting mechanism includes a latch or locking spring similar to that described for locking and releasing mechanism 112 except that arm 518 for locking and releasing mechanism 512 includes a proximal portion angled from the protrusion 528 to extend distally in the direction of a longitudinal axis of the instrument and a distal portion bent from the proximal portion to extend distally in a direction outwardly from the longitudinal axis, the distal portion terminating distally at the locking finger or member 522 engaged with the retraction plate 494 when the locking spring is in its normal condition as illustrated in FIG. 7. An extension 523 of arm 518 extends distally from the locking member substantially parallel with the instrument longitudinal axis. A plurality of trigger members 524 are disposed longitudinally along the extension at spaced locations therealong with a most proximal one of the trigger members 524 positioned distally of the operating member in the initial position as illustrated in FIG. 7. A plurality of trigger members 526 extend longitudinally along extension 523 at spaced locations therealong with a most distal one of the trigger members 526 disposed proximally of the operating member in the initial position. When the trigger members are formed of or cut from the material of the locking spring as shown in FIG. 7, an extra layer or strip of material 525 can be provided on arm 518 including extension 523 for additional strength. As best illustrated in FIG. 8, a nub 489 extends radially inwardly from an inner surface of the wall of the safety shield 463, the nub extending from the operating flange 488. A longitudinal slot 491 is formed in the penetrating member 462 to receive the nub such that, with the operating flange in the initial position, the hub is disposed at a distal end of the slot in engagement with the wall of the penetrating member.
Operation of the automatic retractable safety penetrating instrument 460 is similar to that previously described for automatic retractable safety penetrating instrument 60 in that the instrument 460 is normally provided in a rest state and is moved to the ready position by releasing end cap 506 from hub 466 via actuation of buttons 530. The instrument is moved to the extended position illustrated in FIG. 7 via squeezing operation of the end cap 506 causing the retracting mechanism to be moved distally by the arm 518 to lock the retraction plate 494 in place against the locking member 522 with the end cap held in place by protrusion 528 within the hub. With the instrument 460 in the extended position, the operating member 488 will be in the initial position disposed proximally of a most proximal one of the trigger members 524 and distally of a most distal one of the trigger members 526, the distal end junction 484 of the penetrating member will be substantially aligned with the distal end of the portal sleeve and the distal end 467 of the safety shield will extend beyond the tip 478 of the penetrating member such that the penetrating member is in a safe, protected position. When the instrument 460 is forced against tissue to enter an anatomical cavity, the safety shield 463 will be moved proximally-against causing the operating member 488 to move to a set position with trigger members 526 deflecting proximally allowing movement of the operating member therepast. Movement of the safety shield causes hub 489 to be moved proximally within the longitudinal slot 491 as shown in dotted lines in FIG. 8, and a proximal end of the slot can serve as a stop or abutment limiting proximal movement of the safety shield. Once the distal end of the portal sleeve 464 has entered the anatomical cavity, the operating spring 498 will move the safety shield distally causing the operating member 488 to move distally toward the initial position and engage the distally closest trigger member 526 to flex the locking spring and release the retraction plate 498 from the locking member 522. Once the retraction plate is released, retracting spring 502 will automatically move the penetrating member 462 proximally to a retracted position, the penetrating member carrying with it the safety shield 463 due to engagement of the penetrating member wall with the nub 489. Accordingly, both the penetrating member and safety shield distal ends can be retracted within the portal sleeve minimizing extension of the automatic retractable safety penetrating instrument into the anatomical cavity. Where trigger members 526 are not provided or the set position is such that there is no trigger member 526 between the initial and set positions, trigger members 524 can be utilized to trigger retraction in that the momentum of the operating spring upon penetration into the anatomical cavity overrides the bias of the cushion spring to move the operating member distally of the initial position causing the operating member to engage a trigger member 524 and flex the locking spring to release the retraction plate. Where the nub 489 and slot 491 are not provided, the penetrating member alone will be retracted upon penetration through the issue with the safety shield remaining extended. Instrument 460 can be designed to allow removal of the penetration member and the safety shield together or individually from the portal sleeve.
Another modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 9 at 560. The automatic retractable safety penetrating instrument 560 includes a penetrating member 562, a portal sleeve 564 concentrically disposed around the penetrating member, a probe 565 disposed within a passage of the penetrating member, a hub 566 mounting penetrating member 562 and probe 565 and a valve housing 568 mounting portal sleeve 564. The hub 566 can be latched to housing 568 with detents formed on the hub at a forward end thereof, the detents being in the nature of beads or protrusions for being snapped or locked in place in recesses formed along an inner surface of the wall of the housing at a rear end thereof. The detents can be frictionally retained in the recesses allowing the hub to be removed from the housing with manual force such that the penetrating unit can be removed from the portal unit. The penetrating member 562 is similar to penetrating member 462 and has a tapered distal end 576 with a pyramidal configuration defined by equally spaced end surfaces or facets 582 converging at to a tip 578 and terminating proximally at a scalloped junction 584 joining the facets to an elongate body 574, the body 574 terminating proximally at a retraction plate 594 disposed in hub 566. Probe 565 includes an elongate member which can be cylindrical or have any other desired configuration in cross section terminating distally at a blunt tip 569 extending through an aperture or opening in one of the facets and proximally at an operating member 588. The probe can be solid, hollow or tubular or partly hollow or tubular; and, as shown in FIG. 9, the probe 565 is in the nature of a solid, cylindrical rod, bar or wire having a minimal outer diameter or size with a relatively thicker piece of material joined proximally to the bar at a right angle thereto to define the operating member 588. Body 574 can be hollow or tubular or formed with an internal passage along the length of the penetrating member with the probe disposed in the lumen or passage of the body to be laterally offset from and parallel with a longitudinal axis of the instrument 560 as shown in FIG. 9 or aligned with the instrument axis including being concentrically disposed within the penetrating member. A push member 571, which can be solid or tubular, extends distally through a rear wall of hub 566 and into a proximal end of the penetrating member for setting the instrument in the extended position shown in FIG. 9, the push member being aligned with the instrument longitudinal axis with the probe laterally offset therefrom. A helical coil operating spring 598 is connected between operating flange 588 and the rear wall of the hub laterally offset from the push member to bias the probe in a distal direction. A helical coil cushion spring 600 is connected between the operating flange 588 and the retraction plate 594 to bias the probe in a proximal direction against the distal bias of the operating spring such that the operating member is maintained at an initial position with the instrument in the extended position as illustrated in FIG. 9. A helical coil retracting spring 602 is connected between retraction plate 594 and a rear wall of the hub to bias the retraction member proximally. The hub rear wall has an opening therein allowing passage therethrough by the push member 571, and a tubular collar 573 extends proximally, externally from the hub rear wall with the push member 571 extending proximally through the collar to terminate at an external knob 575 for rotating the push member around an axis aligned with the instrument longitudinal axis. A helical or spiral-like groove 577 is formed in an outer surface of the push member to receive a cam or pin 579 mounted externally along the hub rear wall and extending into the lumen of the collar such that rotation of the push member around the instrument axis produces longitudinal movement of the push member relative to the hub. With the push member fully inserted in the hub such that knob 575 abuts the collar 573 as shown in FIG. 9, the pin 579 is received in a proximal end of the groove 577, and a nub 581 protruding from the control tube distally of the groove is longitudinally aligned with a longitudinal slot 583 in the penetrating member, the slot extending through the retraction plate 594. The locking and releasing mechanism 612 for actuating the retracting mechanism includes a latch or locking spring similar to the locking spring for locking and releasing mechanism 112 except that no trigger members 126 are provided and trigger member 624 is made from a portion of arm 618 angled in a distal direction toward the instrument longitudinal axis to be disposed distally of the operating member in the initial position.
In use, the automatic retractable safety penetrating instrument 560 is normally provided in a rest state with the distal end 576 of the penetrating member 562 retracted within portal sleeve 564 to be in a safe, protected position, the rest state coinciding with the retracted position for the penetrating member illustrated in FIG. 12. In the rest state, push member 571 is fully inserted in hub 566 with pin 579 disposed at a proximal end of the groove 577 and nub 581 disposed in the longitudinal slot 583 at a distal end thereof. When it is desired to utilize the instrument 560 to penetrate tissue and enter an anatomical cavity, knob 575 is rotated counterclockwise looking distally at FIG. 12 such that pin 579 and groove 577 cause the push member 571 to move proximally, longitudinally relative to the hub withdrawing the push member therefrom until a distal end of the groove 577 is disposed in the collar 573 with the pin 579 received therein in a ready position for the instrument as illustrated in FIG. 13. With the push member 571 withdrawn, the nub 581 is no longer longitudinally aligned with the slot 583 but, rather, is aligned with a solid portion of the retraction plate 594 offset 180° from the slot. The knob 575 is then rotated clockwise looking distally at FIG. 13 causing movement of the push member 571 longitudinally into the hub with movement of the retraction plate distally via engagement with nub 581. Once the push member has been fully inserted in the hub, the instrument will be in the extended position shown in FIG. 9 with the retraction plate 594 locked in place against the locking member 622 and the nub 581 longitudinally aligned with the slot 583. In the extended position, the Junction 584 will be substantially aligned with the distal end of the portal sleeve and the distal end 569 of the probe 565 will be disposed beyond the facet or end surface 582 and proximally of the tip with the cushion and operating springs positioning the operating member in the initial position proximally of the trigger member 624. When the instrument 560 is forced against tissue, such as tissue T forming a wall of an anatomical cavity, the probe 565 will be moved proximally as shown in FIG. 10 causing the operating member 588 to be moved proximally without bending or flexing the arm 618. Once a distal end of the sleeve 564 has entered the anatomical cavity, the probe 565 will be moved distally, and the momentum of the operating spring 598 moves the operating member 588 distally of the initial position to engage trigger member 624 and flex arm 618 in a direction outwardly from the instrument axis to release the retraction plate 594 as illustrated in FIG. 11. Once the retraction plate is released, retracting spring 602 automatically moves the penetrating member and with it the probe to a retracted position with the slot 583 moving along the nub 581. In the retracted position, the tip 578 of the penetrating member is disposed within the portal sleeve and the tip of the probe is disposed within the penetrating member as illustrated in FIG. 12, the instrument 560 can be reset in the extended position by withdrawing push member 571 from the hub to align nub 581 with the solid portion of the retraction plate and reinserting the push member in the hub to move the retracting mechanism distally.
The probe 565 can be arranged in the penetrating member 562 in many various ways, and FIGS. 14-17 illustrate byway of example alternative arrangements for the probe within the penetrating member where the probe is offset from a longitudinal axis of the penetrating member. In FIG. 14, the penetrating member distal end includes three equally spaced end surfaces or facets 582 joined along three edges 585 terminating distally at tip 578 and proximally at a junction joining the facets to body 574 with the probe 565 protruding through one of the end surfaces inwardly of the junction, i.e. inwardly of the circumference of body 574, a substantially equal angular distance from the edges 585 of the one end surface. The penetrating member of FIG. 15 includes three equally spaced end surfaces 582 Joined along edges 585 with the probe 565 protruding in part through two adjoining end surfaces 582 inwardly of the circumference of the body 574 and along the edge 585 joining the two end surfaces. In FIG. 16, the penetrating member includes three equally spaced end surfaces 582 joined along edges 585 with the probe 565 protruding in part through two adjoining end surfaces along the edge 585 joining the two end surfaces and along the circumference of the body 574. The penetrating member of FIG. 17 includes three equally spaced end surfaces 582 joined along edges 585 with the probe 565 protruding through one of the end surfaces along the circumference of the body 574 a substantially equal angular distance from the edges of the one end surface. It will be appreciated that the arrangements for the probe illustrated in FIGS. 14-17 are exemplary only and that the probe can be arranged in the penetrating member in many various ways in accordance with the structure for the probe and the configuration of the penetrating member. By positioning the probe to protrude from the penetrating member close to the junction 584 and the circumference of body 574, retraction of the penetrating member immediately upon the sleeve distal end entering the anatomical cavity can be realized.
Another modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated at 660 in FIG. 18. Penetrating member 662 of instrument 660 is made up of a distal part 670 and an end part 672, the distal part 670 having a distal end 676 defined by end surfaces 682 tapering distally to tip 678 and terminating proximally at a scalloped junction 684 joining the facets to a cylindrical neck 686 which in turn is joined to an elongate body 674 having an outer diameter or size less than the outer diameter of neck 686. Body 674 extends proximally from neck 686 to terminate at an end flange 687 disposed in the end part with body 674 passing through an opening in a forward wall of the end part. The end part forward wall is rigidly held between the end flange and a projection or plate 693 on body 674 such that the distal and end parts move together as a unit. End part 672 terminates proximally at an operating member or flange 688 at a proximal end of the penetrating member disposed in hub 666, the end part being hollow or tubular or formed with an internal passage to receive a push member 671 that is the same as push member 571 for setting the instrument in the ready and extended positions as was described for automatic retractable safety penetrating instrument 560. Operating spring 698 is connected between operating flange 688 and the rear wall of the hub to bias the penetrating member in a distal direction, and cushion spring 700 is connected between the operating flange and a retraction plate 694 disposed in the hub distally of the operating member to maintain the operating member at an initial position with the instrument in the extended position as shown in FIG. 18. As best illustrated in FIG. 19, retraction plate 694 has an opening therein allowing passage therethrough by the end part 672 with a leg 695 and an extension 697 extending proximally from the retraction plate at diametrically opposing locations. The leg 695 and extension 697 extend through respective slots in the operating flange 688 with retracting spring 702 connected between the leg 695 and the rear wall of the hub to bias the retraction plate in a proximal direction. A locking and releasing mechanism 712 for actuating retraction of the penetrating member includes a locking spring similar to that described for locking and releasing mechanism 612 except that trigger member 724 is disposed distally of locking member 722, the trigger member 724 being disposed on an extension 723 of arm 718. Extension 723 extends distally from locking member 722 with trigger member 724 disposed distally of the operating member in the initial position and the locking member in engagement with the extension 697 of the retraction plate in the normal condition for the locking spring illustrated in FIG. 18.
Operation of the automatic retractable safety penetrating instrument 660 is similar to that previously described for instrument 560 in that the push member 671 can be utilized to move the instrument from the rest to the ready position and thereafter to the extended position illustrated in FIG. 18 with the junction 684 of the penetrating member disposed beyond a distal end of the portal sleeve and the retraction plate 694 locked in place via engagement of extension 697 with the locking member 722 and the operating member 688 in the initial position disposed proximally of the trigger member 724. When the instrument 660 is forced through tissue to enter an anatomical cavity, the penetrating member 662 will be moved proximally causing proximal movement of the operating flange 688 to a set position with the locking member 722 serving as a stop or abutment limiting proximal movement of the operating flange. Upon the portal sleeve distal end entering the anatomical cavity, the operating flange will move distally, and the momentum of the operating spring 698 will cause movement of the operating member distally of the initial position to engage trigger member 724 and flex the locking spring to release the retraction plate 794.
An additional modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated at 760 in FIG. 20, the instrument 760 being similar to automatic retractable safety penetrating instrument 460 in that movement of a safety shield distally upon a distal end of the portal sleeve entering an anatomical cavity is utilized to trigger retraction. As illustrated in FIGS. 20 and 22, the penetrating member 762 for automatic retractable safety penetrating instrument 760 has a distal end 776 defined by a plurality of facets 782 terminating distally at tip 778 and proximally at a junction 784 joining the facets to a body 774. As illustrated in FIGS. 20 and 21, the safety shield 763 has a distal end 767 joined to an elongate body concentrically disposed around the body of the penetrating member, the safety shield distal end being defined by one or more end surfaces 801 for being disposed along a corresponding facet or facets 782 of the penetrating member when the instrument is in an operative position during penetration of tissue as shown in FIG. 21. The end surfaces 801 of the safety shield are disposed at an angle with a longitudinal axis of the instrument 760 that is the same as the angle that the corresponding facet or facets 782 are disposed with the longitudinal axis such that the safety shield distal end completes or conforms to the geometric configuration of the penetrating member in the operative position. The penetrating member and safety shield distal ends can have various configurations to produce a predetermined solid or hollow geometric configuration in the operative position. Body 774 terminates proximally at a retraction plate 794 disposed in hub 766, and one or more than one retracting spring 802 is connected between retraction plate 794 and the rear wall of the hub to bias the penetrating member in a proximal direction, one retracting spring being illustrated in FIG. 20 and two retracting springs being illustrated in FIG. 24. The safety shield terminates proximally at an operating member 788 disposed in hub 766 with an operating spring 798 disposed concentrically around the penetrating member and connected between the retraction plate 794 and the operating flange 788 to bias the safety shield in a distal direction. An end cap 806 similar to end cap 106 is mounted for longitudinal sliding movement relative to the hub by bias members including mounting springs 810 connected between the hub rear wall and the rear wall of the end cap to bias the end cap in a proximal direction. As best illustrated in FIGS. 20 and 23, a locking and releasing mechanism 812 for the instrument 760 includes a locking spring similar to that described for locking and releasing mechanism 712 in that arm 818 has an extension 823 extending distally from the locking member 822 to carry a trigger member 826 pivotally mounted on extension 823. Trigger member 826 includes a trigger cam 827 angled in a proximal direction and a leg 829 disposed parallel with extension 823 to allow proximal movement of the operating flange past the trigger cam without causing flexing of arm 818 and to cause flexing of arm 818 in response to distal movement of the operating member against the trigger cam. A notch or slot 833 can be formed in the retraction plate 794 to facilitate assembly of the instrument 760.
Operation of the automatic retractable safety penetrating instrument 760 is similar to that previously described for automatic retractable safety penetrating instrument 460 in that the instrument can be supplied in a rest state and moved to a ready position illustrated in FIG. 20 by releasing the end cap 806 from the hub 766. In the ready position, the penetrating member 762 and safety shield 763 are in a retracted position with end cap 806 biased proximally. End cap 806 is moved distally to set the instrument in the extended position illustrated in FIG. 24, the arm 818 serving as a push member for moving the retracting mechanism distally via engagement of the locking member 822 with the retraction plate 794. Once the protrusion 828 has entered the hub through the slot in the hub rear wall, the end cap will be locked in place at which time the retraction plate 794 is locked or held in place against the locking member 822. With the instrument in the extended position, the junction 784 of the penetrating member will be aligned with the distal end of the portal sleeve, and the distal end of the safety shield will be disposed beyond the tip 778 of the penetrating member. When the instrument 760 is forced through tissue forming a wall of an anatomical cavity, the safety shield will move proximally causing proximal movement of the operating member 788 past the trigger cam 827 without causing flexing of arm 818. In the operative position, the end surfaces 801 of the safety shield will be disposed along the corresponding facets 782 of the penetrating member to produce a predetermined geometric configuration. Once the distal end of the portal sleeve has entered the anatomical cavity, the safety shield 763 will be moved distally causing distal movement of the operating member 788 to engage trigger cam 827 and pivot leg 829 causing arm 818 to flex and release the retraction plate 794. Accordingly, retracting spring 802 will move the penetrating member and with it the safety shield to the retracted position shown in FIG. 20.
As illustrated in FIGS. 25 and 26 the hub 766 can have a side wall thereof formed with a central recessed channel 835 with a slot 837 formed in the hub wall to be disposed in the recessed channel. The slot 837 includes a longitudinal slot portion 839, a proximal transverse slot portion 841 and a distal transverse slot portion 843. A pin 845 is threadedly secured on the penetrating member, such as in the periphery of retraction plate 794, the pin 845 extending through the longitudinal slot portion 839 to terminate at an external knob 818 with the location of the proximal transverse slot portion 841 corresponding to the location of the pin 845 in the extended position. A pin 847 is secured to the safety shield, such as in the periphery of the operating flange 788, the pin 847 similarly extending through the longitudinal slot portion 839 to terminate at an external knob with the location of the distal transverse slot portion 843 corresponding to the location of the pin 847 in the extended position. The length of the longitudinal slot portion is sufficient to allow movement of the safety shield and the penetrating member between the extended and retracted positions with the knobs moving within the longitudinal slot portion. Where retraction is not desired, the pin 845 can be moved into the proximal transverse slot portion 841 preventing retraction of the penetrating member and safety shield such that the safety shield distal end is disposed beyond the tip of the penetrating member upon the portal sleeve distal end entering an anatomical cavity for use as a standard safety trocar instrument. Where it is desired to penetrate tissue with the safety shield distal end disposed beyond the tip of the penetrating member, pin 847 can be moved into the distal transverse slot portion 843 to lock the safety shield against proximal movement; and, accordingly, retraction of the penetrating member will be prevented. Where the safety shield distal end does not complete the configuration of the penetrating member distal end in the operative position and it is desired that the safety shield distal end be locked in a position substantially aligned with the portal sleeve distal end for use as a standard trocar instrument, an intermediate transverse slot portion 849 can be provided along the slot 837 corresponding in location to the location of pin 843 when the safety shield is in the retracted position allowing the pin 847 to be moved into the intermediate transverse slot portion as shown in dotted lines in FIGS. 25 and 26. A probe can be used with the instrument 760 to trigger retraction; and, as shown in FIG. 22, a probe 765 can be mounted within the penetrating member 762 to extend through a hole in an end surface or facet 782. Various types of release mechanisms can be used with the instrument 760 to release the end cap from the hub allowing the instrument to be reset in the extended position.
A modification of the automatic retractable safety penetrating instrument according to the present invention is illustrated at 860 in FIG. 27 wherein safety shield 863 includes a distal end 867 having a configuration that is the same as the configuration of the distal end 876 of the penetrating member 862 such that the safety shield can be utilized to cut tissue when disposed beyond the distal end of the penetrating member as illustrated in FIG. 27. As shown in FIG. 27, distal end 867 of safety shield 863 has a plurality of end surfaces or facets 901 tapering distally to a sharp tip 903, and the penetrating member distal end 876 includes a plurality of corresponding facets 882 tapering distally to sharp tip 878 with the facets 901 of the safety shield being disposed at an angle with the longitudinal axis of the penetrating member that is the same as the angle that the facets 882 are disposed with the longitudinal axis. By forming the safety shield distal end of a severable material, the distal end 867 of the safety shield can be cut prior to use to remove the sharp tip 903 where use of the safety shield to cut tissue is not desired.
Another modification of the automatic retractable safety penetrating instrument according to the present invention is illustrated at 960 in FIG. 28 wherein the penetrating member 962 is in the nature of a cannulated needle having a distal end 976 defined by an angled edge 982 terminating distally at a sharp tip 978. A safety probe 965 is disposed concentrically within the penetrating member, the safety probe 965 having a distal end 969 with an angled end surface 905. The edge 982 of the penetrating member is disposed at an angle with the longitudinal axis of the penetrating member that is the same as the angle that the end surface 905 is disposed with the axis such that the probe and penetrating member form a substantially smooth, solid geometric configuration in the operative position. Instrument 960 can be designed to allow removal of the probe and the penetrating member together or individually from the portal unit, and the probe can remain extended beyond the distal end of the portal sleeve upon retraction of the penetrating member as was described for the safety shield in instrument 760.
Another embodiment of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 29 wherein a hollow penetrating member 1062 is partially solid having a passage 1007 therethrough of a semicircular configuration in cross-section. A distal end 1076 of the penetrating member has a partially conical configuration terminating at a sharp tip 1078 from which extends a peripheral edge 1082 forming an opening in the distal end of the penetrating member. A safety probe 1065 is formed of a solid elongate member 1009 having a semi-circular configuration in cross-section and terminating at a distal end 1069 having a partially conical configuration corresponding to the configuration of the distal end of the penetrating member.
In the extended position, the distal end 1069 of the safety probe will protrude beyond sharp tip 1078 to protect the tip as shown in FIG. 31; and, during penetration of tissue, the safety probe will move to the retracted position as shown in FIG. 32 such that the distal end 1069 of the safety probe is positioned within the opening formed by peripheral edge 1082 in substantial alignment to form, with distal end 1076 of the penetrating member, a solid geometrical configuration similar to a trocar. By utilizing the positive stop mechanisms previously illustrated, the safety probe will be prevented from retracting further than the position corresponding with the configuration of the penetrating member such that the conical configuration of the penetrating distal end of the safety penetrating instrument is assured as shown in FIG. 32.
FIG. 30 shows a modification of the automatic retractable safety penetrating instrument of FIG. 29 wherein a penetrating member 1062' has the same external configuration as penetrating member 1062 but is tubular and the safety probe 1065' has an elongate member of circular configuration in cross-section corresponding to the tubular configuration of the penetrating member. The safety penetrating instrument of FIG. 30 will assume the same configuration as the safety penetrating instrument of FIG. 29 in the extended position as shown in FIG. 31 and the retracted position as shown in FIG. 32.
A modification of the automatic retractable safety penetrating instrument of FIG. 29 is illustrated in FIGS. 33, 34, 35 and 36 wherein the safety probe and penetrating member cooperate to produce a solid geometric pyramid configuration. More particularly, a hollow penetrating member 1162, which can be either tubular similar to the penetrating member illustrated in FIG. 30 or have a passage therethrough similar to the penetrating member illustrated in FIG. 29, has a distal end 1176 having a partial geometric configuration of a pyramid with sides or facets 1182 tapering to a sharp tip 1178 while an opening in the distal end defined by a peripheral edge 1182' terminates at sharp tip 1178. A safety probe 1165 has a cross-sectional configuration corresponding to that of the hollow penetrating member and has a distal end 1169 formed of sides or facets 1201 tapering to a narrow end, the configuration of the distal end 1169 cooperating with the configuration of the distal end 1176 of the penetrating member, when the safety probe is in the retracted position as illustrated in FIGS. 34 and 35, to produce a substantially complete geometric pyramid configuration having four sides or facets symmetrically arranged around a sharp point 1178.
Still a further modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 37 at 1260, the instrument 1260 being similar to automatic retractable safety penetrating instrument 760 except that safety shield 1263 for automatic retractable safety penetrating instrument 1260 terminates distally at a peripheral scalloped edge 1213 and proximally at an operating member or flange 1288 disposed in hub 1266 with cushion spring 1300 disposed around the body of the safety shield and connected between the operating flange 1288 and the front wall of the hub. Operating spring 1298 is disposed around the penetrating member and connected between the operating member and the retraction plate 1294 such that the operating member 1288 is maintained at an initial position with the instrument in the extended position illustrated in FIG. 37. The locking and releasing mechanism 1312 for automatic retractable safety penetrating instrument 1260 is similar to the locking and releasing mechanism 812; however, the locking spring for locking and releasing mechanism 1312 has two protrusions 1328 and 1328' with protrusion 1328' distally spaced from protrusions 1328.
Operation of automatic retractable safety penetrating instrument 1260 is similar to that previously described in that instrument 1260 is moved to the extended position via squeezing operation of end cap 1306 causing arm 1318 to move retraction plate 1294 distally until protrusion 1328 enters the hub at which time the end cap 1306 will be locked in place with protrusion 1328' disposed within the hub distally of protrusion 1328 and the retraction plate 1294 locked in place against the locking member 1322. In the extended position, operating flange 1288 will be disposed in the initial position proximally of trigger cam 1327, and the distal edge 1213 of the safety shield will be disposed proximally of the tip 1278 of the penetrating member 1262. When the instrument 1260 is forced through tissue to enter an anatomical cavity, safety shield 1263 will be moved proximally causing proximal movement of operating flange 1288; and, upon the portal sleeve distal end entering the anatomical cavity, operating flange 1288 will be moved distally of the initial position to engage trigger cam 1327 and pivot leg 1329 thusly flexing arm 1318 to release retraction plate 1294. Accordingly, retracting spring 1302 will move the penetrating member and with it the safety shield proximally causing the retraction plate 1294 to engage protrusion 1328' such that arm 1398 is pivoted in a direction outwardly from a longitudinal axis of the instrument causing protrusion 1328 to be aligned with the slot 1320 in the hub rear wall to automatically release the end cap in response to movement of the penetrating member to the retracted position.
An additional modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated at 1360 in FIG. 38. Automatic retractable safety penetrating instrument 1360 is similar to automatic retractable safety penetrating instrument 60 except that the operating member, the retraction member, the locking and releasing mechanism, the push member and the valve assembly for instrument 1360 are different than those for instrument 60. The penetrating member 1362 for automatic retractable safety penetrating instrument 1360 terminates proximally at an operating member or flange 1388 having an ear 1315 projecting outwardly therefrom; however, depending on the configuration for the operating flange, ear 1315 need not be provided. The retraction member for instrument 1360 is in the nature of a U-shaped member defining a retraction plate 1394, a forward or engagement wall 1351 distally spaced from the retraction plate and a connecting or sidewall 1353 joining the engagement wall to the retraction plate with the penetrating member 1362 passing through a hole in the engagement wall 1351. Operating spring 1398 is disposed concentrically around control tube 1396 and connected between the operating flange 1388 and the retraction plate 1394 to bias the penetrating member distally with operating flange 1388 in abutment with the engagement wall 1351. Retracting spring 1402 is disposed concentrically around control tube 1396 and connected between the rear wall of the hub 1366 and the retraction plate 1394 to bias the retracting member in a proximal direction. The locking and releasing mechanism 1412 for automatic retractable safety penetrating instrument 1360 is best shown in FIGS. 39, 39a and 40 and includes a latch or locking spring having a base 1414 for being secured to a wall of hub 1366 with arm 1418 joined to base 1414 by a bend or angle 1416, the arm 1418 being in the nature of a plate or flat piece of material. A locking member 1422 protrudes beyond a longitudinal edge of arm 1418 to engage retraction plate 1394 and prevent proximal movement thereof in a normal condition for the latch in the extended position for the instrument illustrated in FIG. 38. A trigger or release member 1426 protrudes from the longitudinal edge parallel with and distally spaced from the locking member 1422, the trigger member 1426 being disposed in the normal condition in the path of longitudinal movement of ear 1315 or operating flange 1388 where ear 1315 is not provided. Arm 1418 can be bent from base 1414 at a right angle along bend 1416 as shown in FIG. 39, or the arm can be joined to the base by a curved U-shaped bend 1416 as illustrated in FIG. 39a allowing arm 1418 to pivot around a pivot axis extending along the angle or bend. Locking member 1422 is in the nature of a cylindrical protrusion or pin, and trigger member 1426 is in the nature of a flat strip of material angled in a proximal direction from arm 1418 to allow proximal movement of ear 1315 thereby without causing pivoting of arm 1418. Various mechanisms including a pin secured on the retracting member and projecting through a slot in the hub can be utilized in the instrument 1360 to set the instrument in an extended position by moving the retracting mechanism distally such that retraction plate 1394 is moved distally to be locked against locking member 1422. As shown in FIG. 38, an end cap 1406 and push member 1471 are provided in the instrument 1360, the push member being in the nature of a spring arm mounted in end cap 1406 and having a bent end for engaging the retraction plate with a protrusion 1428, the push member being similar to the locking and releasing mechanisms previously described for use as push members. The valve assembly for instrument 1360 includes a one-piece, hollow cylindrical, truncated conical or tubular valve body 1438 having a peripheral flange for mounting in a rear end of housing 1368. Valve body 1438 is made from flexible, stretchable, elastic or resilient material, such as silicone or rubber, and is provided with one or more than one slit 1455 extending longitudinally therealong allowing instrument of various sizes to be inserted through the lumen of the valve body with the valve body conforming to the size of the instruments to produce a seal therewith.
Operation of automatic retractable safety penetrating instrument 1360 is similar to that previously described in that the instrument is moved to the extended position via squeezing operation of retracing mechanism distally to the extended position illustrated in FIG. 38. In the extended position, the junction 1384 of the penetrating member 1362 is disposed beyond the distal end of the portal sleeve 1364, operating member 1388 is in the initial position abutting engagement wall 1351 to be disposed distally of trigger member 1426, trigger member 1426 is disposed in the path of longitudinal movement of the ear 1315 and retraction plate 1394 is locked in place against locking member 1422. In order to facilitate movement of the retraction plate 1394 distally past the locking member when setting the instrument in the extended position, a forward edge 1457 of the retraction plate can be angled as shown in FIG. 41. With the instrument in the extended position, locking member 1422 will engage the retraction plate 1394 just inwardly of the forward edge 1457 as best illustrated in FIG. 41. Once the retraction plate is locked in place against the locking member 1422, further squeezing of the end cap 1406 causes the angled distal portion of protrusion 1428 to be engaged by the hub rear wall causing the push member 1471 to be pivoted in a direction outwardly form a longitudinal axis of the instrument such that the bent end is disengaged from the retraction plate. The push member will be moved out of the path of movement of the retraction plate with protrusion 1428 locking the end cap relative to the hub. When instrument 1360 is utilized to penetrate tissue, penetrating member 1362 will be moved proximally causing proximal movement of operating flange 1388 and with it ear 1315 to a set position such that junction 1384 is substantially aligned with the distal end of the portal sleeve in an operative position for the instrument, and compression of the operating spring can serve as a positive stop limiting proximal movement of the penetrating member. Ear 1315 moves proximally by trigger member 1326 causing arm 1418 to pivot around the pivot axis, i.e. over the trigger member as illustrated in FIG. 42, inwardly toward a longitudinal axis of the instrument with the pivot axis being parallel with the instrument axis. Accordingly, locking member 1422 will move inwardly along the retraction plate 1394 further from the edge 1457 as shown by the arrow in FIG. 42 such that the retraction plate 1394 remains locked in place. Once the distal end of the portal sleeve has entered the anatomical cavity, penetrating member 1362 will be moved distally causing distal movement of the operating member 1388 toward the initial position with ear 1315 moving distally, i.e. under the trigger member 1426 as shown in dotted lines in FIG. 43, causing arm 1418 to pivot around the pivot axis in a direction outwardly from the instrument axis and toward base 1416 such that the locking member 1422 is moved outwardly of the edge 1457 as shown by the arrow in FIG. 43 thusly releasing the retraction plate 1394. Accordingly, retracting spring 1402 will move the retraction member and with it the penetrating member to the retracted position. It will be appreciated that the locking member 1422 can have various structural configurations to prevent proximal movement of the retracting mechanism and to release the retraction member in response to pivoting of the latch around an axis parallel with the instrument axis. Trigger member 1426 can have various configurations to allow proximal movement of the operating member thereby without releasing the retraction plate and to cause pivoting of arm 1418 around the pivot axis in response to distal movement of the operating member toward the initial position. The operating member 1388 can have various configurations with or without ear 1315 to move proximally by the trigger member 1426 without causing disengagement of locking member 1422 from retraction plate 1394 to pivot arm 1418 to release the retraction plate in response to distal movement of the operating member toward the initial position. While one locking and releasing mechanism 1412 is provided in the instrument 1360, more than one locking and releasing mechanism can be provided. The locking and releasing mechanism 1412 can be made in many various ways including a length of wire bent in a desired configuration to form the locking and trigger members and an elongated strip or bar with the trigger and locking members thereon. The locking and releasing mechanism can be made of a spring material to produce the desired pivotal or flexing movement or the locking and releasing mechanism can be pivotably or rotatably mounted in the instrument and biased to the normal position. Depending upon its configuration, the locking and releasing mechanism can be pivotally mounted in many ways; and, where the locking and releasing mechanism is made from a wire or strip of material, one or both ends of the wire or strip can be pivotally secured in the instrument to mount the locking and releasing mechanism for pivotal movement around an axis parallel with the longitudinal axis of the instrument with a torsional bias biasing the locking and releasing mechanism to the normal position.
Another modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated at 1460 in FIG. 44, the instrument 1460 being similar to the instrument 1360 except that the retraction member for instrument 1460 includes only the retraction plate 1494 with the locking member 1522 disposed distally of the trigger member 1526 to lock the retraction plate against a front wall of the hub 1466 in the extended position for the instrument.
In use, instrument 1460' is forced through tissue causing proximal movement of operating member 1488 by trigger member 1526 to the set position to produce pivotal movement of the locking and releasing mechanism 1512 without disengaging locking member 1522 from retraction plate 1494. Upon a distal end of the portal sleeve entering the anatomical cavity, the operating member 1488 will be moved distally toward the initial position to engage trigger member 1526 and pivot the locking and releasing mechanism 1512 around an axis parallel with a longitudinal axis of the instrument in a direction outwardly from the longitudinal axis such that the retraction plate is released for retraction by retracting spring 1502. By forming the locking member as a retraction plate only and by positioning the locking member distally of and close to the trigger member, the space required for the locking and releasing mechanism can be reduced allowing the length of the hub 1466 to be minimized.
A still further modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 45 at 1560. Automatic retractable safety penetrating instrument 1560 is similar to automatic retractable safety penetrating instrument 1460; however, a safety shield 1563 is utilized in instrument 1560 to trigger retraction, the safety shield terminating proximally at an operating member 1588. The locking and releasing mechanism 1612 for instrument 1560 is similar to locking and releasing mechanism 1512; however, the operating member 1588 for automatic retractable safety penetrating instrument 1560 is positioned by an operating spring 1598 and a cushion spring 1600 in an initial position disposed proximally of a trigger member 1624 with the instrument in the extended position illustrated in FIG. 45. The penetrating member 1562 terminates proximally at retraction plate 1594 with the operating spring connected between the retraction plate and the operating member and the cushion spring connected between the operating member and the front wall of hub 1566. Instead of a spring, the retracting mechanism for instrument 1560 includes a magnetic bias with magnets 1669 being mounted in a rear wall of the hub 1566 and the retraction plate 1594 being made of a magnetizable material. Where use of magnets 1659 in the hub rear wall is not desired, the rear wall of the hub can be made of a material having one polarity with the retraction plate being made of a material having the opposite polarity. End cap 1606 is movably mounted relative to hub 1566 by bias members including mounting springs 1610 secured between a rear wall of the end cap and attachment blocks 1661 secured to and disposed in hub 1566. A push member 1671 is mounted in end cap 1600 for setting the instrument in the extended positions the push member 1671 being similar to push member 1471. An end cap release mechanism for locking the end cap relative to the hub and for releasing the end cap from the hub includes an actuating button 1630 made up of a spring 1631 externally secured on skirt 1608 of end cap 1606, the spring 1631 having a normal condition defining one or more than one bumps or protrusions for being received in an opening in a wall of the hub 1566 with the instrument in an extended position as illustrated in FIG. 45 and for being moved to a collapsed or flattened position allowing the end cap to be released from the hub.
Operation of the automatic retractable safety penetrating instrument 1560 is similar to that previously described in that the instrument can be moved to the extended position by squeezing end cap 1606 causing push member 1671, via engagement with the retraction plate 1594, to move the penetrating member and with it the safety shield distally such that the retraction plate is moved past locking member 1622 to be locked in place. Continued squeezing of the end cap causes protrusion 1628 to enter the hub such that the push member is flexed in a direction outwardly from the instrument axis to be disengaged from the retraction plate. Distal movement of the end cap causes spring 1631 to be collapsed or flattened until it is aligned with the opening in the hub at which time the push member will be out of the path of movement of the retraction plate 1594 and the operating member 1588. Once aligned with the opening in the hub, spring 1631 will return to the normal condition locking the end cap in place. During penetration of tissue, safety shield 1563 will be moved proximally such that operating member 1588 is moved proximally from the initial position to a set position in the operative position for the instrument. Upon a distal end of the portal sleeve entering the anatomical cavity, the safety shield will be move distally causing operating member 1588 to be moved distally of the initial position to engage trigger member 1624 and pivot the locking and releasing mechanism 1612 around an axis parallel with a longitudinal axis of the instrument to release the retraction plate 1594. Accordingly, the magnetic bias will move the penetrating member and the safety shield to the retracted position.
A modification of a locking and releasing mechanism for use with the automatic retractable safety penetrating instruments according to the present invention is illustrated at 1712 in FIG. 46, the locking and releasing mechanism 1712 being similar to locking and releasing mechanisms 1412, 1512 and 1612 except that locking and releasing mechanism 1712 is made from a length of metal or plastic wire or filament bent to define a locking member 1722 and a trigger member 1726. Locking and releasing mechanism 1712 has ends formed as or secured to coil springs 1799 for torsionally biasing the locking and releasing mechanism to a normal position when the ends are secured, such as to the front and rear walls of the hub of an automatic retractable safety penetrating instrument.
Yet another modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 47 at 1760, only the penetrating unit for the instrument 1760 being shown. Penetrating member 1762 for instrument 1760 is made up of a distal part 1770 mounted for telescoping movement relative to a tubular end part 1772. Distal part 1770 has a distal end 1776 terminating distally at tip 1778 and proximally at a junction 1784 joining the distal end to an elongate outer tubular body 1842. Outer body 1842 is concentrically disposed around an inner body 1774 extending proximally from an internal end wall or shoulder 1780 disposed in outer body 1842 transverse to a longitudinal axis of the instrument. Inner body 1774 terminates proximally at an operating member 1788 disposed in end part 1772 with the inner body passing through an opening in a forward or stop or abutment wall 1792 at a distal end of the end part 1772. The distal end of end part 1772 is disposed in outer body 1842 with the end part terminating proximally at a proximal end joined to or formed as part of hub 1766. A sheath 1844 is concentrically disposed around the end part 1772 at the proximal end thereof, the sheath terminating distally at a forward end spaced from the outer body 1842 by a distance that is equal to the retraction distance for the distal part 1770. Outer body 1842 has an outer diameter that is the same as the outer diameter of sheath 1844 to be received by the inner diameter of the portal sleeve 1764. A retracting member is disposed in the end part 1772 and includes a U-shaped or rectangular member defining a retraction plate 1794, one or more connecting or side walls 1853 extending distally from the retraction plate and a forward wall 1851 distally joined to side walls 1853 with the forward wall having an opening therein allowing passage therethrough by the inner body 1774. Inner body 1774 is hollow or tubular or partly hollow or tubular to receive a control tube 1796 extending distally from a rear wall of the hub, the control tube passing through an opening in the retraction plate 1794. The retracting member defines an enclosure or structure for receiving the operating flange 1788, an operating spring 1798 concentrically disposed around the control tube and connected between the operating flange 1788 and the retraction plate 1794 to bias the distal part 1770 in a distal direction relative to the end part 1772 and a cushion spring 1800 concentrically disposed around the inner body 1774 and connected between the operating flange 1788 and the forward wall 1851 to bias the distal part in a proximal direction such that the operating flange is maintained at an initial position with the instrument in the extended position as illustrated in FIG. 47. One ore more than one retracting spring 1802 biases the retraction member in a proximal direction. Various different types of springs as well as other types of bias devices can be utilized in the instrument 1760 to bias the retracting member; and, as shown in FIG. 48, the retracting spring can be a torsion spring. As illustrated in FIG. 48, the retracting spring 1802 is a coil torsion spring that can be mounted in instrument 1760 with an end of the spring connected to the retraction plate 1794, such that the spring is unwound to bias the retraction member proximally in the extended position as illustrated in FIG. 47 and is rewound to move the retraction member proximally to a retracted position upon release of the retraction plate as will be explained further below, and the spring is wound and unwound about an axis transverse to the direction of movement of the penetrating member between the extended and retracted positions. The spring 1802 can be arranged in instrument 1760 in many ways including within or externally of the penetrating member or within the control tube, the hub or the valve housing to wind on an axis transverse to the direction of retraction. Locking and releasing mechanism 1812 for automatic retractable safety penetrating instrument is similar to locking and releasing mechanism 512 except that the locking and releasing mechanism 1812 is mounted within control tube 1796 with trigger members 1824 and 1826 extending through a longitudinal slot in the control tube to be disposed in the path of movement of operating flange 1788, the operating flange projecting inwardly from an internal surface of the wall of inner body 1774. Locking member 1822 for locking and releasing mechanism 1812 includes a protrusion on arm 1818 proximally spaced from trigger members 1826, the locking member having a distal portion disposed transverse to a longitudinal axis of the instrument to prevent proximal movement of retraction plate 1794 thereby and a proximal portion angled in a distal direction to permit distal movement of the retraction member thereby when setting the instrument in the extended position. Various different types of push members can be utilized in the instrument 1760 to move the retracting mechanism distally when setting the instrument in the extended position; and, as shown in FIG. 47, a pair of push members 1871 in the nature of arms connected between a rear wall of end cap 1806 and the retraction plate 1794 are provided. End cap 1806 has a skirt 1808 disposed externally of the hub 1766, and the distance that the end cap must be moved proximally in the ready position will be in accordance with the distance that the push member must be moved proximally to engage the retracting mechanism for movement to the extended position.
In use, the automatic retractable safety penetrating instrument 1760 can be moved to the extended position via squeezing operation of end cap 1806 causing movement of the retracting member distally unwinding springs 1802 with the proximal portion of locking member 1822 allowing the retraction member to move distally thereby until the retraction plate 1794 is locked in place against the distal portion of the locking member. With the instrument in the extended position, junction 1784 of the penetrating member 1762 will be disposed beyond the distal end of the portal sleeve 1764 and the operating member 1788 will be in the initial position disposed proximally of trigger members 1824 and distally of trigger members 1826. During penetration of tissue, the distal part 1770 is moved proximally relative to the end part 1772 causing proximal movement of operating member 1788 past trigger members 1826 to a set position without causing flexing of the arm 1818, and the instrument will be in the operative position with junction 1784 substantially aligned with the distal end of the portal sleeve. Once the distal end of the portal sleeve has entered the anatomical cavity, the distal part 1770 will be moved distally relative to the end part 1772 causing operating member 1788 to move distally toward the initial position to engage a distally closest trigger member 1826 causing flexing of arm 1818 such that locking member 1822 is moved into the control tube thusly releasing the retraction plate 1794. Once the retraction plate is released, springs 1802 are rewound moving the retraction member and with it the distal part 1772 of the penetrating member in a proximal direction to the retracted position with the tip 1778 disposed in the portal sleeve in a safe, protected position. Trigger members 1824 can be utilized to trigger retraction via movement of the operating member 1788 distally of the initial position.
Thus, it will be appreciated that in automatic retractable safety penetrating instrument 1760 the shaft of the penetrating member is formed of telescoping parts such that the distal end 1776 is retracted by telescoping proximal movement of the distal part of the penetrating member relative to the end part of the penetrating member whereby hub 1766 need not house any mechanism and need not provide any longitudinal space for retraction of the penetrating member distal end such that the length of the hub can be minimized. The retracting mechanism retracts the distal end until shoulder 1780 abuts wall 1792 such that the distal end is within the portal sleeve, and the sliding or telescoping movement between the parts of the penetrating member can be accomplished with other structural arrangements, for example, by eliminating outer tubular body 1842 to permit the distal part to telescope only within the end part.
FIG. 49 illustrates an alternative arrangement for the retracting mechanism for the automatic retractable safety penetrating instrument 1760 wherein the torsion spring 1802 is connected to a flange 1846 of a spool 1848 having an axle for winding thereon of a connector 1850 secured between the spool and the retracting member. The connector can be a length of any suitable material including wire, synthetic plastic, string materials and the like for being in a wound condition on the spool 1848 in response to rotation of the spool by torsion spring 1802.
Yet another modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 50 at 1860, only the penetrating unit for the instrument 1860 being shown. Penetrating member 1862 for instrument 1860 is made up of a distal part 1870 mounted for telescoping movement within a tubular end part 1872. Distal part 1870 includes a distal end 1876 proximally joined to a cylindrical neck 1886 at a junction 1884, the neck 1886 terminating proximally at a shoulder 1880. A body 1874 having an outer diameter or size less than the outer diameter of neck 1886 extends proximally from shoulder 1880 to be disposed within the end part 1872 with the body 1874 extending through an opening in a forward or abutment wall 1892 at a distal end of the end part. End part 1872 has an outer diameter that is the same as the outer diameter of neck 1886 to be received by the inner diameter of the portal sleeve. Body 1874 terminates proximally at an end wall 1852, and a tubular neck or extension 1954 extends proximally from the end wall to terminate at an operating flange 1888 disposed in end part 1872. A coil torsion operating spring 1898 is connected between operating member 1888 and abutment wall 1892, the spring 1898 being partially unwound to bias the distal part 1870 in a distal direction relative to the end part 1872. A retraction plate 1894 is disposed within the end part and has an opening therein allowing passage therethrough by the neck 1854. A coil torsion retracting spring 1902 is connected between the retraction plate 1894 and a non-movable part, such as a wall of end part 1872, of the instrument 1860, the retracting spring being unwound to bias the retraction plate in a proximal direction to abut the operating flange in the extended position for the instrument illustrated in FIG. 50. Connecting walls 1953 extend distally from retraction plate 1894 to terminate at a forward wall 1951 serving as a stop or abutment limiting proximal movement of the distal part 1870 during penetration of tissue. Locking and releasing mechanism 1912 for instrument 1860 is similar to the locking and releasing mechanism 112 except that two locking springs are provided in the instrument 1860 having triggers 1926 disposed proximally of the operating member 1888 in the initial position illustrated in FIG. 50. The locking springs for instrument 1860 can be utilized as push members or the locking springs can be utilized only for locking and releasing the retracting mechanism with separate push members provided for moving the instrument to the extended position.
Operation of the automatic retractable safety penetrating instrument 1860 is similar to that previously described in that the distal part 1870 of the penetrating member 1862 will be moved proximally relative to the end part 1872 during penetration of tissue causing proximal movement of operating member 1888 from the initial position past triggers 1926 to the set position at which time the instrument will be in the operative position with junction 1884 substantially aligned with the distal end of portal sleeve 1864. Movement of the operating member proximally causes operating spring 1898 to be further unwound with the forward wall 1951 serving as a positive stop limiting proximal movement of the distal part. Once the distal end of the portal sleeve has entered the anatomical cavity, operating spring 1898 will rewind causing the distal part 1870 to be moved distally relative to the end part 1872 such that the operating flange 1888 engages the distally closest triggers 1926 to flex the arms 1918 in a direction outwardly from a longitudinal axis of the instrument such that the retracting plate 1894 is released from the locking members 1922. Accordingly, retracting spring 1902 will rewind causing telescoping proximal movement of the distal part 1870 relative to the end part 1872 such that the distal end 1876 of the penetrating member 1862 is moved to a retracted position within the portal sleeve with abutment 1892 limiting retraction of the distal part.
A further modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 51 at 1960. Automatic retractable safety penetrating instrument 1960 is similar to instrument 1760 except that the penetrating member 1962 for instrument 1960 does not have an outer body and the locking and releasing mechanism 2012 for instrument 1960 includes a latch that is similar to the latch for instrument 1360. The penetrating member 1962 for automatic retractable safety penetrating instrument 1960 includes a distal part 1970 mounted for telescoping movement relative to a tubular end part 1972. Distal part 1970 has a distal end 1976 terminating distally at tip 1978 and proximally at a junction 1984 joining the distal end to a cylindrical neck 1986 terminating proximally at an end wall or shoulder 1980. An elongate body 1974 extends proximally from shoulder 1980 to terminate at an operating member 1988 disposed in end part 1972, the neck 1986 having an outer diameter that is the same as the outer diameter of end part 1972. Body 1974 can be hollow or tubular or partly hollow or tubular as illustrated in FIG. 51 to receive an extension 1997 extending distally from retraction plate 1994 of a retraction member. A connecting wall 2053 extends distally from the retraction plate to terminate at a forward wall 2051 with the operating member 1988 being disposed between the forward wall and the retraction plate. The retraction member defines a structure for mounting the operating member 1988, an operating spring 1998 disposed around the extension 1967 and connected between the operating member and the retraction plate 1994 and a cushion spring 2000 disposed around body 1974 and connected between the operating member 1988 and the forward wall 2051 to position the operating member in an initial position with the instrument in the extended position as illustrated in FIG. 51. The latch or locking spring for locking and releasing mechanism 2012 includes a locking member 2022 engaged with retraction plate 1994 to prevent proximal movement thereof and a trigger member 2024 disposed distally of the operating member 1988 in the initial position. A coil torsion retracting spring 2002 connected with the retraction member is provided in the instrument 1960 to bias the retraction plate 1994 in a proximal direction. A push member 1971 can be provided for setting the instrument in the extended position.
Operation of automatic retractable safety penetrating instrument 1960 is similar to that described for instrument 1760 in that the distal part 1970 is moved proximally relative to the end part 1972 during penetration of tissue causing proximal movement of the operating member 1988 from the initial position to a set position at which time the instrument will be in an operative position with junction 1984 substantially aligned with the distal end of portal sleeve 1964. Once a distal end of the portal sleeve has entered the anatomical cavity, the distal part 1970 will be moved distally relative to the end part 1972 causing movement of operating member 1988 distally of the initial position to engage trigger 2024 such that the locking and releasing mechanism 2012 pivots around an axis parallel with a longitudinal axis of the instrument 1960 to release retraction plate 1994 from locking member 2022.
Another modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 52 at 2060, the instrument 2060 being similar to automatic retractable safety penetrating instrument 60 except that the end part 2072 of penetrating member 2062 does not retract with the distal part 2070, and the valve assembly for instrument 2060 is different than the valve assembly for instrument 60. End part 2072 for penetrating member 2062 terminates distally at a stop or abutment 2092 and proximally at a proximal end secured in or formed with a front wall of hub 2066. Distal part 2070 includes a cylindrical body 2074 extending proximally from shoulder 2080 to terminate at an end wall 2152 with a tubular neck 2154 extending proximally from end wall 2152 to terminate at operating member 2088 disposed in hub 2066. A retraction plate 2094 is disposed in hub 2066 and has an opening therein allowing passage therethrough by neck 2154. A retracting spring 2102 is connected between the retraction plate 2094 and a rear wall of hub 2066 to bias the retraction plate in a proximal direction. A locking and releasing mechanism 2112 is disposed in hub 2066, the locking and releasing mechanism 2112 being similar to the locking and releasing mechanism 112 for automatic retractable safety penetrating instrument 60. End wall 2152 is disposed within the end part 2072, and an operating spring 2098 is disposed around neck 2154 and connected between the operating member 2088 and the retraction plate 2094 to bias the distal part 2070 in a distal direction. A cushion spring 2100 is disposed concentrically around neck 2154 and connected between the retraction plate 2094 and the end wall 2152 to bias the distal part in a proximal direction such that operating member 2088 is in an initial position disposed proximally of trigger member 2124 and distally of trigger members 2126 with the retraction plate 2094 held against the front wall of the hub via locking member 2122 in the extended position for the instrument illustrated in FIG. 52. The valve assembly for instrument 2060 is similar to the valve assembly disclosed in applicant's U.S. patent application Ser. No. 07/557,869, filed Jul. 26, 1990, the specification of which is incorporated herein by reference. The valve assembly includes a valve block 2158 having a peripheral flange for being disposed in a recess at a rear end of housing 2068 and a cylindrical member extending distally from the flange to mount a cylindrical or spherical valve body 2138. Valve body 2138 has a plurality of different size lumens or passages that can be selectively aligned with the open proximal end of the portal sleeve 2064 and a passage in the valve block to provide communication through housing 2068. The valve assembly includes a spring rotationally biased to maintain the valve body 2138 in a closed position wherein a solid surface of the valve body is aligned with the passage in the valve block to close off and seal the valve housing. An external ridge 2160 is provided on the valve body for rotating the valve body to an open position corresponding to one of the lumens being aligned with the passage. A pin 2117 protrudes distally from the front wall of hub 2066 for penetrating through the valve block 2158 and into the valve body 2138 when the hub 2066 is combined with the valve housing 2068 as illustrated in FIG. 52.
In operation, the hub 2066 is combined with the valve housing 2068 with pin 2117 penetrating the valve assembly to enter the valve body 2138 thusly preventing rotational movement of the valve body toward the closed position such that strain or friction on penetrating member 2062 is eliminated. When the instrument 2060 is forced through tissue, distal part 2070 will be moved proximally relative to end part 2072 causing proximal movement of operating member 2088 from the initial position to a set position at which time the instrument will be in the operative position. Once a distal end of portal sleeve 2064 has entered the anatomical cavity, distal part 2070 will move distally relative to end part 2072 causing movement of operating member 2088 distally toward the initial position to engage a trigger 2126 or distally of the initial position to engage trigger 2124 such that arm 2118 will be flexed releasing retraction plate 2094 from locking member 2122.
A still further modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 53 at 2160, wherein only the penetrating unit for instrument 2160 is shown. Penetrating member 2162 for instrument 2160 includes a distal end 2176 joined to an elongate tubular or partly tubular body 2174 terminating proximally at an operating flange 2188 disposed in hub 2166. A control tube 2196 extends distally from a rear wall of end cap 2206 and into body 2174, the operating flange 2188 extending inwardly from an internal surface of the wall of the body to be disposed in a longitudinal slot 2191 in the control tube. A retraction plate 2194 is disposed in hub 2166, the retraction plate extending inwardly through a hole in body 2174 to be disposed in the slot 2191. Operating spring 2198 is disposed concentrically around the control tube and connected between a rear wall of hub 2166 and the operating flange 2188, and a cushion spring 2200 is disposed concentrically around body 2174 and connected between the operating flange 2188 and the retraction plate 2194 to position the operating flange in an initial position with the instrument in the extended position illustrated in FIG. 53. The locking and releasing mechanism 2212 for instrument 2160 is disposed within control tube 2196 and includes a latch or locking spring having an arm 2218 formed with a protrusion 2228 for locking the end cap 2206 within the hub 2166 in the extended position for the instrument, a locking member 2222 for holding the retraction plate 2194 against a front wall of hub 2166 and triggers 2224 and 2226. A stop or abutment in the nature of an additional bump or protrusion 2192 formed on arm 2218 serves as a positive stop limiting proximal movement of operating member 2188 during penetration of tissue. Actuating buttons 2230 for instrument 2160 are made up of casings or housings mounted in openings in skirt 2208 with helical springs 2231 disposed in the casings concentrically around release arms 2232 biasing the casings in a direction outwardly from a longitudinal axis of the instrument and allowing the casings to be moved inwardly toward the instrument axis to compress bend 2116. Although illustrated in FIG. 53 as extending through skirt 2208 adjacent a rear wall of the end cap, the buttons 2230 can be mounted at any suitable location in accordance with the location for the locking and releasing mechanism. A valve can be provided along the rear wall of end cap 2206 in communication with the lumen of the control tube 2196 to provide fluid flow through the instrument.
Automatic retractable safety penetrating instrument 2160 can be utilized to penetrate tissue and enter an anatomical cavity as previously described with the penetrating member moving proximally during penetration of tissue causing proximal movement of operating flange 2188 from the initial position to a set position at which time the instrument 2160 will be in an operative position. Upon the portal sleeve distal end entering the anatomical cavity, the penetrating member 2162 will be moved distally causing operating flange 2188 to move toward the initial position to engage trigger 2226 or distally of the initial position to engage trigger 2224 causing arm 2218 to move within control tube 2196 releasing locking member 2222 from retraction plate 2194 while protrusion 2228 remains engaged with the rear wall of the hub. Accordingly, retracting spring 2202 will move the retracting member 2194 and with it the penetrating member to a retracted position.
A still further modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 54 at 2260. Penetrating member 2262 for automatic retractable safety penetrating instrument 2260 is similar to penetrating member 1962 for automatic retractable safety penetrating instrument 1960 and includes an elongate body 2274 joined to neck 2286 at shoulder 2280, the body 2274 terminating proximally at a retraction plate 2294 disposed in end part 2272. Body 2274 can be removably secured to neck 2286 such as by threads 2290 allowing distal end 2276 to be removed from body 2274 and replaced with various other distal ends of diverse configurations. A safety shield 2263 is disposed around the penetrating member 2262, and includes an outer body concentrically disposed around the neck 2286 and end part 2272 of the penetrating member and an inner tubular body 2274' joined to the outer tubular body at an internal shoulder or end wall 2280'. Inner body 2274' is concentrically disposed around body 2274 and terminates proximally at an operating member 2288 disposed in end part 2272 distally of retraction plate 2294 with body 2274' passing through an opening in a forward wall of the end part. A locking and releasing mechanism 2318 is mounted in end part 2272, the locking and releasing mechanism 2318 being similar to the locking and releasing mechanism 1812. A control tube 2296 extends from a rear wall of end cap 2306 and into body 2274, and a retracting spring 2302 is connected between retraction plate 2294 and a rear wall of hub 2266 to bias the distal part 2270 of the penetrating member in a proximal direction. Control tube 2296 can be rotatably, releasably mounted in end cap 2306 to be partially withdrawn from body 2274 with ears, nubs or projections provided on the control tube to allow the control tube to serve as a push member for setting the instrument in the extended position as disclosed in applicant's co-pending U.S. patent application Ser. No. 07/868,578 filed Apr. 15, 1992, the specification of which is incorporated herein by reference. An operating spring 2298 is disposed concentrically around body 2274 and connected between retraction plate 2294 and operating member 2288, and a cushion spring 2300 is concentrically disposed around body 2274' and connected between operating flange 2272 and the forward wall of end part 2278 to position the operating flange at an initial position in the extended position for the instrument illustrated in FIG. 54. In the extended position, operating flange 2288 will be in the initial position disposed proximally of triggers 2324 and distally of triggers 2326, and the retraction plate 2294 will be locked in place against locking member 2322.
Operation of automatic retractable safety penetrating instrument 2260 is similar to that previously described in that safety shield 2263 will move proximally during penetration of tissue causing movement of operating flange 2288 from the initial position to a set position at which time the instrument will be in an operative position. Once a distal end of the portal sleeve has entered the anatomical cavity, the safety shield will be moved distally causing movement of operating flange 2288 toward the initial position to engage a trigger 2326 or distally of the initial position to engage a trigger 2324 such that arm 2318 is flexed releasing retraction plate 2294 from locking member 2322. Accordingly, retracting spring 2302 will move the distal part 2270 of the penetrating member and, via engagement of shoulder 2280 with end wall 2280', the safety shield, to a retracted position. A probe can be utilized in the instrument 2260 in place of the safety shield to trigger retraction as shown in dotted lines at 2265. By utilizing a pin and slot arrangement, retraction of the distal part of the penetrating member and/or the safety shield and the probe where a probe is provided can be prevented.
Another modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 55 at 2360, the instrument 2360 being similar to automatic retractable safety penetrating instrument 2260 in that a safety shield 2363 is utilized to trigger retraction. Penetrating member 2362 for instrument 2360 is made up of a distal part 2370 and an end part 2372, the distal part including a distal end 2376 joined to an elongate body 2374 with an extension 2454 in the form of a plate extending proximally from an end wall 2452 of body 2374. Extension 2454 terminates proximally within the body of safety shield 2363 at a bent end defining a retraction member or including retraction plate 2394. End part 2372 includes a plate extending distally from a rear wall of hub 2366 and terminating distally at a bent or angled end with a retracting spring 2402 connected between the angled end of end part 2372 and the end wall 2452 of distal part 2370 to bias the distal part in a proximal direction. A locking and releasing mechanism 2412 similar to locking and releasing mechanism 2112 is disposed partly in hub 2366 and partly in the body of safety shield 2363 with a base 2416 of the locking and releasing mechanism being secured to end part 2372. A locking member 2422 of locking and releasing mechanism 2412 engages retraction plate 2394 to prevent proximal movement of the distal part 2370 when the instrument is in the extended position illustrated in FIG. 55. Safety shield 2363 is concentrically disposed around body 2374, the safety shield terminating proximally at an end flange disposed in hub 2366 with the body of the safety shield passing through an opening in a front wall of the hub. An operating member or flange 2388 projects inwardly from an inner surface of the wall of the safety shield body for engaging triggers 2424 or 2426 on arm 2418 of locking and releasing mechanism 2412. An operating spring 2398 is connected between the end flange and a rear wall of the hub, and a cushion spring 2400 is connected between the end flange and a front wall of the hub to position the operating member at an initial position proximally of triggers 2424 and distally of triggers 2426 in the extended position for the instrument. A push member 2371 can be provided in instrument 2360 to be moved by end cap 2406 to engage the end flange of the safety shield for use in setting the instrument in the extended position.
In operation, instrument 2360 is forced through tissue causing safety shield 2363 to be moved proximally such that operating member 2388 is moved proximally from the initial position to a set position without causing bending or flexing of arm 2418. Once a distal end of the portal sleeve has entered the anatomical cavity, the safety shield 2363 will be moved distally causing operating member 2388 to engage a trigger 2426 in response to movement of the operating member toward the initial position or a trigger 2424 in response to movement of the operating member distally of the initial position to flex arm 2418 and release locking member 2422 from retraction plate 2394. Accordingly, retracting spring 2402 will move the distal part 2370 of the penetrating member proximally relative to the end part 2372 to a retracted position. By arranging the operating member 2388 to be engaged by the retraction plate 2394, the safety shield 2363 can be moved to a retracted position with the penetrating member. Push member 2371 can be utilized to set the instrument in the extended position via squeezing operation of end cap 2406 causing distal movement of the safety shield and, via engagement of operating member 2388 with retraction plate 2394, the penetrating member.
Yet another modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated at 2460 in FIG. 56. Penetrating member 2462 for automatic retractable safety penetrating instrument 2460 is similar to penetrating member 1862 being made up of a distal part 2470 and an end part 2472 with the distal part including a distal end 2476, a body 2474 and a neck 2554. End part 2472 terminates proximally at a retraction plate 2494 disposed in hub 2466, and a retraction spring 2502 is connected between the retraction plate and the rear wall of the hub to bias the end part in a proximal direction. A locking and releasing mechanism 2512 similar to locking and releasing mechanism 1912 is disposed in hub 2466 for locking the retraction plate 2494 against a front wall of the hub in an extended position for the instrument illustrated in FIG. 56. Locking and releasing mechanism 2512 is mounted in end cap 2506 to serve as a push member for setting the instrument in an extended position, and an additional push member 2471 can be mounted in end cap 2506 for use in moving the end part 2472 distally when setting the instrument in the extended position. A plurality of internal walls or shoulders 2552' are disposed within end part 2472 with the walls 2552 having openings therein allowing passage therethrough by the neck 2554. Neck 2554 terminates proximally at an operating member or flange 2488 disposed in hub 2466. A helical coil operating spring 2498 is concentrically disposed around neck 2554 and connected between the neck and a wall 2552' of the end part to bias the distal part 2470 in a distal direction. More than one operating spring can be provided; and, as shown in FIG. 56, two operating springs 1498 are provided with each operating spring connected between the neck 2554 and an internal wall 2252'. A cushion spring 2500 is disposed concentrically around the neck 2554 and connected between body 2474 and a wall 2552' to bias the distal part in a proximal direction such that operating flange 2488 is maintained in an initial position disposed proximally of trigger 2524 and distally of triggers 2526 with the instrument in the extended position. Protrusions in the form of nubs or pins 2545' are provided on neck 2554 for use in mounting the operating and cushion springs between the neck 2554 and the internal walls 2552' and for compressing or collapsing the springs upon movement of the distal part in a proximal direction.
In use, the automatic retractable safety penetrating instrument 2460 is forced through tissue causing distal part 2470 to be moved proximally relative to end part 2472 such that operating member 2488 is moved proximally of the initial position to a set position, the nubs 2545' collapsing the operating and cushion springs along the neck 2554. With the operating member in the set position, shoulder 2480 will be in abutment with stop 2492, and the instrument will be in an operative position. Once a distal end of the portal sleeve 2464 has entered the anatomical cavity, the distal part 2470 will be moved distally causing operating member 2488 to move toward the initial position to engage trigger 2526 or distally of the initial position to engage trigger 2524 and flex arm 2518 thusly releasing the retraction plate 2494.
An additional modification of an automatic retractable safety penetrating instrument is illustrated in FIG. 57 at 2560. Instrument 2560 is similar to automatic retractable safety penetrating instrument 2460 except that neck 2654 for automatic retractable safety penetrating instrument 2560 is offset from and not aligned with a longitudinal axis of the instrument as is neck 2554 for instrument 2460. The retraction member for instrument 2560 is formed as an internal wall or shoulder 2652' extending inwardly from an inner surface of the wall of the end part 2572 to be engaged, within the end part, by locking member 2622, the retraction member having an opening therein allowing passage therethrough by the neck 2654. End part 2572 terminates proximally at a retraction plate or flange disposed in hub 2566 with retracting springs 2602 connected between the retraction plate and a rear wall of the hub to bias the end part in a proximal direction. Accordingly, in the automatic retractable safety penetrating instrument 2560, the locking member 2622 engages the retraction member, wall 2652', and not the retraction plate 2594 to hold the end part 2572 against proximal movement. Locking and releasing mechanism 2612 for automatic retractable safety penetrating instrument 2560 is mounted in end cap 2606 for use as a push member, via engagement of locking member 2622 with wall 2652', for setting the instrument in an extended position. An additional push member 2571 is mounted in end cap 2606 for engaging retraction plate 2594 when setting the instrument in the extended position via squeezing operation of the end cap. In the automatic retractable safety penetrating instrument 2560, triggers 2624 and 2626 are disposed within the end part 2572 such that the length of hub 2566 can be minimized to be no larger than necessary to allow retraction of end part 2572. Neck 2654 terminates proximally at an operating member or flange 2588 disposed in end part 2572 with the operating member having an angled end to facilitate proximal movement past triggers 2626 and engagement of triggers 2624 or 2626 upon distal movement of the operating member. An additional internal wall 2652" is provided in end part 2572, with an operating spring 2598 disposed around neck 2654 and connected between the internal wall 2652" and the body 2574 to bias the distal part 2570 distally. A cushion spring 2600 disposed around neck 2654 is connected between the neck 2654 and wall 2652' to bias the distal part proximally such that the operating member is maintained at an initial position proximally of triggers 2624 and distally of triggers 2626 in the extended position illustrated in FIG. 57.
Operation of instrument 2560 is similar to that for automatic retractable safety penetrating instrument 2460. During penetration of tissue, distal part 2570 moves proximally relative to end part 2572 causing proximal movement of operating member 2588 past triggers 2626. Once a distal end of portal sleeve 2564 has entered the anatomical cavity, operating member 2588 will move distally engaging triggers 2624 or 2626 to flex arm 2618 and release the retraction member, wall 2652'. Accordingly, retracting springs 2602 move the end part 2572 and with it distal part 2570 to the retracted position.
Yet another modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated at 2660 in FIG. 58. Penetrating member 2662 for automatic retractable safety penetrating instrument 2660 is similar to penetrating member 1862 and includes an end part 2672 and a distal part 2670 having a distal end 2676, a tubular or partly hollow or tubular body 2674 and a neck 2754. A retraction member engages the proximal end of distal part 2670 and includes a retraction plate 2694 disposed in hub 2664 with an extension 2697 extending distally from the retraction plate to terminate at a forward wall or end flange 2751 disposed in body 2674 with the extension 2697 being concentrically disposed in neck 2654. Neck 2654 terminates proximally at an operating member or flange 2688 disposed in end part 2672, and an operating spring 2698 is disposed concentrically around extension 2697 and connected between operating member 2688 and retraction plate 2694 to bias the distal part 2670 in a distal direction. A cushion spring 2700 is concentrically disposed around the extension 2697 and connected between the forward wall 2751 and an end wall 2752 of body 2674 to bias the distal part in a proximal direction such that operating member 2688 is maintained in an initial position with the instrument in the extended position as illustrated in FIG. 58. A retracting spring 2702 is disposed in hub 2664 and connected between the retraction plate 2694 and a rear wall of the hub to bias the retraction member in a proximal direction. Locking and releasing mechanism 2712 for automatic retractable safety penetrating instrument 2660 is made up of a linkage arrangement including a link arm 2718 having an end pivotally connected at a joint to a trigger 2724 including a trigger cam 2727 and a trigger leg 2729 and an opposite end pivotally connected at a joint to a link 2723' pivotally mounted in hub 2664. Link 2723' is disposed in engagement with the retraction plate in the extended position for the instrument illustrated in FIG. 58 and is mounted on a joint in hub 2664 to rotate, such as in a counterclockwise direction looking at FIG. 58, to be disposed out of the path of longitudinal movement of retraction plate 2694 in response to proximal movement of link arm 2718. A locking arm 2718' is pivotally mounted in the hub, such as along the hub rear wall, and is biased to a locked position wherein an end or finger 2822 of the locking arm engages a lateral or upper edge or side of the retraction plate 2694 to prevent proximal movement thereof. The locking arm 2718' can be biased to the locked position in various ways, such as by a spring at the joint mounting the arm 2718' along the hub rear wall. With the arm 2718' in the locked position, locking member 2822 will be disposed in the path of movement of link arm 2718. The linkage can be biased, such as with springs provided at one or more joints of the linkage, to rotate link 2723' to release retraction plate 2694 with arm 2718' preventing movement of the linkage due to the bias. Where the arm 2718' both engages the retraction plate and holds link 2723' thereagainst, redundant protection is provided.
Operation of automatic retractable safety penetrating instrument 2660 is similar to that previously described in that the distal part 2670 will be moved proximally relative to end part 2672 during penetration of tissue causing operating member 2688 to be moved proximally from the initial position to the set position. Once a distal end of the portal sleeve has entered the anatomical cavity, distal part 2670 will be moved distally relative to end part 2772 causing operating member 2688 to move distally of the initial position to engage trigger cam 2727 and pivot trigger leg 2729 clockwise looking at FIG. 58 moving link arm 2718 proximally to engage a nub 2710' on locking member 2822 such that the locking arm 2718' is moved laterally, i.e. in a direction transverse to the direction of proximal movement of link arm 2718 to be released from retraction plate 2694 allowing the distal part 2670 of the penetrating member to be moved relative to the end part 2672 to a retracted position.
An additional modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 59 at 2760. Penetrating member 2762 for automatic retractable safety penetrating instrument 2760 is similar to penetrating member 2362 except that body 2774 for penetrating member 2762 is hollow or tubular or partly hollow or tubular to receive the forward wall 2851 of the retraction member and the end part 2772 of the penetrating member is secured in or formed with a front wall of hub 2766. The retraction member for instrument 2760 includes forward wall 2851, retraction plate 2794 disposed in hub 2766 and a side or connecting member 2853 joining the retraction plate to the forward wall with neck 2854 of distal part 2770 extending through the connecting member to terminate proximally at an operating flange 2788 disposed in end part 2772. An operating spring 2798 is connected between the forward wall 2851 and an end wall 2852 of body 2774 to bias the distal part in a distal direction, and a cushion spring 2800 is disposed around neck 2854 and connected between forward wall 2851 and an internal shoulder or abutment 2780 of body 2774 to bias the distal part in a proximal direction such that operating member 2788 is maintained in an initial position proximally of trigger 2824 with the instrument in the extended position illustrated in FIG. 59. A retracting spring 2802 is connected between retraction plate 2794 and a rear wall of hub 2766 to bias the retraction member in a proximal direction. A locking and releasing mechanism 2812 is disposed in end part 2772 and includes a linkage arrangement having a link arm 2818 pivotally connected at a joint at one end to a locking member 2822 engaged with a bent or angled portion of connecting wall 2853 to prevent movement of the retracting mechanism proximally. Arm 2818 is pivotally connected at a joint at an opposite end thereof to trigger 2824 pivotally mounted in the end part and including a trigger cam 2827 and a trigger leg 2829. A locking arm 2818' pivotally mounted at a joint along the rear wall of hub 2766 terminates distally at a locking member 2822' biased to engage the linkage to prevent proximal movement of link arm 2818 such that the locking member 2822 is maintained in engagement with the retraction member in the extended position for the instrument. The linkage can be biased to rotate locking member 2822 counterclockwise looking at FIG. 59 to release the retraction member with arm 2818' preventing movement of the linkage due to the bias.
When automatic retractable safety penetrating instrument 2760 is utilized to penetrate tissue and enter an anatomical cavity, distal part 2770 of penetrating member 2762 will be moved proximally during penetration of the tissue causing movement of operating member 2788 from the initial position to a set position. The distal part 2770 will be moved distally upon a distal end of the portal sleeve entering the anatomical cavity, and the operating member 2788 will be moved distally of the initial position to engage trigger cam 2827 causing rotation of trigger 2824 clockwise and movement of link arm 2818 proximally to engage hub 2810' moving locking arm 2818' in a direction transverse to the direction of proximal movement of arm 2818 such that the locking member 2822 is released from the retraction member. Accordingly, retracting spring 2802 will move the retraction member proximally carrying with it the distal part 2770 of the penetrating member to a retracted position.
An additional modification of an automatic retractable safety penetrating instrument according to the present invention is illustrated in FIG. 60 at 2860 wherein the operating spring and the retracting mechanism are in the nature of a linkage arrangement. Penetrating member 2862 for automatic retractable safety penetrating instrument 2860 includes a distal part 2870 terminating proximally at an operating member or flange 2888 disposed in hub 2866 and an end part 2872 terminating proximally at a retraction plate 2894 disposed in hub 2866. A linkage 2898 including a pair of links 2898' and 2898" pivotally connected to each other at a central joint is pivotally connected to the operating flange and the retraction plate at distal and proximal end joints. A spring mounted at the central joint rotationally biases the links 2898' and 2989" to a normal position wherein the operating members 2888 is maintained in an initial position and the junction of the distal part 2870 is disposed beyond the distal end of the portal sleeve by a distance equal to the spacing between shoulder 2880 and abutment 2892 in the extended position illustrated in FIG. 60. A cross link 2900' is pivotally connected to linkage 2898 at retraction plate 2894 and to a linkage 2902. Linkage 2902 includes a distal link 2902' pivotally connected at a joint to cross link 2900', a proximal link 2902" pivotally secured to a rear wall of the hub and a cross link 2902" pivotally connected to the distal and proximal links at joints. Linkage 2902 is biased, such as with springs at one or more joints of the linkage, to a collapsed condition with cross link 2900' moving end part 2872 proximally. A locking and releasing mechanism 2912 is disposed in hub 2866 and includes an arm 2918 having a plurality of teeth or barbs 2921 thereon for engaging distal link 2902' to Lock the linkage 2902 in an expanded, non-collapsed position in the extended position for the instrument illustrated in FIG. 60 and a trigger 2926. Trigger 2926 has a trigger cam 2927 disposed proximally of the operating flange in the initial position and a bent trigger leg 2929 pivotally mounted in hub 2866 at 2929' to be disposed in abutment with retraction plate 2894 with the instrument in the extended position. Trigger leg 2929 is hinged, pivotal or made flexible at 2929" along a portion of the leg disposed along arm 2918 allowing a forward portion of the trigger leg to rotate, clockwise looking a FIG. 60, around pivot 2929' and a rearward portion of the trigger leg to rotate, counter-clockwise looking at FIG. 60, in response to counterclockwise rotation of trigger cam 2927. A push member 2871 is disposed in end cap 2906 for moving the linkage 2902, via engagement of protrusion 2928 with link 2902', distally to engage teeth 2921 when setting the instrument in the extended position.
During operation, automatic retractable safety penetrating instrument 2860 is forced through tissue causing proximal movement of distal part 2870 such that operating member 2888 is moved proximally by trigger cam 2927 without causing flexing of arm 2918. Once a distal end of the portal sleeve has entered the anatomical cavity, the distal part 2870 will be moved distally causing movement of operating member 2888 toward the initial position to engage trigger cam 2927 to bend or pivot trigger leg 2929 at 2929" causing trigger leg 2929 to rotate around pivot 2929' to be disposed out of the path of movement of retraction plate 2894 and arm 2918 to be flexed in a direction outwardly from a longitudinal axis of the instrument such that link 2902' is released from the barbs causing the linkage 2902 to move to a collapsed position carrying end part 2872 and with it distal part 2870 to a retracted position.
Inasmuch as the present invention is subject to many variations, modifications and changes in detail, it is intended that all subject matter discussed above or shown in the accompanying drawings be interpreted as illustrative only and not be taken in a limiting sense. | An automatic retractable safety penetrating instrument for introduction of sleeves, such as portal sleeves, cannulas and catheters, into anatomical cavities by means of penetrating members, such as solid tip trocars, other solid configuration obturators and cannulated penetrating members, such as needles, include locking and releasing mechanisms for automatic retraction of the penetrating member into the sleeve upon the sleeve entering the anatomical cavity. Various locking and releasing mechanisms are utilized for disposition in the penetrating member hub, in the shaft of the penetrating member or partially in the shaft and the hub, and the penetrating member can be made of telescoping distal and shaft sections to minimize the length of the penetrating member hub. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority benefit of Taiwan application serial no. 99146918, filed on Dec. 30, 2010. The entirety of the above-mentioned patent application is hereby incorporated by reference herein and made a part of this specification.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a flat panel display, more particularly, to a liquid crystal display (LCD) and an LCD panel thereof.
2. Description of the Related Art
In the presence of all structures of the pixel array of the current LCD panel, one specie is so-called the half source driving (hereinafter “HSD”) structure. The HSD structure would reduce the quantity used of source drivers to half by reducing the number of the source lines to half, such that the fabricating cost of the display panel module can be substantially reduced. In order to further reduce the fabricating cost, one kind of pixel array is submitted and which is so-called the one third source driving (hereinafter “OTSD”) structure. The OTSD structure would reduce the number of the source lines to one third compared with the original/traditional pixel array structure, and thus the fabricating cost of the display panel module can be further reduced.
FIG. 1 is a diagram of the pixel array of the OTSD structure in the prior art, and FIG. 2 is a driving diagram of the pixel array in FIG. 1 . Referring to FIGS. 1 and 2 , it can be seen that, in FIGS. 1 and 2 , the pixel array of the conventional OTSD structure would not change the number of the scan lines (Gn) in the display panel, but would reduce the number of the data lines (Sm) in the display panel to one third, such that the purpose of saving the fabricating cost can be achieved. However, since the images displayed by the LCD with the conventional OTSD structure is three-dot inversion, so the display quality is lower compared to the displayed images with single-dot inversion, and the pixel aperture ratio thereof is also lower, approximately 30%.
Accordingly, the conventional OTSD structure can be significantly improved.
SUMMARY OF THE INVENTION
The present invention is directed to an LCD and an LCD panel thereof, wherein the pixel array of the LCD panel is the OTSD structure and the LCD has better display quality and higher pixel aperture ratio compared to the LCD panel with the conventional OTSD structure as mentioned in the prior art.
The present invention provides an LCD including an LCD panel. The LCD panel includes a plurality of scan lines, a plurality of data lines, and) a plurality of pixels arranged in an array. The i th scan line is coupled to the (6j+1) th pixel of the (i−2) th pixel row, the (6j+2) th , the (6j+4) th , the (6j+5) th and the (6j+6) th pixels of the i th pixel row, and the (6j+3) th pixel of the (i+2) th pixel row, where i is an odd positive integer greater than or equal to 3, and j is a positive integer greater than or equal to 0. The (i+1) th scan line is coupled to the (6j+6) th pixel of the (i−1) th pixel row, the (6j+1) th , the (6j+2) th , the (6j+3) th and the (6j+5) th pixels of the (i+1) th pixel row, and the (6j+4) th pixel of the (i+3) th pixel row. The r th data line is coupled to even pixels in all pixels of the (3k+1) th , the (3k+3) th and the (3k+5) th pixel columns, and odd pixels in all pixels of the (3k+2) th , the (3k+4) th and the (3k+6) th pixel columns, where r is an odd positive integer, and the k=(r−1). The (r+1) th data line is coupled to even pixels in all pixels of the (3k+4) th , the (3k+6) th and the (3k+8) th pixel columns, and odd pixels in all pixels of the (3k+5) th , the (3k+7) th and the (3k+9) th pixel columns.
In one embodiment of the present invention, the 1 st scan line is coupled to the (6j+2) th , the (6j+4) th , the (6j+5) th and the (6j+6) th pixels of the 1 st pixel row, and the (6j+3) th pixel of the 3 rd pixel row; and the 2 nd scan line is coupled to the (6j+1) th , the (6j+2) th , the (6j+3) th and the (6j+5) th pixels of the 2 nd pixel row, and the (6j+4) th pixel of the 4 th pixel row.
In one embodiment of the present invention, each of the 1 st to the 3 rd pixel columns in the LCD panel is a dummy pixel column; and each of the 1 st and the 2 nd pixel rows in the LCD panel is a dummy pixel row.
In one embodiment of the present invention, the LCD further includes a gate driver. The gate driver is coupled to the LCD panel and has a plurality of gate lines, wherein the gate driver provides a plurality of scan signals to the scan lines through the gate lines.
In one embodiment of the present invention, a frame period of the LCD has a plurality of periods. The s th , the (s+1) th and the (s+s 2) th gate lines simultaneously output the enabled scan signals during the (3s+1) th period, where s is a positive integer greater than or equal to 0. The s th and the (s+1) th gate lines simultaneously output the enabled scan signals during the (3s+2) th period. The s th gate line outputs the enabled scan signal during the (3s+3) th period.
In one embodiment of the present invention, the LCD further includes a source driver. The source driver is coupled to the LCD panel and has a plurality of source lines, wherein the source driver provides a plurality of data signals to the data lines through the source lines.
In one embodiment of the present invention, a driving polarity corresponding to each of the data signals is converted once at a frame period of the LCD.
In one embodiment of the present invention, the LCD further includes a timing controller and a backlight module. The timing controller is coupled to the gate driver and the source driver, and used for controlling operations of the gate driver and the source driver. The backlight module is used for providing a backlight source required by the LCD panel.
The present invention would claim the whole structure of the above-mentioned LCD panel.
From the above, the structure of the pixel array of the LCD panel is the structure of the one third source driving (OTSD), namely, the number of the driving channels of the source driver can be reduced to two third. And, compared to the LCD with the conventional OTSD structure, the LCD panel of the present invention has higher pixel aperture ratio by skillfully layout the coupled relationship among each pixel, each signal line and each scan line. In addition, the source driver of the present invention can make the LCD panel to display images with single-dot inversion by adopting the column inversion driving manner, and thus promoting the display quality.
It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 is a diagram of the pixel array of the OTSD structure in the prior art.
FIG. 2 is a driving diagram of the pixel array in FIG. 1 .
FIG. 3 is a system diagram of the LCD 300 according to one embodiment of the present invention.
FIG. 4 is a diagram of the LCD panel 301 in FIG. 3 .
FIG. 5 is a diagram of a part of driving waveforms for the LCD panel 301 according to one embodiment of the present invention.
FIG. 6 is a waveform diagram of the data signal according to one embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
FIG. 3 is a system diagram of the LCD 300 according to one embodiment of the present invention, and FIG. 4 is a diagram of the LCD panel 301 in FIG. 3 . Referring to FIGS. 3 and 4 , the LCD 300 includes the LCD panel 301 , a source driver 303 , a gate driver 305 , a timing controller (T-con) 307 and a backlight module 309 .
In the present embodiment, the LCD panel 301 includes a plurality of data lines S 1 to Sm, a plurality of scan lines G 1 to Gn, and a plurality of pixels Pix arranged in an array. Each of the pixels Pix in the 1 st and the 2 nd pixel rows and the 1 st to the 3 rd pixel columns is a dummy pixel, and is not disposed within the display area AA of the LCD panel 301 . In other words, each of the 1 st to the 3 rd pixel columns in the LCD panel 301 is a dummy pixel column; and each of the 1 st and the 2 nd pixel rows in the LCD panel 301 is a dummy pixel row.
The source driver 303 is coupled to the LCD panel 301 , and has a plurality of source lines D 0 to Dm−1, wherein the source lines D 0 to Dm−1 can be understood as the driving channels of the source driver 301 . The source driver 303 provides a plurality of data signals to the data lines S 1 to Sm through the source lines D 0 to Dm−1, so as to perform the pixel writing to the corresponding pixels Pix in the LCD panel 301 . Herein, the source lines D 0 to Dm−1 are respectively corresponding to the data lines 51 to Sm.
The gate driver 305 is coupled to the LCD panel 301 , and has a plurality of gate lines P 0 to Pn−1. The gate driver 305 provides a plurality of scan signals to the scan lines G 1 to Gn through the gate lines P 0 to Pn−1, so as to perform the pixel on or off to the corresponding pixels Pix in the LCD panel 301 . The gate lines P 0 to Pn−1 are respectively corresponding to the scan lines G 1 to Gn. In addition, the T-con 307 is coupled to the source driver 303 and the gate driver 305 , and used for controlling the operations of the source driver 303 and the gate driver 305 . The backlight module 309 is used for providing the backlight source required by the LCD panel 301 .
In the present embodiment, relating to the scan lines G 1 to Gn of the LCD panel 301 , the 1 st scan line G 1 is coupled to the (6j+2) th , the (6j+4) th , the (6j+5) th and the (6j+6) th pixels of the 1 st pixel row, and the (6j+3) th pixel of the 3 rd pixel row in the LCD panel 301 , where j is a positive integer greater than or equal to 0. For example, if j=0, the 1 st scan line G 1 is coupled to the 2 nd , the 4 th , the 5 th and the 6 th to pixels of the 1 st pixel row and the 3 rd pixel of the 3 rd pixel row. Moreover, if j=1, the 1 st scan line G 1 is coupled to the 8 th , the 10 th , the 11 th and the 12 th pixels of the 1 st pixel row and the 9 th pixel of the 3 rd pixel row, and so on.
In addition, the 2 nd scan line G 2 is coupled to the (6j+1) th , the (6j+2) th , the (6j+3) th and the (6j+5) th pixels of the 2 nd pixel row, and the (6j+4) th pixel of the 4 th pixel row in the LCD panel 301 . For example, if j=0, the 2 nd scan line G 2 is coupled to the 1 st , the 2 nd , the 3 rd and the 5 th pixels of the 2 nd pixel row, and the 4 th pixel of the 4 th pixel row. Moreover, if j=1, the 2 nd scan line G 2 is coupled to the 7 th , the 8 th , the 9 th and the 11 th pixels of the 2 nd pixel row, and the 10 th pixel of the 4 th pixel row, and so on.
Except the 1 st and the 2 nd scan lines G 1 and G 2 , the i th scan line is coupled to the (6j+1) th pixel of the (i−2) th pixel row, the (6j+2) th , the (6j+4) th , the (6j+5) th and the (6j+6) th pixels of the i th pixel row, and the (6j+3) th pixel of the (i+2) th pixel row, where i is an odd positive integer greater than or equal to 3. For example, if i=3 and j=0, the 3 rd scan line G 3 is coupled to the 1 st pixel of the 1 st pixel row, the 2 nd , the 4 th , the 5 th and the 6 th pixels of the 3 rd pixel row, and the 3 rd pixel of the 5 th pixel row. Moreover, if i=3 and j=1, the 3 rd scan line G 3 is coupled to the 7 th pixel of the 1 st pixel row, the 8 th , the 10 th , the 11 th and the 12 th pixels of the 3 rd pixel row, and the 9 th pixel of the 5 th pixel row, and so on.
Further for example, if i=5 and j=0, the 5 th scan line G 5 is coupled to the 1 st pixel of the 3 rd pixel row, the 2 nd , the 4 th , the 5 th and the 6 th pixels of the 5 th pixel row, and the 3 rd pixel of the 7 th pixel row. Moreover, if i=5 and j=1, the 5 th scan line G 5 is coupled to the 7 th pixel of the 3 rd pixel row, the 8 th , the 10 th , the 11 th and the 12 th pixels of the 5 th pixel row, and the 9 th pixel of the 7 th pixel row, and so on.
And, the (i+1) th scan line is coupled to the (6j+6) th pixel of the (i−1) th pixel row, the (6j+1) th , the (6j+2) th , the (6j+3) th and the (6j+5) th pixels of the (i+1) th pixel row, and the (6j+4) th pixel of the (i+3) th pixel row. For example, if i=3 and j=0, the 4 th scan line G 4 is coupled to the 6 th pixel of the 2 nd pixel row, the 1 st , the 2 nd , the 3 rd and the 5 th pixels of the 4 th pixel row, and the 4 th pixel of the 6 th pixel row. Moreover, if i=3 and j=1, the 4 th scan line G 4 is coupled to the 12 th pixel of the 2 nd pixel row, the 7 th , the 8 th , the 9 th and the 11 th pixels of the 4 th pixel row, and the 10 th pixel of the 6 th pixel row, and so on.
Relating to the data lines S 1 to Sm in the LCD panel 301 , the r th data line is coupled to even pixels in all pixels of the (3k+1) th , the (3k+3) th and the (3k+5) th pixel columns, and odd pixels in all pixels of the (3k+2) th , the (3k+4) th and the (3k+6) th pixel columns, where r is an odd positive integer, and the k=(r−1). For example, if r=1, the 1 st data line S 1 is coupled to even pixels in all pixels of the 1 st , the 3 rd and the 5 th pixel columns, and odd pixels in all pixels of the 2 nd , the 4 th and the 6 th pixel columns. Moreover, r=3, the 3 rd data line S 3 is coupled to even pixels in all pixels of the 7 th , the 9 th and the 11 th pixel columns, and odd pixels in all pixels of the 8 th , the 10 th and the 12 th pixel columns, and so on.
In addition, the (r+1) th data line is coupled to even pixels in all pixels of the (3k+4) th , the (3k+6) th and the (3k+8) th pixel columns, and odd pixels in all pixels of the (3k+5) th , the (3k+7) th and the (3k+9) th pixel columns. For example, if r=1, the 2 nd data line S 2 is coupled to even pixels in all pixels of the 4 th , the 6 th and the 8 th pixel columns, and odd pixels in all pixels of the 5 th , the 7 th and the 9 th pixel columns. Moreover, if r=3, the 4 th data line S 4 is coupled to even pixels in all pixels of the 10 th , the 12 th and the 14 th pixel columns, and odd pixels in all pixels of the 11 th , the 13 th and the 15 th pixel columns, and so on.
From the above, FIG. 5 is a diagram of a part of driving waveforms for the LCD panel 301 according to one embodiment of the present invention. Referring to FIGS. 3 and 5 , it can be clearly seen that, in FIG. 5 , one frame period of the LCD 300 has a plurality of periods, for example, T 1 to T 18 , but not limited thereto. In the present embodiment, the s th , the (s+1) th and the (s+2) th gate lines simultaneously output the enabled scan signals during the (3s+1) th period, where s is a positive integer greater than or equal to 0. In addition, The s th and the (s+1) th gate lines simultaneously output the enabled scan signals during the (3s+2) th period. Furthermore, the s th gate line outputs the enables scan signal during the (3s+3) th period.
For example, if s=0, the 0 th to the 2 nd gate lines P 0 to P 2 of the gate driver 305 simultaneously output the enabled scan signals SG 1 to SG 3 to the scan lines G 1 to G 3 during the 1 st period T 1 ; the 0 th and the 1 st gate lines P 0 and P 1 of the gate driver 305 simultaneously output the enabled scan signals SG 1 and SG 2 to the scan lines G 1 and G 2 during the 2 nd period T 2 ; and the 0 th gate line P 0 of the gate driver 305 outputs the enabled scan signal SG 1 to the scan line G 1 during the 3 rd period T 3 .
Moreover, if s=1, the 1 st to the 3 rd gate lines P 1 to P 3 of the gate driver 305 simultaneously output the enabled scan signals SG 2 to SG 4 to the scan lines G 2 to G 4 during the 4 th period T 4 ; the 1 st and the 2 nd gate lines P 1 and P 2 of the gate driver 305 simultaneously output the enabled scan signals SG 2 and SG 3 to the scan lines G 2 and G 3 during the 5 th period T 5 ; and the 1 st gate line P 1 of the gate driver 305 outputs the enabled scan signal SG 2 to the scan line G 2 during the 6 th period T 6 , and so on.
Below, fifty-four serial numbers of pixels Pix in FIG. 4 , and both the source driver 303 and the gate driver 305 in FIG. 5 would be taken as an example for explaining how does the source driver 303 and the gate driver 305 to drive each of the pixels Pix in the LCD panel 301 .
Firstly, during the 1 st period T 1 , the 0 th to the 2 nd gate lines P 0 to P 2 of the gate driver 305 would simultaneously output the enabled scan signals SG 1 to SG 3 to the scan lines G 1 to G 3 , so as to turn on the pixels with marked number of 2, 4, 5, 6, 8, 21, 27, 10, 11, 12, 14, 16, 17, 18, 31, 1, 7, 20, 22, 23, 24, 26, 39 and 45. Meanwhile, the source driver 303 would write the corresponding data signals into the Pixels Pix connected to the data lines S 1 to Sm and turned on during the period T 1 through the source lines D 0 to Dm−1.
Next, during the 2 nd period T 2 , the 0 th and the 1 st gate lines P 0 ad P 1 of the gate driver 305 would simultaneously output the enabled scan signals SG 1 and SG 2 to the scan lines G 1 and G 2 , so as to turn on the pixels with marked number of 2, 4, 5, 6, 8, 21, 27, 10, 11, 12, 14, 16, 17, 18 and 31. Meanwhile, the source driver 303 would write the corresponding data signals into the Pixels Pix connected to the data lines S 1 to Sm and turned on during the period T 2 through the source lines D 0 to Dm−1.
Next, during the 3 rd period T 3 , the 0 th gate line P 0 of the gate driver 305 would output the enabled scan signals SG 1 to the scan line G 1 , so as to turn on the pixels with marked number of 2, 4, 5, 6, 8, 21 and 27. Meanwhile, the source driver 303 would write the corresponding data signals into the Pixels Pix connected to the data lines S 1 to Sm and turned on during the period T 3 through the source lines D 0 to Dm−1.
Moreover, the source driver 303 would provide the corresponding data signals through the source lines D 0 to Dm−1 during the following periods T 4 to T 18 until all of the pixels Pix in the LCD panel 301 are written completely, and thus making the LCD 300 display the images to user. Moreover, in the present embodiment, the driving polarity corresponding to each of the data signals provided by the source driver 303 is converted once at one frame period of the LCD 300 . For example, the data signals SD 1 and SD 2 respectively provided to the source lines D 0 and D 1 by the source driver 303 can be shown as FIG. 6 . During the previous frame period, the driving polarities of the data signals SD 1 and SD 2 are respectively positive (+) and negative (−); and during the next frame period, the driving polarities of the data signals SD 1 and SD 2 are respectively converted to negative (−) and positive (+). In other words, the source driver 303 would drive the LCD panel 301 by using the column inversion driving manner so as to achieve the purpose of displaying effect with single-dot inversion.
In summary, in the present invention, the specific coupled relationship among each pixel, each signal line and each scan line, and the corresponding driving waveforms for the gate driver are used to achieve the structure of OTSD. Accordingly, not only the fabricating cost can be reduced, but also the LCD panel of the present invention can have higher pixel aperture ratio, approximately 50% compared to the LCD panel with the conventional OTSD structure as mentioned in the prior art. In addition, the source driver of the present invention can make the LCD panel to display images with single-dot inversion by adopting the column inversion driving manner, and thus promoting the display quality.
It will be apparent to those skills in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents. | A liquid crystal display (LCD) and an LCD panel thereof are provided. The structure of the pixel array of the LCD panel is the structure of the one third source driving (OTSD), and by which skillfully layout the coupled relationship among each pixel, each signal line and each scan line, such that the LCD panel can be driven by a column inversion to achieve the purpose of single-dot inversion displaying, and thus not only reducing the power consumption of the whole LCD, but also promoting the display quality. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the priority of copending provisional U.S. Ser. No. 60/396,482, filed on Jul. 16, 2002, the disclosure of which is hereby incorporated by reference herein in its entirety. Applicants claim the benefits of this application under 35 U.S.C. §119(e).
GOVERNMENT RIGHTS CLAUSE
[0002] The research leading to the present invention was supported, at least in part, by U.S. Army Grant No. DAMD17-01-C-0343. Accordingly, the Government may have certain rights in the invention.
FIELD OF THE INVENTION
[0003] The invention relates generally to the field of oncology, cancer metastasis and cellular proliferation. In particular, this invention relates to the identification of methods of interrupting certain elements of the cell survival pathway, which then allows for enhanced efficacy of traditional modes of cancer therapy, including chemotherapy and radiation therapy. More particularly, the invention relates to the use of kinase or transcription inhibitors for pre-treatment to sensitize for, or concurrent treatment to potentiate chemotherapy or radiation therapy for treatment of cancers or hyperproliferative disorders. The invention also provides for the use of kinase or transcription inhibitors to downregulate expression of alpha 5 integrins and/or phosphorylation of Akt to treat cancer or hyperproliferative disorders. Blocking antibodies specific for alpha 5 or beta 1 integrins are also envisioned for use in either pretreatment to sensitize for, or to be used concurrently with chemotherapy or radiation therapy for treatment of cancer or hyperproliferative disorders. Methods of treatment of cancer or hyperproliferative disorders using fibronectin binding blocking peptides to sensitize for or potentiate chemotherapy or radiation therapy are also envisioned by the present invention. Furthermore, the invention relates to methods of use of retinoids to decrease the expression or phosphorylation of Akt and treatment of cancer or hyperproliferative disorders. The instant invention also provides, for pharmaceutical compositions comprising, and methods of using the agents of the present invention for treatment of cancer or hyperprolifeartive disorders. Screening methods for identification of novel agents for use in treating cancer or hyperproliferative disorders in accordance with the present invention is also disclosed.
BACKGROUND OF THE INVENTION
[0004] Breast cancer cells metastasize to the bone marrow early in the course of the disease (Braun, S., et al. (2000) The New England J. Med. 342,525-533). Most metastatic cells die upon reaching the marrow microenvironment, but some well-differentiated cells that survive can remain dormant, or growth arrested without loss of viability, for years (Boyce, B. F., et al. (1999) Endocrine - Related Cancer 6, 333-347; Chang, J., et al. (1999) J. Clinical Oncology 17, 3058-3063). They remain protected from death and, in fact, survive multiple rounds of adjuvant chemotherapy administered specifically to eradicate them (Braun, S., et al. (2000) J. Clin. Onc. 18, 80-86). The factors and the mechanisms that induce dormancy, that is, growth arrest coupled with long-term survival, of occult breast cancer cells in bone marrow microenvironment and which protect the cells from chemotherapy remain largely unknown. However, a variety of growth factors and ligands of cellular integrins in thee marrow. microenvironment may influence the fate of the metastatic cell. These factors have well-established effects on cell behavior, including protection of hematopoietic stem cells (Ploemacher, R. E. (1997) Baillieres Clinical Haematology 10, 429-444; Knaan-Shanzer, S., et al., (1999) Experimental Hematology 27, 1440-1450).
[0005] Bone marrow stroma is a rich source of growth factors such as epidermal growth factor (EGF), insulin-like growth factor (IGF-1) and basic fibroblast growth factor (FGF-2). FGF-2, a factor implicated in mammary ductal differentiation, induces growth arrest in a variety of relatively differentiated breast cancer cells.
[0006] However, there is a further need for identification of the factors responsible for growth arrest and long-term survival of occult cancer cells, as well as a better understanding of the mechanisms involved. Upon identification of the factors involved, novel therapeutics may be developed which could be used as stand-alone therapies or may be used as adjunct therapy with other standard forms of therapy to treat cancer or hyperproliferative disorders, such as chemotherapy or radiation therapy. It is with respect to this unmet need that the current invention is directed.
[0007] Other advantages of the present invention will become apparent from the ensuing detailed description taken in conjunction with the following illustrative drawings.
SUMMARY OF THE INVENTION
[0008] It is known that malignant cells from breast cancer micrometastases as well as other hyperproliferative disorders in bone marrow remain dormant without loss of viability for prolonged periods of time. It is in this growth arrested estate that the cells are resistant to standard forms of therapy including chemotherapy or radiation therapy. The factors that induce this dormancy are unknown at this time. It is thus an object of the present invention to identify the factors responsible for this dormancy, and to utilize these factors for identification, use of, and screening for new therapeutic regimens for treatment of cancer and other hyperproliferative disorders.
[0009] A first aspect of the invention provides for the identification and use of kinase or transcription inhibitors as pretreatment or concurrent treatment, to sensitize for or potentiate chemotherapy in the treatment of cancer or hyperproliferative disorders. In a preferred embodiment, the agents identified by the present invention are inhibitors of MAP kinase, Rho kinase, P13 kinase and/or PKC kinase.
[0010] In another preferred embodiment, the kinase or transcription inhibitors are used to treat metastatic cancers and/or hyperproliferative disorders. In another preferred embodiment, the kinase or transcription inhibitors are used to treat breast cancer. In yet another preferred embodiment, the kinase or transcription inhibitors are used to treat metastatic breast cancer.
[0011] In a second aspect of the invention, the kinase or transcription inhibitors are used to downregulate expression of alpha 5 or beta 1 integrins.
[0012] In a third aspect of the invention, the kinase or transcription inhibitor decreases expression and/or phosphorylation of Akt and is utilized for treatment of cancer or hyperproliferative disorders.
[0013] A fourth aspect of the invention provides for the use of antibodies to integrin alpha 5 or beta 1 as pretreatment or concurrent treatment to sensitize for, or potentiate chemotherapy or radiation therapy in the treatment of cancer or hyperproliferative disorders.
[0014] In a preferred embodiment, the antibodies are used to treat metastatic cancers or other hyperproliferative disorders. In another preferred embodiment, the antibodies are used to treat breast cancer. In yet another preferred embodiment, the antibodies are used to treat metastatic breast cancer. The antibodies may be polyclonal or monoclonal. They may be single chain antibodies. They may be chimeric antibodies. They may be Fab fragments or soluble components thereof. They may be human or humanized. They may be produced in other animals, including but not limited to horses, goats, sheep, mice, rats, rabbits and guinea pigs.
[0015] A fifth aspect of the invention provides for the use of fibronectin binding blocking peptides as pretreatment or concurrent treatment, to sensitize for or potentiate chemotherapy or radiation therapy in the treatment of cancer or hyperproliferative disorders.
[0016] In a preferred embodiment, the fibronectin binding blocking peptides are used to treat breast cancer. In yet another preferred embodiment, the fibronectin binding blocking peptides are used to treat metastatic breast cancer.
[0017] A sixth aspect of the invention provides for the use of retinoids to decrease expression or phosphorylation of Akt and treatment of cancers or hyperproliferative disorders.
[0018] In a preferred embodiment, the retinoids are used to treat metastatic cancers or other hyperproliferative disorders. In another preferred embodiment, the retinoids are used to treat breast cancer. In yet another preferred embodiment, the retinoids are used to treat metastatic breast cancer.
[0019] A seventh aspect of the invention provides for a method of inhibiting cellular proliferation in a mammal suffering from a disease or a disorder characterized by cellular proliferation, the method comprising administering an effective amount of a kinase or transcription inhibitor prior to, or concurrent with chemotherapy or radiation therapy. In a preferred embodiment, the kinase inhibitor is selected from the group consisting of LY294002, UO 126, AG82, Y27632, SB203580, PD169316, PD98059, RO318220, or C3 transferase inhibitor.
[0020] In another preferred embodiment, the disease or disorder characterized by cellular proliferation is cancer or a hyperproliferative disorder. In another preferred embodiment, the cancer is a metastatic cancer. In another preferred embodiment, the cancer is breast cancer. In yet another preferred embodiment, the breast cancer has metastasized.
[0021] In a yet further preferred embodiment, the kinase or transcription inhibitor downregulates expression of alpha 5 integrins or phosphorylation of Akt to sensitize for or potentiate chemotherapy or radiation therapy in mammals in need thereof.
[0022] An eighth aspect of the invention provides for a method for disrupting survival signaling from the microenvironment in cancer cells, wherein said disrupting results in sensitizing cells to chemotherapy, biological therapies or radiation therapy of cancer micrometastases and hyperproliferative disorders in a mammal. In a preferred embodiment, the integrins are alpha 5 and/or beta 1 integrins and the extracellular matrix protein is fibronectin. In another preferred embodiment, the cancer is breast cancer or prostate cancer. In yet another preferred embodiment, the method comprises administration of an antibody specific for an integrin or a blocking peptide or modified peptide that disrupts interaction of the integrin with the extracellular matrix. In a yet further preferred embodiment, the method comprising administration of all trans retinoic acid or a retinoic acid derivative. A yet further embodiment comprises decreasing expression of cell surface integrins with a transcription inhibitor, or blocking survival signaling initiated by ligation of integrins by microenvironment proteins. A most preferred embodiment provides for treatment with an inhibitor of a kinase, said kinase selected from the group consisting of MAP kinase, Rho kinease, PI3 kinase and PKC kinase. The most preferred inhibitors are selected from the group consisting of LY294002, UO 126, AG82, Y27632, SB203580, PD169316, PD98059, RO318220, and a 3 transferase inhibitor.
[0023] A ninth aspect of the invention provides for a method for treating hyperproliferative disorders in a mammal, comprising administration of an agent capable of blocking the binding of integrins with the extracellular matrix. In a preferred embodiment the integrins comprise alpha 5 and/or beta 1 and the matrix is fibronectin.
[0024] A tenth aspect of the invention provides for the use of an agent for the preparation of a composition for treatment of hyperproliferative disorders, said agent capable of downregulation of the expression of alpha 5 and/or beta 1 integrins and their binding to the extracellular matrix.
[0025] An eleventh aspect of the invention provides for pharmaceutical compositions comprising the kinase or transcription inhibitor and a pharmaceutically acceptable carrier, or an antibody, blocking peptide or modified peptide and a pharmaceutically acceptable career.
[0026] Other objects and advantages will become apparent from a review of the ensuing detailed description and attendant claims. All references cited in the present application are incorporated herein in their entirety.
BRIEF DESCRIPTION OF THE FIGURES
[0027] FIG. 1 . Breast cancer cells that metastasize to the bone marrow are arrested by deposits of FGF-2 in the bone marrow stroma. FGF-2 induces overexpression of integrins α5 and β1 and leads to massive cell death through unligated or inappropriately ligated integrins by a process termed integrin-mediated death (IMD). Adherence and appropriate ligation of α5β1 on the surviving cells by fibronectin in the stroma interrupts IMD and initiates survival signaling through PI3K. This results in dormancy of the non-cycling sells and protection from cell death induced by cytotoxins. Disruption of the integrin-fibronectin interaction would discontinue survival signaling and initiate IMD. This would render the metastatic cells sensitive to chemotherapy.
[0028] FIG. 2 . Survival effects of fibronectin on FGF-2-inhibited breast cancer cells MCF-7 cells were incubated at a concentration of 1000 cells/well on 24 well plates coated with A. collagen I or B. fibronectin or laminin I for variable periods from 3 to 9 days, stained with crystal violet and photographed. A. Colony cultures in collagen I-coated dishes demonstrating increased colony formation with time in the two control rows and with 10 ng/ml EGF-treatment and almost complete abolition of colony formation by FGF-2 10 ng/ml. Experiments were done at least twice with similar results. B. Similar cellular obliteration was observed on laminin I-coated plates, but incubation on fibronectin yielded survival of a small number of nonproliferating cells. Shown are typical 5 day colonies in control wells and impaired colony formation in wells containing FGF-2 10 ng/ml.
[0029] FIG. 3 . FGF-2 inhibits the clonogenicity of MCF-7 cells but has no effect on MDA-MB231 cell One thousand MCF-7 or MDA MB-23 1 cells per well were incubated in 24 well tissue culture plates with and without the presence of 10 ng/ml basic fibroblast growth factor (FGF-2) or epidermal growth factor (EFG). Plates were stained with crystal violet after a 5 day incubation and clones consisting of A. 29±2 cells and B. 8±2 cells were counted. C. Ten thousand T-47D cells per well were incubated in 24 well tissue culture plates coated with fibronectin with and without the presence of 10 ng/ml basic fibroblast growth factor (FGF-2) or epidermal growth factor (EFG). Plates were stained with crystal violet after 3 days and clones consisting of 8 or more cells were counted.
[0030] FIG. 4 . Cloning efficiency of MCF-7 cells in the presence of FGF-2 Five thousand MCF-7 cells were incubated per well in duplicate on 6 well tissue culture dishes with various substrata with FGF-2 10 ng/ml. Colonies of 8 cells or greater were counted after staining the plates with crystal violet after 5, 10 and 15 day incubations. Incubation on fibronectin continued to preserve the clonogenicity of these cell lines for up to the 15 days assayed.
[0031] FIG. 5 . Nonrad GEArray Q series gene chip microarray analysis of MCF-7 cells incubated with and without FGF-2 for 5 days on tissue culture dishes coated with fibronectin Gene chip microarray analysis of MCF-7 cells incubated for 5 days on tissue culture dishes coated with fibronectin 20 μg with and without the presence of FGF-2 10 ng/ml. Approximately one third as many cells remained in the FGF-2-treated population as in the control cells. A. Nonrad GEArray Q series Human Extracellular Matrix and Adhesion Protein chip (Super Array, Bethesda, Md.). Arrows point to integrin α5 (solid line) and α6 (dotted line) mRNA's that are elevated in the surviving population. Boxes are drawn around the control gene cDNAs on the two chips consisting of GAPDH, Cyclophyllin A, ribosomal L23 and β actin as positive controls and PUC18 plasmid DNA and blanks as negative controls. B. Nonrad GEArray Q series Human Pathway Finder chip (Super Array, Bethesda, Md.). Arrow points to the p16 INK4 gene whose expression is downregulated by FGF-2 treatment on fibronectin. Numbers on right of chips indicate the numbering of the rightmost member cDNA of each row.
[0032] Changes in gene expression due to FGF-2 treatment on a fibronectin-coated plate for five days were observed in the following genes on the two chips noted in Table 1 and Table 2.
[0033] FIG. 6 . FGF-2 regulates expression of integrins. A. Gene chip analysis of integrin α5 and β1 mRNA expression in MCF-7 cells incubated±FGF-2 for 3 or 5 days on fibronectin-coated plates. Densitometer quantitations normalized against GAPDH and actin mRNA standards are shown. B. Western blots of integrin α5 from cells incubated±FGF-2 for 3 days on tissue culture- or fibronectin-coated dishes. C. Indirect immunofluorescence of integrin α5 in T47D cells on cover slips±FGF-2 10 ng/ml for 24 hours. D. Western blots of integrins α2, α3, α4, α6, β1, β3 and β4 in MCF-7 and T-47D cells incubated±FGF-2 for 3 days. Nonspecific bands were as loading controls.
[0034] FIG. 7 . Integrin α5-dependent clonogenic survival of MCF-7 cells on fibronectin Five thousand MCF-7 cells were incubated per well in quadruplicate on 5-well tissue culture dishes with and without 10 ng/ml FGF-2, in the presence or absence of 2 μg neutralizing mouse monoclonal antibody to integrin α5 or integrin α3 (Chemicon, Inc, Temecula, Calif.). Cells were cultured for 5 days, stained with crystal violet and clones with 8±2 cells were counted.
[0035] FIG. 8 . Fibronectin-specific blocking peptides selectively inhibit clonogenicity on fibronectin. 10 3 MCF-7 (and TA47D, not shown) cells were incubated±fibronectin with 10 ng/ml FGF-2. Fibronectin-blocking peptide GRGDSP 1 ng/ml (American Peptide Co., Inc, Sunnyvale, Calif.) was added after 3 days and 4, 8 and 12 cell colonies were counted 6 days later. Blocking peptide only inhibited colonies on fibronectin, and not on plastic.
[0036] FIG. 9 . Ligation of Integrin α5β1 provides specific protection from cell death in well-differentiated breast cancer cells A. MCF-7 cells (and T-47D cells, not shown) were incubated with FGF-2 on variably coated plates. Blocking peptides were added after 3 days. Colonies with ≦10 cells were stained with crystal violet at 6 days and counted. B. TA47D cells were incubated on fibronectin-coated plates with FGF-2 and blocking peptides were added after 3 days. Cells were probed 24 hours later with anti-integrin α5 antibody and Texas Red-tagged secondary antibody and assayed by TUNEL-FTIC.
[0037] FIG. 10 . Induction of sustained Akt phosphorylation by FGF-2 on fibronectin Western blots of lysates from MCF-7, T47D and MDA-MB-231 cells incubated on fibronectin-coated plates with FGF-2 for up to 5 days were stained with antibody to phospho-Akt or total Akt. Blots show sustained phosphorylation of Akt by FGF-2 in MCF-7 and T-47D cells but no effect on constitutive Akt phosphorylation in MDA-MB-231 cells. No effect was noted on total Akt levels. Stained membrane was used as a loading control.
[0038] FIG. 11 . All-trans retinoic acid dampens EGF-mediated AKT phosphorylation MCF-7 cells were treated with EGF 100 ng/ml for 10 min followed by ATRA 10 −7 M or control media 2 h later for an additional 24 h. Western blots of lysates were stained with anti-phospho-Akt ab.
[0039] FIG. 12 . Effects of EGF and FGF-2 on the clonogenic potential of well and poorly-differentiated breast cancer cells in tissue culture MCF-7 and T-47D (1,000 cells/well) and MDA MB-231 (200 cells per well) were incubated in 24 well plates±10 ng/ml EFG or FGF-2 for 6 days, stained with crystal violet and clones with ≧29 actively growing cells (▪) or with ≦10 well spread, growth arrested cells ( ) were counted.
[0040] FIG. 13 . Adhesion of breast cancer cells to stromal proteins Both MCF-7 and T-47D cells were cultured±FGF-2 on tissue culture (A) or on fibronectin-coated plates (B), detached with Cell Dissociation Solution, washed with PBS and counted. Cells were incubated with 2 μg/ml blocking monoclonal antibodies to the integrins or mouse IgG for 30 minutes at 37° C. and 50,000 cells were incubated in 24 well variably-coated tissue culture plates for 45 minutes at 37° C. Attached cells were stained with crystal violet and the A 600 of the extracted dye was measured, as described. Results were similar for both cells. Shown are data for T47D (A) and MCF-7 cells (B). Antibody to integrin αblocked adhesion to fibronectin in FGF-2 treated cells by 75% but only inhibited untreated cell adhesion by a third. Blocking antibody to α2 decreased adhesion to collagen and laminin in both FGF-2 treated and untreated cells equally. While adhesion to collagen surpassed adhesion to fibronectin, it did not support dormant clone survival. These adhesion controls demonstrated that the data are consistent with a specific survival effect derived from ligation to fibronectin in dormant cells and not merely an effect due to nonspecific adhesion.
[0041] FIG. 14 . Stroma restricts growth of well-differentiated T47D breast cancer cells. A. Confluent stromal cultures in 24 well plates seeded with 500 T-47D or MDA-MB-231 cells/well were cultured for 6 days. B. Cytokeratin 19 immunofluorescence (red) staining of MCF-7 cells on stromal co-culture (blue background) demonstrating a primarily single cell status of MCF-7 cells after 6 days. C. Western blots of stromal cell lysates (100 μg) with recombinant FGF-2 and lysates from T47D cells transfected with a vector expressing 18, 22, 22.5 and 24 kD FGF-2 isoforms. D. MCF-7 cells were seeded on stromal monolayers on 24 well plates (1,000 cells/well). Blocking peptides were added after 3 days. At 6 days, plates were stained with anti-cytokeratin 19 antibody and horseradish peroxidase-tagged secondary antibody, developed and colonies of ≦10 cells counted.
[0042] FIG. 15 . Akt-inhibitor reduces fibronectin-promoted survival of dormant breast cancer cell clones. MCF-7 and T47D cells were incubated with FGF-2 on fibronectin for three days, media was changes and supplemented with variable concentrations of inhibitor and fresh FGF-2 and incubated for an additional three days. Colonies ≦10 cells were counted after crystal violet staining. Data is plotted as percent change from colony numbers on tissue culture coated plastic dishes.
[0043] FIG. 16 . The phosphatidyl inositol 3-kinase (PI3 kinase) inhibitor LY294002 reduces fibronectin-promoted survival of dormant breast cancer cell clones. MCF-7 and T-47D cells were incubated with FGF-2 on fibronectin for three days, media was changed and supplemented with variable concentrations of inhibitor and fresh FGF-2 and incubated for an additional three days. Colonies ≦10 cells were counted after crystal violet staining.
[0044] FIG. 17 . Inhibition of dormant clone survival by kinase inhibitors. A. MCF-7 cells (and T-47D cells, not shown) and B. T-47D cells were incubated with FGF-2 on fibronectin for three days, media was changed and supplemented with variable concentrations of a variety of kinase inhibitors and a small GTPase inhibitor and fresh FGF-2, and incubated for an additional three days. Control cells were incubated in 10 μM DMSO as control for the solvent used with the inhibitors. Colonies ≦10 cells were counted after crystal violet staining. Data are plotted as percent change from colony numbers on tissue culture coated plastic dishes demonstrating significant inhibition of dormant clones by abrogating a number of signaling pathways. C. The inhibitors used were:
Inhibitor Target ED50 UO 126 MEK 1 72 nM MEK 2 58 nM AG82 FAK 7 μM Y27632 Rho kinase 140 nM SB203580 p38 600 nM PD169316 p38 89 nM PD98059 MEK 2 μM RO318220 Protein kinase C 10 nM Protein kinase A 900 nM C3 transferase RhoA 2-5 μg/ml inhibitor
DETAILED DESCRIPTION
[0045] Before the present methods and treatment methodology are described, it is to be understood that this invention is not limited to particular methods, and experimental conditions described, as such methods and conditions may vary. It is also to be understood that the terminology used herein is for purposes of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only in the appended claims.
[0046] As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, references to “the method” includes one or more methods, and/or steps of the type described herein and/or which will become apparent to those persons skilled in the art upon reading this disclosure and so forth.
[0047] Unless defined otherwise, all 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. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference.
DEFINITIONS
[0048] The terms used herein have the meanings recognized and known to those of skill in the art, however, for convenience and completeness, particular terms and their meanings are set forth below.
[0049] “Agent” refers to all materials that may be used to prepare pharmaceutical and diagnostic compositions, or that may be compounds, nucleic acids, polypeptides, fragments, isoforms, variants, or other materials that may be used independently for such purposes, all in accordance with the present invention.
[0050] The term “antibody” as used herein includes intact molecules as well as fragments thereof such as Fab and F(ab′) 2 , which are capable of binding the epitopic determinant. Antibodies that bind the proteins of the present invention can be prepared using intact polypeptides or fragments containing small peptides of interest as the immunizing antigen attached to a carrier molecule. Commonly used carriers that are chemically coupled to peptides include bovine serum albumin and thyroglobulin. The coupled peptide is then used to immunize the animal (e.g, a mouse, rat or rabbit). The antibody may be a “chimeric antibody”, which refers to a molecule in which different portions are derived from different animal species, such as those having a human immunoglobulin constant region and a variable region derived from a murine mAb. (See, e.g., Cabilly et al., U.S. Pat. No. 4,816,567; and Boss et al., U.S. Pat. No. 4,816,397.). The antibody may be a human or a humanized antibody. The antibody may be a single chain antibody. The antibody may be prepared in mice, rats, rabbits, goats, sheep, swine, dogs, cats, or horses.
[0051] “Analog” as used herein, refers to a chemical compound, a nucleotide, a protein, or a polypeptide that possesses similar or identical activity or function(s) as the chemical compounds, nucleotides, proteins or polypeptides having the desired activity and therapeutic effect of the present invention (eg. to inhibit cellular proliferation and to sensitize for, or potentiate chemotherapy or radiation therapy for treatment of mammals having cancer or hyperproliferative disorders), but need not necessarily comprise a sequence that is similar or identical to the sequence of the preferred embodiment, or possess a structure that is similar or identical to the agents of the present invention. As used herein, a nucleic acid or nucleotide sequence, or an amino acid sequence of a protein or polypeptide is “similar” to that of a nucleic acid, nucleotide or protein or polypeptide having the desired activity if it satisfies at least one of the following criteria: (a) the nucleic acid, nucleotide, protein or polypeptide has a sequence that is at least 30% (more preferably, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95% or at least 99%) identical to the nucleic acid, nucleotide, protein or polypeptide sequences having the desired activity as described herein (b) the polypeptide is encoded by a nucleotide sequence that hybridizes under stringent conditions to a nucleotide sequence encoding at least 5 amino acid residues (more preferably, at least 10 amino acid residues, at least 15 amino acid residues, at least 20 amino acid residues, at least 25 amino acid residues, at least 40 amino acid residues, at least 50 amino acid residues, at least 60 amino residues, at least 70 amino acid residues, atea amino acid residues, at least 90 amino acid residues, at least 100 amino acid residues, at least 125 amino acid residues, or at least 150 amino acid residues) of the AAPI; or (c) the polypeptide is encoded by a nucleotide sequence that is at least 30% (more preferably, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95% or at least 99%) identical to the nucleotide sequence encoding the polypeptides of the present invention having the desired therapeutic effect. As used herein, a polypeptide with “similar structure” to that of the preferred embodiments of the invention refers to a polypeptide that has a similar secondary, tertiary or quartemary structure as that of the preferred embodiment. The structure of a polypeptide can determined by methods known to those skilled in the art, including but not limited to, X-ray crystallography, nuclear magnetic resonance, and crystallographic electron microscopy.
[0052] “Derivative” refers to either a protein or polypeptide that comprises an amino acid sequence of a parent protein or polypeptide that has been altered by the introduction of amino acid residue substitutions, deletions or additions, or a nucleic acid or nucleotide that has been modified by either introduction of nucleotide substitutions or deletions, additions or mutations. The derivative nucleic acid, nucleotide, protein or polypeptide possesses a similar or identical function as the parent pblypeptide. It may also refer to chemically synthesized organic molecules that are functionally equivalent to the active parent compound, but may be structurally different. It may also refer to chemically similar compounds which have been chemically altered to increase bioavailability, absorption, or to decrease toxicity.
[0053] “Fragment” refers to either a protein or polypeptide comprising an amino acid sequence of at least 5 amino acid residues (preferably, at least 10 amino acid residues, at least 15 amino acid residues, at least 20 amino acid residues, at least 25 amino acid residues, at least 40 amino acid residues, at least 50 amino acid residues, at least 60 amino residues, at least 70 amino acid residues, at least 80 amino acid residues, at least 90 amino acid residues, at least 100 amino acid residues, at least 125 amino acid residues, at least 150 amino acid residues, at least 175 amino acid residues, at least 200 amino acid residues, or at least 250 amino acid residues) of the amino acid sequence of a parent protein or polypeptide, or a nucleic acid comprising a nucleotide sequence of at least 10 base pairs (preferably at least 20 base pairs, at least 30 base pairs, at least 40 base pairs, at least 50 base pairs, at least 50 base pairs, at least 100 base pairs, at least 200 base pairs) of the nucleotide sequence of the parent nucleic acid. Any given fragment may or may not possess a functional activity of the parent nucleic acid or protein or polypeptide.
[0054] A “therapeutically effective amount” is an amount sufficient to decrease or prevent the symptoms associated with the cancer or hyperproliferative disorders or other related conditions contemplated for therapy with the compositions of the present invention.
[0055] “Treatment” refers to therapy, prevention and prophylaxis and particularly refers to the administration of medicine or the performance of medical procedures with respect to a patient, for either prophylaxis (prevention) or to cure or reduce the extent of or likelihood of occurrence of the infirmity or malady or condition or event in the instance where the patient is afflicted.
[0056] “Combination therapy” refers to the use of the agents of the present invention with other active agents or treatment modalities, in the manner of the present invention for treatment of cancers or hyperproliferative disorders. These other agents or treatments may include drugs such as other anti-cancer drugs such as those that are standardly used to treat various cancers, radiation therapy, anti-viral drugs, corticosteroids, non-steroidal anti-inflammatory compounds, other agents useful in treating or alleviating pain, growth factors, cytokines, or colony stimulating factors. The combined use of the agents of the present invention with these other therapies or treatment modalities may be concurrent, or the two treatments may be divided up such that the agent of the present invention may be given prior to or after the other therapy or treatment modality.
[0057] “Local administration” means direct administration by a non-systemic route at or in the vicinity of the site of an affliction, disorder, or perceived pain.
[0058] “Slow release formulation” refers to a formulation designed to release a therapeutically effective amount of a drug or other active agent such as a polypeptide or a synthetic compound over an extended period of time, with the result being a reduction in the number of treatments necessary to achieve the desired therapeutic effect. In the matter of the present invention, a slow release formulation would decrease the number of treatments necessary to achieve the desired effect in terms of inhibiting cellular proliferation and decreasing the tumor burden or metastatic potential of a cancer or hyperprolilferative disorder.
[0059] The term “clonogenic potential” refers to the ability of single cells to divide and grow into a cluster of cells. This is a characteristic of metastatic cancer cells in the body. In the lab, it is a reflection of many factors, including viability, health of the cell, injury, and ability to divide on the support provided in the tissue culture dish or in suspension
[0060] “EGF” is epidermal growth factor; a protein that binds to cell surface receptors and initiates signals that tell the cell to divide, crawl and survive.
[0061] “IGF” is insulin-like growth factor; a protein that binds to the insulin-like growth factor receptor that initiates signals that tell the cell to do perform a variety of function from cell division survival, depending on the cell type.
[0062] “FGF-2” is fibroblast growth factor 2, basic fibroblast growth factor; a protein that binds to cell surface receptors that initiates a variety of signals that tell different cells to perform different functions. In breast cancer, it can act as a differentiation factor, inhibiting growth and motility.
[0063] The term “hyperproliferative disorders” refers to diseases that result from the abnormal growth of cells. These can include cancers, pre-malignant states as well as inflammatory states such as rheumatoid arthritis or conditions such as psoriasis.
[0064] “Integrins” are intrinsic cell surface proteins. They mediate cell adhesion by binding with components of the extra cellular matrix, such as fibronectin. This adhesion process is closely tied to the cells ability to survive and reproduce. Many different integrins have been discovered and most have similar structural features eg. they are heterodimeric transmembrane proteins and contain an alpha subunit and a beta subunit. The major fibronectin receptor on most cells is the alpha 5, beta 1 integrin. This integrin interacts with the RGD site of the fibronectin molecule.
[0065] A kinase is a protein that acts as an enzyme to transfer a phosphate group onto another protein. A “kinase inhibitor” blocks the action of such a protein
[0066] A “transcription inhibitor” is a chemical or biological that interferes with the synthesis of messenger RNA from a DNA template.
[0067] “ATRA” refers to all-trans retinoic acid; a member of a family of compounds called retinoids that act by binding to nuclear receptors called retinoic acid receptors and retinoid X receptors that, when bound to their retinoid ligands, act as transcription factors. ATRA inhibits cell proliferation, induces cell death and potentiates chemotherapy agents in breast cancer cells.
[0068] As used herein, the term “modified peptide” may be used to refer to a peptide that is capable of binding to a protein and modulating its activity (e.g., a cell surface receptor). Modified peptides may possess features that, for example, modulate (increase or decrease) binding, alter the half-life of the peptide, decrease renal clearance, or improve absorption.
[0069] As used herein, the term “amino acid” and any reference to a specific amino acid is meant to include naturally occurring proteogenic amino acids as well as non-naturally occurring amino acids such as amino acid analogs. One of skill in the art would know that this definition includes, unless otherwise specifically indicated, naturally occurring proteogenic (D) or (L) amino acids, chemically modified amino, acids, including amino acid analogs such as penicillamine (3-mercapto-D-valine), naturally occurring non-proteogenic amino acids such as norleucine and chemically synthesized compounds that have properties known in the art to be characteristic of an amino acid. As used herein, the term “proteogenic” indicates that the amino acid can be incorporated into a protein in a cell through well-known metabolic pathways.
[0070] The choice of including an (L)- or a (D)-amino acid into a peptide of the present invention depends, in part, on the desired characteristics of the peptide. For example, the incorporation of one or more (D)-amino acids can confer increasing stability on the peptide in vitro or in vivo. The incorporation of one or more (D)-amino acids also can increase or decrease the binding activity of the peptide as determined, for example, using the binding assays described herein, or other methods well known in the art. In some cases it is desirable to design a peptide which retains activity for a short period of time, for example, when designing a peptide to administer to a subject. In these cases, the incorporation of one or more. (L)-amino acids in the peptide can allow endogenous peptidases in the subject to digest the peptide in vivo, thereby limiting the subject's exposure to an active peptide.
[0071] As used herein, the term “amino acid equivalent” refers to compounds which depart from the structure of the naturally occurring amino acids, but which have substantially the structure of an amino acid, such that they can be substituted within a peptide which retains is biological activity. Thus, for example, amino acid equivalents can include amino acids having side chain modifications or substitutions, and also include related organic acids, amides or the like. The term “amino acid” is intended to include amino acid equivalents. The term “residues” refers both to amino acids and amino acid equivalents.
[0072] As used herein, the term “peptide” is used in its broadest sense to refer to compounds containing amino acid equivalents or other non-amino groups, while still retaining the desired functional activity of a peptide. Peptide equivalents can differ from conventional peptides by the replacement of one or more amino acids with related organic acids (such as PABA), amino acids or the like or the substitution or modification of side chains or functional groups.
[0073] It is to be understood that limited modifications can be made to a peptide without destroying its biological function. Thus, modification of a peptides of the present invention that does not completely destroy its activity are within the definition of the compound claims as such. Modifications can include, for example, additions, deletions, or substitutions of amino acids residues, substitutions with compounds that mimic amino acid structure or functions, as well as the addition of chemical moieties such as amino or acetyl groups. The modifications can be deliberate or accidental, and can be modifications of the composition or the structure.
[0074] An exemplary cell surface receptor envisioned for targeting by a peptide or “modified peptide” of the invention is a member of the integrin receptor family. In an embodiment of the invention, a “modified peptide” may be used to inhibit integrin receptor activity, including, without limitation, the ability of integrin-expressing cells to bind to extracellular matrix proteins and surrounding cells. Modified peptides capable of inhibiting integrin binding/activity have been described in U.S. Pat. Nos. 5,536,814; 5,627,263; 5,912,234; 5,922,676; 5,981,478; 5,912,234; and 6,177,542, the entire contents of each of which is herein incorporated in its entirety by reference.
[0075] Retinoids are a class of compounds consisting of four isoprenoid units joined in a head-to-tail manner. All retinoids may be formally derived from a monocyclic parent compound containing five carbon-carbon double bonds and a functional group at the terminus of the acyclic portion. Derivatives of retinoids may be generated by means known to skilled artisans to render the retinoid derivative more therapeutically effective. A retinoid derivative may be, for example, an aldehyde derivative, a carboxylic acid derivative, a substituted derivative, a hydrogenated derivative, or it may be derivatized by functional substitution of a basic hydrocarbon. Retinoid derivatives may, for example, be generated that are more specifically targeted to hyperproliferative cells. As used herein, the term “retinoid derivative” may also be used to refer to a compound or agent having retinoid activity, but which does not necessarily act through a retinoid receptor.
[0076] As used herein, the term “biological therapy” refers to a therapeutic regimen designed to enhance a subject's or patient's response to treatment administered to reduce the number of cancer cells and/or symptoms associated with cancer. In general, “biological therapy” involves the use of a variety of cytokines, including, but not limited to, growth factors, interferons, colony stimulating factors, tumor necrosis factors, and interleukins.
[0077] As used herein, the term “sensitization” or “sensitizing” refers to treating a subject so as to render the subject or cells therein more susceptible to the effects of a therapeutic regimen; A number of sensitizing agents have been characterized that render cancer cells, for example, more susceptible to therapeutic modalities designed to eradicate cancer from a subject. Such sensitizing agents have been previously described in, for example, U.S. Pat. No. 5,436,337, the entire contents of which is incorporated herein by reference in its entirety.
[0078] As used herein, the phrase “disrupting survival signaling from the microenvironment” refers to a situation in which interactions between integrins and their ligands are reduced or decreased. Such interactions may be physically blocked using antibodies or peptides; or may be prevented by decreasing the cell surface expression levels of integrins via transcriptional inhibition; or by blocking survival signaling initiated by integrin receptor ligation by proteins in the microenvironment.
[0000] General Description
[0079] The present invention relates to the novel finding that increased expression of integrins alpha-5 and beta-1 on metastasized breast cancer cells in the bone marrow transmit a survival signal from matrix proteins in the bone marrow. Ligation of the integrins to fibronectin interrupt integrin-mediated cell death signaling and initiate the cell survival signaling that leads to dormancy, protection from chemotherapy and ultimately relapse in the breast cancer patient. The invention provides for a method to inhibit the expression of these integrins and interrupt specific elements of the survival pathway that will allow traditional chemotherapy or radiation therapy to be utilized to kill the remaining cells in the bone marrow and avoid a relapse and ultimately resistance by the cells and the death of the patient suffering from a hyperproliferative disorder such as but not limited to breast cancer, or prostate cancer. The over expression of alpha-5 and beta-1 is down regulated through the use of kinase or transcription inhibitors such as demonstrated in FIG. 1 .
[0080] The schema of FIG. 1 demonstrates the fate of metastatic cells in the bone marrow and the effect of fibronectin ligation through its integrin receptor alpha5 beta1 on maintaining survival and chemoresistance. Disruption of this interaction by decreasing synthesis of these integrins or disruption of their interactions with their ligands would allow the cells to become sensitive to chemotherapy and undergo cell death.
[0081] In the present invention, evidence is provided which supports a paradigm in which FGF-2 initiates a more differentiated, dormant state in well-differentiated micrometastatic breast cancer cells. This encompasses cell cycle arrest and changes in the integrin repertoire. Cells with improperly ligated integrins such as α5β1, upregulated by FGF-2 in fibroblasts and endothelial cells undergo cell death, likely due to ligand incompatibility. Ligation of integrin α5β1 by fibronectin, a component of bone marrow stroma, which can initiate survival signaling (Matter, M. L, & Ruoslahti, E. (2001) J. Biol. Chem. 276, 27757-27763; Lee, J. W. & Juliano, R. L. (2000) Molecular Biology of the Cell 11, 1973-1987), promotes survival of FGF-2-responsive cells.
[0082] In particular, the present invention is directed to methods for disrupting survival signaling from the microenvironment in cancer cells, wherein said disrupting results in sensitizing cells to chemotherapy, biological therapies or radiation therapy of cancer micrometastases and hyperproliferative disorders in a mammal. The method comprises blocking the interaction of integrins with the extracellular matrix proteins of the microenvironment. The preferred embodiments include the alpha 5 and/or beta 1 integrins and the preferred extracellular matrix protein is fibronectin. The invention is directed to treating primary tumors, tumor metastasis, micrometastases and hyperproliferative disorders. A further preferred embodiment is treating breast cancer or prostate cancer.
[0083] A further preferred embodiment comprises administration of an antibody specific for an integrin or a blocking peptide or modified peptide that disrupts interaction of the integrin with the extracellular matrix. A yet further preferred embodiment comprises administration of all trans retinoic acid or a retinoic acid derivative. A yet further preferred embodiment comprises decreasing expression of cell surface integrins with a transcription inhibitor. The method also comprises treatment with an inhibitor of a kinase, said kinase selected from the group consisting of MEP/MAP kinase, p38, RhoA, Rho kinase, PI3 kinase, PKC, and PKA. The methods further comprise blocking survival signaling initiated by ligation of integrins by microenvironment proteins. The method also comprises use of the inhibitors selected from the group consisting of LY294002, UO126, AG82, Y27632, SB203580, PD169316, PD98059, RO318220, and a C3 transferase inhibitor.
[0084] Thus, methods of treating primary cancers, metastatic cancers, micrometastases, and hyperproliferative disorders are encompassed by the present invention. Combination therapy is also envisioned with other standard forms of chemotherapy, radiation therapy and biological therapies and other anti-neoplastic regimens. It is envisioned that the therapies described in the present invention can be used as adjunct therapy with other anti-neoplastic treatment modalities.
[0085] The roles of various stromal proteins and growth factors that are relevant to the bone marrow microenvironment in inducing breast cancer dormancy were studied using a panel of breast cancer cell lines.
[0086] To test the potential role of FGF-2 in inducing growth arrest of breast cancer cells in the bone marrow microenvironment, the clonogenic potential of MCF-7, T47D and MDA-MB-231 breast cancer cells on stromal proteins in the presence of FGF-2 was measured. Clonogenic potential is the ability of single cells to grow into multi-cell clusters, that is a hallmark of metastatic growth of malignant cells. The presence of FGF-2, but not EGF, significantly blocked clonogenic growth of relatively well-differentiated MCF-7 and T47D cells but had no effect on the highly dedifferentiated aggressive MDA-MB-231 cells. FGF-2 arrested cells failed to survive on collagen1 i and laminin-1, while they survived on fibronectin for many days.
[0087] To study the molecular basis for the long-term survival of growth arrested cells, a comparison was made between the expression levels of various integrins in breast cancer cells that remained dormant on fibronectin for 3 and 5 days in the presence of FGF-2, to that of actively growing cells on fibronectin. Microarray analysis showed increased expression levels of integrin alpha-5, a fibronectin receptor. Western blots demonstrated that FGF-2 induced an increased expression of both integrins alpha 5 and beta 1, which together make up the fibronectin receptor in their naturally paired state, in MCF-7 and T-47D cells but had no effect on constitutively very high levels of integrin alpha 5 in MDA-MB-231 cells. The block in growth of FGF-2-treated cells on fibronectin was further accentuated by pre-treatment of the cells with anti-integrin alpha 5 antibody, strongly suggesting a role for fibronectin in supporting the survival of dormant breast cancer cells in bone marrow. Blocking peptides that disrupt the interaction of fibronectin with their integrin receptor that downregulated the expression of integrins alpha 5 and beta 1 also reversed the survival effects of fibronectin binding to cells in the presence of FGF-2. FGF-2 also induced the phosphorylation of the kinase Akt involved in survival signaling. All trans retinoic acid was able to reverse Akt phosphorylation induced by EGF and reversed FGF-2 induced increases in total and Phosphorylated AKt, suggesting an additional mechanisms of disrupting survival in these cells.
[0000] Therapeutic Indications
[0088] The administration of kinase or transcription inhibitors or antibodies or blocking peptides or modified peptides as a pre-treatment to sensitize the dormant or metastatic cells for chemotherapy or radiation therapy. The inhibitor could be administered in a variety of methods including but not limited to injectable, oral, liquid, tablet or suppository.
[0000] Pharmaceutical Compositions and Methods of Administration
[0089] The present invention also provides pharmaceutical compositions used in the method of the invention. Such compositions comprise a therapeutically effective amount of the agents of the present invention, and a pharmaceutically acceptable carrier. In a particular embodiment, the term “pharmaceutically acceptable” means approved by a regulatory agency of the Federal or a state government or listed in the U.S. Pharmacopeia or other generally recognized pharmacopeia for use in animals, and more particularly in humans. The term “carrier” refers to a diluent, adjuvant, excipient, or vehicle with which the therapeutic is administered. Such pharmaceutical carriers can be sterile liquids, such as water and oils, including those of petroleum, animal, vegetable or synthetic origin, such as peanut oil, soybean oil, mineral oil, sesame oil and the like. Water is a preferred carrier when the pharmaceutical composition is administered intravenously. Saline solutions and aqueous dextrose and glycerol solutions can also be employed as liquid carriers, particularly for injectable solutions. Suitable pharmaceutical excipients include starch, glucose, lactose, sucrose, -gelatin, malt, rice, flour, chalk, silica gel, sodium stearate, glycerol monostearate, talc, sodium chloride, dried skim milk, glycerol, propylene, glycol, water, ethanol and the like. The composition, if desired, can also contain minor amounts of wetting or emulsifying agents, or pH buffering agents.
[0090] The therapeutic agent, whether it be a polypeptide, analog or active fragment-containing compositions or small organic molecules, are conventionally administered by various routes including intravenously, intramuscularly, subcutaneously, as by injection of a unit dose, for example. The term “unit dose” when used in reference to a therapeutic composition of the present invention refers to physically discrete units suitable as unitary dosage for humans, each unit containing a predetermined quantity of active material calculated to produce the desired therapeutic effect in association with the required diluent; i.e., carrier, or vehicle.
[0091] The compositions are administered in a manner compatible with the dosage formulation, and in a therapeutically effective amount. The quantity to be administered depends on the subject to be treated, capacity of the subject's immune system to utilize the active ingredient, and degree of inhibition or neutralization of binding capacity desired. Precise amounts of active ingredient required to be administered depend on the judgment of the practitioner and are peculiar to each individual. Suitable regimes for initial administration and subsequent injections are also variable, but are typified by an initial administration followed by repeated doses at intervals by a subsequent injection or other administration.
[0092] These compositions can take the form of solutions, suspensions, emulsion, tablets, pills, capsules, powders, sustained-release formulations and the like. The composition can be formulated as a suppository, with traditional binders and carriers such as triglycerides. Oral formulation can include standard carriers such as pharmaceutical grades of mannitol, lactose, starch, magnesium stearate, sodium saccharine, cellulose, magnesium carbonate, etc. Examples of suitable pharmaceutical carriers are described in “Remington's Pharmaceutical Sciences” by E. W. Martin. Such compositions will contain a therapeutically effective amount of the compound, preferably in purified form, together with a suitable amount of carrier so as to provide the form for proper administration to the subject. The formulation should suit the mode of administration.
[0093] The compounds of the invention can be formulated as neutral or salt forms. Pharmaceutically acceptable salts include those formed with free amino groups such as those derived from hydrochloric, phosphoric, acetic, oxalic, tartaric acids, etc., and those formed with free carboxyl groups such as those derived from sodium, potassium, ammonium, calcium, ferric hydroxides, isopropylamine, triethylamine, 2-ethylamino ethanol, histidine, procaine, etc.
[0094] Administration of the compositions to the site of injury, the target cells, tissues, or organs, may be by way of oral administration as a pill or capsule or a liquid formulation or suspension. It may be administered via the transmucosal, sublingual, nasal, rectal or transdermal route. Parenteral administration may also be via intravenous injection, or intramuscular, intradermal or subcutaneous. Due to the nature of the diseases or conditions for which the present invention is being considered, the route of administration may also involve delivery via suppositories. This is especially true in conditions whereby the ability of the patient to swallow is compromised.
[0095] The plant compositions or extracts may be provided as a liposome formulation. Liposome delivery has been utilized as a pharmaceutical delivery system for other compounds for a variety of applications. See, for example Langer (1990) Science 249:1527-1533; Treat et al. (1989) in Liposomes in the Therapy of Infectious Disease and Cancer, Lopez-Berestein and Fidler (eds.), Liss: New York, pp. 353-365 (1989). Many suitable liposome formulations are known to the skilled artisan, and may be employed for the purposes of the present invention. For example, see: U.S. Pat. No. 5,190,762.
[0096] In a further aspect, liposomes can cross the blood-brain barrier, which would allow for intravenous or oral administration. Many strategies are available for crossing the blood-brain barrier, including but not limited to, increasing the hydrophobic nature of a molecule; introducing the molecule as a conjugate to a carrier, such as transferrin, targeted to a receptor in the blood-brain barrier; and the like.
[0097] Transdermal delivery of the plant compositions or extracts is also contemplated. Various and numerous methods are known in the art for transdermal administration of a drug, e.g., via a transdermal patch. It can be readily appreciated that a transdermal route of administration may be enhanced by use of a dermal penetration enhancer.
[0098] Controlled release oral formulations may be desirable. The plant composition or extract may be incorporated into an inert matrix which permits release by either diffusion or leaching mechanisms, e.g., gums. Slowly degenerating matrices may also be incorporated into the formulation. Some enteric coatings also have a delayed release effect. Another form of a controlled release of this therapeutic is by a method based on the Oros therapeutic system (Alza Corp.), i.e. the drug is enclosed in a semipermeable membrane which allows water to enter and push drug out through a single small opening due to osmotic effects.
[0099] Pulmonary delivery may be used for treatment as well. Contemplated for use in the practice of this invention are a wide range of mechanical devices designed for pulmonary delivery of therapeutic products, including but not limited to nebulizers, metered dose inhalers, and powder inhalers, all of which are familiar to those skilled in the art. With regard to construction of the delivery device, any form of aerosolization known in the art, including but not limited to spray bottles, nebulization, atomization or pump aerosolization of a liquid formulation, and aerosolization of a dry powder formulation, can be used in the practice of the invention.
[0100] Ophthalmic and nasal delivery may be used in the method of the invention. Nasal delivery allows the passage of a pharmaceutical composition of the present invention to the blood stream directly after administering the therapeutic product to the nose, without the necessity for deposition of the product in the lung. Formulations for nasal delivery include those with dextran or cyclodextrins. For nasal administration, a useful device is a small, hard bottle to which a metered dose sprayer is attached. In one embodiment, the metered dose is delivered by drawing the pharmaceutical composition of the present invention solution into a chamber of defined volume, which chamber has an aperture dimensioned to aerosolize and aerosol formulation by forming a spray when a liquid in the chamber is compressed. The chamber is compressed to administer the pharmaceutical composition of the present invention. In a specific embodiment, the chamber is a piston arrangement. Such devices are commercially available.
[0101] The compositions and extracts of the present invention are also suited for transmucosal delivery. In particular, the compositions and extracts are particularly suited for sublingual, buccal or rectal delivery of agents that are sensitive to degradation by proteases present in gastric or other bodily fluids having enhanced enzymatic activity. Moreover, transmucosal delivery systems can be used for agents that have low oral bioavailability. The compositions of the instant invention comprise the plant extract dissolved or dispersed in a carrier that comprises a solvent, an optional hydrogel, and an agent that enhances transport across the mucosal membrane. The solvent may be a non-toxic alcohol known in the art as being useful in such formulations of the present invention and may include, but not be limited to ethanol, isopropanol, stearyl alcohol, propylene glycol, polyethylene glycol, and other solvents having similar dissolution characteristics. Other such solvents known in the art can be found in “The Handbook of Pharmaceutical Excipients”, published by The American Pharmaceutical Association and The Pharmaceutical Society of Great Britain (1986) and the Handbook of Water-Soluble Gums and Resins, ed. By R. L. Davidson, McGraw-Hill Book Co., New York, N.Y. (1980).
[0102] Any transmucosal preparation suitable for administering the components of the present invention or a pharmaceutically acceptable salt thereof can be used. Particularly, the mixture is any preparation usable in oral, nasal, or rectal cavities that can be formulated using conventional techniques well known in the art. Preferred preparations are those usable in oral, nasal or rectal cavities. For example, the preparation can be a buccal tablet, a sublingual tablet, and the like preparation that dissolve or disintegrate, delivering drug into the mouth of the patient. A spray or drops can be used to deliver the drug to the nasal cavity. A suppository can be used to deliver the mixture to the rectal mucosa. The preparation may or may not deliver the drug in a sustained release fashion.
[0103] A specific embodiment for delivery of the components of the present invention is a mucoadhesive preparation. A mucoadhesive preparation is a preparation which upon contact with intact mucous membrane adheres to said mucous membrane for a sufficient time period to induce the desired therapeutic or nutritional effect. The preparation can be a semisolid composition as described for example, in WO 96/09829. It can be a tablet, a powder, a gel or film comprising a mucoadhesive matrix as described for example, in WO 96/30013. The mixture can be prepared as a syrup that adheres to the mucous membrane.
[0104] Suitable mucoadhesives include those well known in the art such as polyacrylic acids, preferably having the molecular weight between from about 450,000 to about 4,000,000, for example, Carbopol™934P; sodium carboxymethylcellulose (NaCMC), hydroxypropylmethylcellulose (HPMC), or for example, Methocel™ K100, and hydroxypropylcellulose.
[0105] The delivery of the components of the present invention can also be accomplished using a bandage, patch, device and any similar device that contains the components of the present invention and adheres to a mucosal surface. Suitable transmucosal patches are described for example in WO 93/23011, and in U.S. Pat. No. 5,122,127, both of which are hereby incorporated by reference. The patch is designed to deliver the mixture in proportion to the size of the drug/mucosa interface. Accordingly, delivery rates can be adjusted by altering the size of the contact area. The patch that may be best suited for delivery of the components of the present invention may comprise a backing, such backing acting as a barrier for loss of the components of the present invention from the patch. The backing can be any of the conventional materials used in such patches including, but not limited to, polyethylene, ethyl-vinyl acetate copolymer, polyurethane and the like. In a patch that is made of a matrix that is not itself a mucoadhesive, the matrix containing the components of the present invention can be coupled with a mucoadhesive component (such as a mucoadhesive described above) so that the patch may be retained on the mucosal surface. Such patches can be prepared by methods well known to those skilled in the art.
[0106] Preparations usable according to the invention can contain other ingredients, such as fillers, lubricants, disintegrants, solubilizing vehicles, flavors, dyes and the like. It may be desirable in some instances to incorporate a mucous membrane penetration enhancer into the preparation. Suitable penetration enhancers include anionic surfactants (e.g. sodium lauryl sulphate, sodium dodecyl sulphate), cationic surfactants (e.g. palmitoyl DL camitine chloride, cetylpyridinium chloride), nonionic surfactants (e.g. polysorbate 80, polyoxyethylene 9-lauryl ether, glyceryl monolaurate, polyoxyalkylenes, polyoxyethylene 20 cetyl ether), lipids (e.g. oleic acid), bile salts (e.g. sodium glycocholate, sodium taurocholate),and related compounds.
[0107] The administration of the compositions and extracts of the present invention can be alone, or in combination with other compounds effective at treating the various medical conditions contemplated by the present invention. Also, the compositions and formulations of the present invention, may be administered with a variety of analgesics, anesthetics, or anxiolytics to increase patient comfort during treatment.
[0108] The compositions of the invention described herein may be in the form of a liquid. The liquid may be delivered as a spray, a paste, a gel, or a liquid drop. The desired consistency is achieved by adding in one or more hydrogels, substances that absorb water to create materials with various viscosities. Hydrogels that are suitable for use are well known in the art. See, for example, Handbook of Pharmaceutical Excipients, published by The American Pharmaceutical Association and The Pharmaceutical Society of Great Britain (1986) and the Handbook of Water-Soluble Gums and Resins, ed. By R. L. Davidson, McGraw-Hill Book Co., New York, N.Y. (1980).
[0109] Suitable hydrogels for use in the compositions include, but are not limited to, hydroxypropyl cellulose, hydroxypropyl methyl cellulose, sodium carboxymethyl cellulose and polyacrylic acid. Preferred hydrogels are cellulose ethers such as hydroxyalkylcellulose. The concentration of the hydroxycellulose used in the composition is dependent upon the particular viscosity grade used and the viscosity desired in the final product. Numerous other hydrogels are known in the art and the skilled artisan could easily ascertain the most appropriate hydrogel suitable for use in the instant invention.
[0110] The mucosal transport enhancing agents useful with the present invention facilitate the transport of the agents in the claimed invention across the mucosal membrane and into the blood stream of the patient. The mucosal transport enhancing agents are also known in the art, as noted in U.S. Pat. No. 5,284,657, incorporated herein by reference. These agents may be selected from the group of essential or volatile oils, or from non-toxic, pharmaceutically acceptable inorganic and organic acids. The essential or volatile oils may include peppermint oil, spearmint oil, menthol, eucalyptus oil, cinnamon oil, ginger oil, fennel oil, dill oil, and the like. The suitable inorganic or organic acids useful for the instant invention include but are not limited to hydrochloric acid, phosphoric acid, aromatic and aliphatic monocarboxylic or dicarboxylic acids such as acetic acid, citric acid, lactic acid, oleic acid, linoleic acid, palmitic acid, benzoic acid, salicylic acid, and other acids having similar characteristics. The term “aromatic” acid means any acid having a 6-membered ring system characteristic of benzene, whereas the term “aliphatic” acid refers to any acid having a straight chain or branched chain saturated or unsaturated hydrocarbon backbone.
[0111] Other suitable transport enhancers include anionic surfactants (e.g. sodium lauryl sulphate, sodium dodecyl sulphate), cationic surfactants (e.g. palmitoyl DL camitine chloride, cetylpyridinium chloride), nonionic surfactants (e.g. polysorbate 80, polyoxyethylene 9-lauryl ether, glyceryl monolaurate, polyoxyalkylenes, polyoxyethylene 20 cetyl ether), lipids (e.g. oleic acid), bile salts (e.g.,sodium glycocholate, sodium taurocholate), and related compounds.
[0112] When the compositions and extracts of the instant invention are to be administered to the oral mucosa, the preferred pH should be in the range of pH 3 to about pH 7, with any necessary adjustments made using pharmaceutically acceptable, non-toxic buffer systems generally known in the art.
[0113] For topical delivery, a solution of the agent of the invention in water, buffered aqueous solution or other pharmaceutically-acceptable carrier, or in a hydrogel lotion or cream, comprising an emulsion of an aqueous and hydrophobic phase, at a concentration of between 50 μM and 5 mM, is used. A preferred concentration is about 1 mM. To this may be added ascorbic acid or its salts, or other ingredients, or a combination of these, to make a cosmetically-acceptable formulation. Metals should be kept to a minimum. It may be preferably formulated by encapsulation into a liposome for oral, parenteral, or, preferably, topical administration.
[0114] The invention provides methods of treatment comprising administering to a subject a therapeutically effective amount of at least one of the agents described herein. In one embodiment, the compound is substantially purified (eg., substantially free from substances that limit its effect or produce undesired side-effects). The subject is preferably an animal, including but not limited to animals such as cows, pigs, horses, chickens, cats, dogs, etc., and is preferably a mammal, and most preferably human. In one specific embodiment, a non-human mammal is the subject. In another specific embodiment, a human mammal is the subject.
[0115] The amount of the agent of the invention which is optimal in treating cancers and hyperproliferative disorders can be determined by standard clinical techniques based on the present description. In addition, in vitro assays may optionally be employed to help identify optimal dosage ranges. The precise dose to be employed in the formulation will also depend on the route of administration, and the seriousness of the disease or disorder, and should be decided according to the judgment of the practitioner and each subject's circumstances. However, suitable dosage ranges for intravenous administration are generally about 20-500 micrograms of active compound per kilogram body weight. Suitable dosage ranges for intranasal administration are generally about 0.01 pg/kg body weight to 1 mg/kg body weight. Effective doses may be extrapolated from dose-response curves derived from in vitro or animal model test systems.
[0000] Treatment Group
[0116] A subject in whom administration of the agents of the present invention is an effective therapeutic regiment is preferably a human, but can be any animal. Thus, as can be readily appreciated by one of ordinary skill in the art, the methods and pharmaceutical compositions of the present invention are particularly suited to administration to any animal; particularly a mammal, and including, but by no means limited to, domestic animals, such as feline or canine subjects, farm animals, such as but not limited to bovine, equine, caprine, ovine, and porcine subjects, wild animals (whether in the wild or in a zoological garden), research animals, such as mice, rats, rabbits, goats, sheep, pigs, dogs, cats, etc., avian species, such as chickens, turkeys, songbirds, etc., i.e., for veterinary medical use.
[0117] Furthermore, the administration of the agent may be given at the time of or after the identification of a cancer or hyperproliferative disorder, alone, or in combination with other agents known to be beneficial for ameliorating the symptoms or decreasing tumor load or enhancing the number or activity of immune cells in patients having cancer or a hyperproliferative disorder.
[0118] In one embodiment, the subject suitable for treatment by the method of the invention is a subject determined to be suffering from cancer or hyperproliferative disorder. This determination may be made clinically by methods known to one of skill in the art.
EXAMPLES
[0119] The following examples are intended to illustrate the invention not limit it.
Example 1
FGF-2 Inhibits Single Cell Growth of Well Differentiated Breast Cancer Cells
[0120] MCF-7 and T-47D cells incubated with FGF-2 have markedly diminished clonogenic potential in colony assays in tissue culture on laminin-, collagen I- and IV-coated and uncoated plates ( FIGS. 2, 3 , 4 and 12 ). The clones that did form in the presence of FGF-2 were arrested in the 8 cell stage. FGF-2 had no effect on the growth of the highly de-differentiated MDA-MB-231 cells. EFG had no effect and served as a negative control in all three cell types.
Example 2
FGF-2 Induces Expression of Cell Integrins Including Integrin α5 and Restricts Growth of Differentiated Single Breast Cancer Cells
[0121] Incubation of well differentiated cells with FGF-2 induces the expression of a variety of cell adhesion molecule genes, including α5, α6, β1 and β3, that contribute to cell death when expressed in an unligated state ( FIGS. 5, 6 , and Tables 1 and 2). FIG. 6 is a Western blot demonstrating induction of integrin α5 expression in MCF-7 and T-47D cells growing on either plastic tissue culture dishes or fibronectin-coated dishes. The increase in integrin α5 expression was assayed for up to five days and remained sustained. No effect is demonstrated on baseline high levels of integrin α5 in MDA-MB-231 cells.
Example 3
Rescue by Fibronectin
[0122] Inhibition of colony formation by FGF-2 can be rescued by incubation of cells 6n fibronectin-coated plates ( FIGS. 2B, 4 , 8 , 9 , 15 and 16 ). The protection of colonies in MCF-7 cells treated with FGF-2 was sustained by incubation on fibronectin for up to 15 days ( FIG. 8 ). Fibronectin is a ligand for integrin α5β1 while collagens I and IV are not. These data suggests an association between unligated integrin α5β1 and inhibition of growth and rescue of clonogenic potential by providing a specific ligand for integrin α5β1.
Example 4
Fibronectin Supports Long-Term Survival of FGF-2 Arrested Cells, Potentially Through a P13K Pathway
[0123] Antibody to integrin α5 inhibits the clonogenic potential of MCF-7 cells on fibronectin both with and without FGF-2 treatments ( FIG. 7 ). Antibody to integrin α3 was used as a negative control. To provide a potential mechanism for survival signaling by integrin α5 on fibronectin in the presence of FGF-2, initial experiments were conducted to determine the phosphorylation of Akt by FGF-2 in the presence of fibronectin. FIG. 10 demonstrates that FGF-2 induced phosphorylation of Akt in MCF-7 and T47D. Phosphorylation was sustained for the five days of assay; Highly de-differentiated MDA-MB-231 cells, however, express constitutively higher levels of integrin α5 and phospho-Akt, implicating these molecules in their unlimited growth potential on fibronectin.
Example 5
Disruption of Fibronectin/Integrin α5β1 Interaction can Reverse Protection from Cell Death
[0124] Our data suggest that stromal proteins in the bone marrow microenvironment, such as fibronectin, provide protection of metastatic cancer cells from cell death induced by physiologic factors in the bone marrow microenvironment and from exogenous toxicity such as chemotherapy or radiaton therapy. The ability to disrupt the interaction between fibronectin/integrin α5β1 with blocking antibodies to integrin α5 ( FIG. 7 ) and β1 (experiments in progress), peptides to the fibronectin binding site ( FIGS. 8, 9 and 14 ), antisense phosphorothioated oligonucleotides to integrins α5 or β1 or downregulation of integrins α5 or β1 in a dose dependent manner, other transcription inhibitors or retinoids, can result in disruption of the survival signal initiated by fibronectin/integrin α5β1 interaction and thereby become sensitive to chemotherapy and radiation therapy or other biologic therapy-mediated cell death. This approach may sensitize both well-differentiated cells that are non-cycling and dormant in the bone marrow that receive survival protection from ligation to fibronectin in the microenvironment and highly de-differentiated cells that are actively proliferating in the bone marrow that also receive survival signaling from interaction with fibronectin through a constitutively upregulated integrin α5.
Example 6
Disruption of the PI3K/Akt Signal Pathway May Disrupt Support for Breast Cancer Colony Growth by Fibronectin
[0125] FGF-2-induced phosphorylation of Akt may be disrupted in a number of ways by disrupting the interaction of fibronectin with integrin α5β1 by downregulating the expression of integrins α5 and β1, with other transcription factor inhibitors, retinoids, antisense oligonucleotides, disruption of their interaction with blocking antibodies to integrins α5β1 or fibronectin, or kinase inhibitors that inhibit activation of PI3K or Akt. Examples of Akt inhibition are shown in FIG. 11 , where incubation of MCF-7 cells with ATRA reversed the EGF-mediated phosphorylation of Akt, as demonstrated on a Western blot, and FIGS. 15 and 16 where inhibition of Akt and PI3K, the upstream activation of Akt inhibits survival of dormant clones. This approach may also provide an array of mechanisms for disruptive survival signaling through the PI3K pathway to breast cancer cells at metastatic sites initiated by interaction of integrin α5β1 with fibronectin. Disruption of signaling pathways, kinases and GTPases may disrupt signaling initiated by interaction of fibronectin with integrins alpha 5 and beta 1 in cancer cells that can support survival in these cells. Examples are included which were conducted with inhibitors of Rhp, Rho kinase and MEP/MAp kinase, p38, PKC and PKA resulting in the survival of dormant clones on fibronection ( FIGS. 17A and B).
[0126] Materials and Methods
[0127] Cell Culture
[0128] MCF-7, SK-Br-3, MDA-MB-231, PC-3 and LNCaP cells were purchased from the American Type Culture Collection (ATCC), (Rockville, Md.). Cells were cultured in Dulbecco's Modified Eagle's Medium (DMEM) (Gibco BRL, Gaithersburg, Md.) with phenol red 15 mg/l, 2 mM glutamine, 10% heat inactivated fetal calf serum (FCS) and penicillin 50 units/ml and streptomycin 50 micrograms μg/ml (Gemini Bioproducts, Calabasas, Calif.). One to ten thousand cells were incubated on 24 well tissue culture plates that were either commercially coated for tissue culture (uncoated) or coated with 20 g fibronectin, laminin I, collagen I or collagen IV, depending on the cell type or experimental conditions described in the figure legends. Colonies were manually counted at 100× magnification after variable days in culture as described in the figure legends after removing the media and staining cells with crystal violet. Proliferation kinetics were performed as before 1 using 2% trypan blue counts on tiypsinized cells on the days indicated in the figure. in triplicate plates.
[0129] Recombinant human FGF-2 and EGF were purchased from R&D Systems, Minneapolis, Minn.). ATRA was purchased from Sigma. Neutralizing mouse monoclonal antibody to integrin α5 or integrin β3 were purchased from Chemicon, Inc. (Temecula, Calif.). Fibronectin-blocking peptide GRGDSP and control peptides were purchased from American Peptide Co., Inc. (Sunnyvale, Calif.).
[0130] Western Blots
[0131] Cells were harvested and lysates were prepared as described 2 and analyzed as before 3 .
[0132] Gene Chip Microarray Analysis
[0133] MCF-7 cells were incubated with and without FGF-2 10 ng/ml for 5 days on tissue culture dishes coated with fibronectin 20 μg. Messenger RNA was prepared using solutions provided in a Nonrad GEArray Q series kit and analyzed using a Human Extracellular Matrix and Adhesion Protein chip and a Human Pathway Finder chip (Super Array, Bethesda, Md.).
TABLE 1 Human Extracellular Matrix and Adhesion Molecules GE Array Q series Position # on chip Gene Gene expression upregulated by FGF-2 on fibronectin for 5 days by large multiples 1. Meth 1 - A disintegrin-like and metalloprotease (reprolysin type) with thrombospondin type 1 motif, 1 7. E-cadherin - cadherin 1, type 1, (epithelial) 12. Collagen type IV alpha 2 13. Homo sapiens cystatin C (amyloid angiopathy and cerebral hemorrhage), CST3 23 DCC - deleted in colorectal carcinoma 36 Integrin alpha 5 (fibronectin receptor, alpha polypeptide) 37 Integrin alpha 6 subunit 47 Integrin beta 3 (glycoprotein IIIa, antigen CD61) 56 MUC-18 - Homo sapiens MICA gene, allele MUC-18 62 MT1-MMP - Homo sapiens mRNA for membrane-type matrix metalloprotease 1, MMP14 69 MMP26 - Homo sapiens matrix metalloprotease-26 mRNA 74 NCAM1 - Neural cell adhesion molecule 1 76 PECAM1 - Homo sapiens platelet/endothelial cell adhesion molecule (CD31 antigen) 80 ELAM-1/E-selectin - human endothelial leukocyte adhesion molecule mRNA 85 PAI-1 - Plasminogen activator inhibitor, type 1 94 TMPRSS$ - Transmembrane protease, serine 4 Gene expression upregulated by FGF-2 on fibronectin for 5 days by small but significant amounts 20 Cathepsin D - (lysosomal aspartyl protease) 21 Cathepsin G - (CTSG) Homo sapiens 26 Fibronectin 1 33 Integrin alpha 2b - platelet glycoprotein IIb of IIb/IIIa complex, antigen CD41B 34 Integrin alpha 3 - antigen CD49C, alpha 3 subunit of VLA-3 receptor 40 Integrin alpha 9 44 Integrin alpha X - (antigen CD11C (p150), alpha polypeptide 48 Integrin beta 4 57 MMP-1 - matrix metalloprotease 1 (interstitial collagenase) 59 Stromelysin-3, human 61 MMP-13 - matrix metalloprotease 13 (collagenase 3) 63 MMP-15 - matrix metalloprotease 15 (membrane inserted) 64 MMP-16 - matrix metalloprotease 16 (membrane inserted) 65 MMP-17 - matrix metalloprotease 17 (membrane inserted) 66 MMP-2 - matrix metalloprotease 2 (gelatinase A, 72 kD gelatinase, 72 kD type IV collagenase) 68 MMP-24 - matrix metalloprotease 24 (membrane inserted) 75 NRCAM - neural cell adhesion molecule 86 SPARC - Homo sapiens secreted protein, acidic cysteine-rich (osteonectin) 96 Vitronectin - serum spreading factor, somatomedin B, complement S protein
[0134]
TABLE 2
Human Pathway Finder GE Array Q series
Position # on chip
Gene
Gene expression upregulated by FGF-2 on fibronectin for
5 days by small but significant amounts
16
p21 WAF1/CIP1 - Cyclin-dependent kinase inhibitor
1A (p21, Cip1)
Gene expression downgulated by FGF-2 on fibronectin for
5 days by large multiples
14
CDC5 - T-cell surface glycoprotein CD5
19
p16INK4 - Cyclin-dependent kinase inhibitor 2A
(melanoma, p16, inhibits CDK4)
Gene expression downregulated by FGF-2 on fibronectin for
5 days by small but significant amounts
30
EGR1 - early growth response 1
31
EN1 - Engrailed homolog 1
32
FASN - fatty acid synthase
41
Hoxa-1 - Homo sapiens homeobox A1
42
Hoxb-1 - Homo sapiens homeobox B1
44
Hsp27 - Heat shock 27 kD protein
45
Hsp90(CDw52) - Human mRNA for 900 kDa
heat-shock protein | The present invention provides for identification of agents that induce growth arrest and survival of cancer cells, which remain dormant in bone marrow, thus preventing their eradication through use of standard chemotherapy or radiation therapy. Basic fibroblast growth factor (FGF-2), a mammary differentiation factor abundant in the bone marrow stroma, induces growth arrest of relatively differentiated breast cancer cells and restricts their survival to fibronectin by upregulating integrin α5β 1. Most of the FGF-2-arrested cells fail to establish optimal ligation to fibronectin and undergo cell death. Cells that do attach to fibronectin, another major constituent of the bone marrow microenvironment, stay alive and growth-arrested for many weeks. Using function-blocking antibodies and peptides, a specific contribution of α5β1-fibronectin interaction in maintaining survival of growth-arrested cells was demonstrated. The present invention thus allows for methods, agents and pharmaceutical compositions that can be used to potentiate the activity of chemotherapy or radiation therapy. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vacuum pump.
2. Description of the Prior Art
State of the Art (DE 20 2005 019 644 U1) discloses a vacuum pump, e.g., a turbomolecular pump having a rotor with rotatable pump active components and mounted on a rotor shaft. The rotatable pump active components cooperate with stationary pump active components, so-called stator.
The above-mentioned state of the art discloses securing of a bell-shaped rotor to an end side of a rotor shaft with a screw. To this end, the rotor shaft is provided with a recess in which the rotor journal engages.
The drawback of the embodiment disclosed in the state of the art consists in that the rotor can rotate relative to the rotor shaft because the connection of the rotor with the rotor shaft is essentially based on a frictional connection. Because of this, a relative rotation can occur in case of overload. The overload leads to loosening of the connection so that the security of the screw connection is not insured.
Loosening of the rotor during operation leads to a total damage of the pump. Prior art (WO 2012/077411 A1) discloses means for preventing rotation of the rotor. According to this state of the art, there is provided a formlocking connection at which the rotor is secured to the end side of the rotor shaft with several screws. This prevents rotation of the rotor relative to the rotor shaft and, thus, disengagement of the rotor from the rotor shaft. However, the drawback of this state-of-the-art embodiment consists in that the mounting of the rotor is rather expensive and a number of high-cost components, screws, is necessary which make the pump more costly.
The object of the invention is to provide a vacuum pump in which the above-discussed drawbacks of the prior art solutions are absent.
SUMMARY OF THE INVENTION
This and other objects of the invention which will become apparent hereinafter are achieved by providing a vacuum pump having at least one gas inlet opening, at least one gas outlet opening, at least one rotor shaft, a rotor mounted on the at least one rotor shaft and having rotatable therewith pump active components arranged opposite stationary pump active components, at least one fastening element extending in an axial direction and provided in or on the rotor shaft for securing the rotor on the rotor shaft, and at least one safety element provided in addition to the at least one element for preventing rotation of the at least one rotor and the at least one rotor shaft relative to each other.
The relative rotation-preventing safety element can be easily designed and formed, thus, providing a cost-effective solution of preventing rotation of the rotor relative to the rotor shaft and, thereby, loosening of at least one axially extending fastening element provided in or on the rotor shaft.
According to a particularly advantageous embodiment of the present invention, the safety element is provided on the centering journal of the rotor. The centering journal is easily accessible for the centrally arranged fastening element during mounting of the rotor, so that the arrangement of the safety element in the centering journal makes sense.
Basically, there also exists a possibility to provide the centering journal on the rotor shaft so that it would engage in a bore formed in the rotor.
When the centering journal is provided on the rotor, it engages in a corresponding opening of the rotor shaft.
There also exists a possibility that no journal is provided on the rotor and the rotor shaft. In this case, centering can be effected with one or several eccentric shaped elements such as register pins or combined shaped and fastening elements such as close-tolerance screws.
According to a particularly advantageous embodiment of the present invention, the safety element is formed as at least one pin engaging through or in the rotor shaft and through or in the rotor.
Such a pin can be very cost-effectively formed. In addition, the pin need not meet high requirements to the fitting precision, because the rotation of the rotor relative to the rotor shaft is prevented even if the pin retains the rotor shaft and the rotor with a clearance in some positions.
There exists a possibility to arrange the pin radially or axially. Basically, there exists also a possibility to arrange the pin radially inclined.
According to a further advantageous embodiment of the present invention, the pin is arranged in a groove or a bore formed in the centering journal of the rotor. The pin engages with one of its ends in the groove or the bore of the rotor and with another end in the groove or the bore of the rotor shaft.
According to a further advantageous embodiment of the present invention, the safety element is formed as a friction ring. The friction ring has, as a result of selection of an appropriate material and/or a corresponding surface coating, a higher friction coefficient in comparison with rotor and stator components, higher than the friction coefficient which is directly achieved between respective surfaces of the rotor and the rotor shaft. The friction ring is arranged between the rotor and the rotor shaft, preferably between the end surface of the rotor shaft and the surface of the centering journal of the rotor facing the end surface of the rotor shaft. This embodiment insures that the relative rotation between the rotor and the rotor shaft is prevented, without the need to structurally change the rotor or the rotor shaft.
According to a still another advantageous embodiment of the present invention, for increasing the friction coefficient, a coating layer is provided on one or both of connection or bearing surfaces of the rotor and the rotor shaft. With this embodiment, it is possible to prevent a relative rotation between the rotor and the rotor shaft, without using a friction ring.
Basically, there exists a possibility to use both the friction ring and providing a coating on one or both connection or bearing surfaces of the rotor and the rotor shaft.
A yet another advantageous embodiment of the present invention provides a projection in one of the cooperating contact surfaces of the rotor and the rotor shaft and that forms a plastic deformation in an opposite of the contact surfaces of the rotor and the rotor shaft, with the plastic deformation defining a counter-projection.
Such a projection can be formed, e.g., as a so-called punch mark. This punch mark can be formed, e.g., of a rotor material. When the rotor is pressed against the rotor shaft, upon tightening of the fastening element, e.g., a screw, the punch mark plastically deforms the adjacent surface. When the punch mark is provided in the rotor, it plastically deforms the rotor shaft. It is also possible to provide a punch mark in the rotor shaft. Then, the punch mark plastically deforms the rotor. Formation one or several punch marks is advantageous when the rotor and the rotor shaft are formed of different materials. In this case, the punch mark is formed in a material having a greater strength, i.e., a high yield stress Re. In this case, the punch mark is pressed in a softer material.
According to a still further advantageous embodiment of the invention, a radially extending projection is provided in the rotor or the rotor shaft, and a recess for formlockingly receiving the projection is provided in another of the rotor and the rotor shaft.
There is also exists, e.g., a possibility to provide a radial circular elevation having different heights on the end surface of the rotor shaft. A corresponding counter-recess is then provided on the rotor in which the elevation is received. This likewise prevents relative rotation between the rotor and the rotor shaft.
According to a further embodiment, a projection extending in the radial direction is provided in the rotor shaft or the rotor, and in another of the rotor and the rotor shaft, a recess for formlockingly receiving the projection is provided. In this embodiment, it is contemplated, e.g., to provide a projecting nose on the centering journal of the rotor and which is received in a groove in the rotor shaft. The groove defines a stop for the nose, so that the relative rotation of the rotor and the rotor shaft is prevented.
The novel features of the present invention, which are considered as characteristic for the invention, are set forth in the appended claims. The invention itself, however, both as to its construction and its mode of operation, together with additional advantages and objects thereof, will be best understood from the following detailed description of preferred embodiments of a rotor/rotor shaft connection, when read with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings show:
FIG. 1 a longitudinal cross-sectional view of a rotor of a turbomolecular pump and of the drive region of the turbomolecular pump according to the state of the art;
FIG. 2 a a longitudinal cross-sectional view of a rotor/rotor shaft connection with a pin;
FIG. 2 b a perspective view of the rotor and the shaft shown in FIG. 2 a in a non-connected condition;
FIG. 3 a a longitudinal cross-sectional view of a rotor/rotor shaft connection according to another embodiment of the present invention;
FIG. 3 b a perspective view of the rotor and the shaft shown in FIG. 3 a in a non-connected condition;
FIG. 4 a a longitudinal cross-sectional view of a rotor/rotor shaft connection with a radially inclined pin;
FIG. 4 b a perspective view of the rotor and the shaft shown in FIG. 4 a in a non-connected condition;
FIG. 5 a a longitudinal cross-sectional view of a rotor/rotor shaft connection according to a further embodiment of the present invention;
FIG. 5 b a perspective view of the rotor and the shaft shown in FIG. 5 a in a non-connected condition;
FIG. 6 a a longitudinal cross-sectional view of a rotor/rotor shaft connection with a radial pin;
FIG. 6 b a perspective view of the rotor and the shaft shown in FIG. 6 a in a non-connected condition;
FIG. 7 a a longitudinal cross-sectional view of a rotor/rotor shaft connection with a friction ring;
FIG. 7 b a perspective view of the rotor and the shaft shown in FIG. 7 a in a non-connected condition;
FIG. 8 a a longitudinal cross-sectional view of a rotor/rotor shaft connection with a punch mark;
FIG. 8 b a perspective view of the rotor and the shaft shown in FIG. 8 a in a non-connected condition;
FIG. 9 a a longitudinal cross-sectional view of a rotor/rotor shaft connection with an axial geometrical safety element;
FIG. 9 b a perspective view of the rotor and the shaft shown in FIG. 9 a in a non-connected condition;
FIG. 10 a a longitudinal cross-sectional view of a rotor/rotor shaft connection with a radial geometrical safety element; and
FIG. 10 b a perspective view of the rotor and the shaft shown in FIG. 10 a in a non-connected condition;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a cross-sectional view of a turbomolecular pump according to the state of the art. In the pump, a shaft 232 , which is located in the pump housing 260 , is surrounded by a safety bearing 295 , a radial bearing coil 291 , a radial sensor 293 , and a motor coil 261 . The motor coil 261 cooperates with a motor magnet 262 secured on the shaft 232 with a sleeve 263 , so that upon energizing the motor coil 261 , the shaft 232 rotates with a greater speed. The radial sensor 292 cooperates with a shaft-side radial sensor target 294 .
The turbomolecular pump stationary structure is formed of a Holweck stator 228 located adjacent to fore-vacuum and in which helix-shape channels extend that cooperate with a sleeve 227 arranged on the rotor, with the Holweck stator 228 and the sleeve 227 forming a Holweck stage 226 .
Further stationary structures are formed by stator discs 212 , 216 , 220 and 224 which are provided with blade rings and which are axially spaced from each other by spacer rings 213 , 217 , 221 , and 225 . In the axial intermediate spaces between the stator disc 212 , 216 , 220 and 224 , pump structures which are formed as rotor blades 211 , 215 , 219 and 223 extend. Stationary and rotor-side pump structures cooperate in pairs. The rotor blade 211 and the stator disc 212 form together a first pump stage 210 adjacent to the chamber and operating in high vacuum. Correspondingly, the stator disc 216 and the rotor blade 215 form the following second stage 214 , the stator disc 220 and the rotor blade 219 from the third stage, and, finally, the stator disc 224 and the rotor blade 223 form the fourth stage 222 that provides for transmission of pressure to the Holweck stage 228 . The blades are located in spaced from each other, planes 250 , 251 , 252 , and 253 , with the plane 254 forming the connection region of the rotor sleeve.
The rotor-side pump structures in form of rotor blades 219 and 223 are provided on the first rotor part 201 and form therewith a one-piece body. The rotor Holweck sleeve is connected with the first rotor part 201 . The first rotor part 201 has a recess 230 in its center. The recess forms a hollow space extending radially and axially from the center, and receives, at least partially, the safety bearing 295 .
The first rotor part 201 is connected to the end side 258 of the rotor shaft 232 by a fastening element, e.g., a screw 280 . The shaft 232 has a recess in which a journal 289 of the first rotor part 201 engages. This simplifies the radial positioning. The first rotor part 201 has, in the embodiment shown in the drawing, a retaining section 201 a that extends axially from the first rotor part 201 in the high-vacuum direction, i.e., in the direction remote from the rotor shaft 232 . A retaining ring 208 is arranged on the retaining section 201 a . The rotor blade 211 is connected with the retaining ring 208 . A further retaining ring 209 and the rotor blade 215 are likewise connected with each other. The retaining rings with rotor blades are conveniently formed.
Balancing boreholes 270 , in which balancing weights 271 can be inserted, are provided in the end side retaining section 201 a . In the rotor blades 219 and 223 , also balancing bores 272 can be provided in which balancing weights 273 can be arranged
In order to prevent rotation of the first rotor part 201 relative to the shaft 232 , a pin 281 is used as a rotation preventing or safety element and has one of its ends secured in the first rotor part 201 and the other of its ends secured in the shaft 232 . Because the pin 281 is radially spaced from the centrally located screw 280 , it prevents rotation of the first part 201 relative to the shaft 232 .
FIG. 2 shows the rotor shaft 232 on which the rotor part 201 is secured with the screw 280 . The pin 281 prevents rotation of the rotor part 201 relative to the rotor shaft 232 .
According to FIG. 2 b , an axial bore 300 is formed in the central journal 289 . In the shaft 232 , likewise, a bore 301 is formed. The pin 281 , not shown in FIG. 2 b , engages with its opposite ends in the bores 300 and 301 .
FIGS. 3 a and 3 b show the rotor shaft 232 in which again the bore 301 is formed. The centering journal 289 of the rotor part 201 has, instead of a bore, a groove 302 . The pin 281 has one of its ends arranged in the bore 301 of the rotor shaft 232 , and has the other of its ends arranged in the groove 302 of the centering journal 289 .
The advantage of the embodiment with the groove 302 in comparison with the embodiment with a bore consists in that the groove 302 permits to build a statically determined fit system, without maintaining precise tolerances. The radial centering of the rotor part 201 and the rotor shaft 232 is effected with the centering journal 289 . Two further bores with a pin, which must be aligned, would negatively influence this solution because of available tolerances and plays.
The groove 302 insures that the pin 281 alone provides for the rotatory degree of freedom, while both radial degrees of freedom, which are insured by the centering journal 289 , are not influenced.
According to FIGS. 4 a and 4 b , the pin 281 is arranged in the groove 303 of the centering journal 289 of the rotor part 201 with a radial inclination and extends into a radial bore 304 of the shaft 232 .
In this embodiment, the pin 281 is secured by a centrifugal force.
According to FIGS. 5 a and 5 b , the pin 281 is arranged in the bore 305 of the rotor part 201 so that it is radially spaced from the region of the centering journal 289 . A corresponding counter-bore 306 is provided in the shaft 232 . The bore 305 is provided in the rotor part 201 in contact with the bearing surface of the shaft 232 .
FIGS. 6 a and 6 b show a further embodiment. The pin 281 extends radially into the rotor centering journal 289 , being arranged in the bore 307 of the centering journal 289 . The other end of the pin 281 engages in a groove 308 in the shaft 232 .
Another embodiment is shown in FIGS. 7 a and 7 b . In this embodiment, a friction ring 309 is provided between the centering journal 289 and the end side 258 of the shaft 232 . The screw 280 presses the rotor part 201 to the shaft 232 . The friction ring 309 prevents rotation of the rotor part 201 relative to the shaft 232 .
According to the embodiment shown in FIGS. 8 a and 8 b , a punch mark 311 is provided on the contact surface 310 of the shaft 232 . The punch mark lies on the contact surface 312 of the rotor part 201 . The shaft 232 is formed of a stronger material than the rotor part 201 . When the rotor part 201 is connected with the shaft 232 by the screw 280 , the punch mark 311 plastically deforms the contact surface 312 of the rotor part 201 . The interlocking of the punch mark 311 with the deformed contact surface provides a form-locking connection that prevents the rotation of the rotor part 201 relative to the shaft 232 . It is possible to provide several punch marks.
According to FIGS. 9 a and 9 b , the shaft 232 , has, as its end, a deformed geometrical safety element 313 projecting in the axial direction, with its counter-part 314 being provided in the rotor part 201 . The projecting in the axial direction, deformed geometrical safety element 313 has two elevations 315 a , 316 b engaging in corresponding indentations 316 a , 316 b . The formlocking connection of elements 313 and 314 prevents relative rotation between the rotor part 201 and the rotor shaft 232 .
A still further embodiment of the present invention is shown in FIGS. 10 a and 10 b . In this embodiment, the centering journal 289 has an extending in the radial direction, deformed projection 317 arranged in a groove 318 of the rotor shaft 232 .
In the groove 318 of the rotor shaft 232 , there is provided a stop (not shown), whereby rotation of the rotor part 201 relative to the shaft 232 is prevented.
It is possible to combine the embodiments shown in FIGS. 1 through 10 with each other.
Though the present invention was shown and described with references to the preferred embodiments, such are merely illustrative of the present invention and is not to be construed as a limitation thereof and various modifications of the present invention will be apparent to those skilled in the art. It is, therefore, not intended that the present invention be limited to the disclosed embodiments or details thereof, and the present invention includes all variations and/or alternative embodiments within the spirit and scope of the present invention as defined by the appended claims. | A vacuum pump has a rotor mounted on a rotor shaft and provided with pump active components cooperating with opposite stationary pump active components, fastening element for securing the rotor on the rotor shaft, and a safety element provided in addition to the fastening element for preventing rotation of the rotor and the rotor shaft relative to each other. | 5 |
FIELD OF THE INVENTION
This invention relates to a DNA probe which detects Salmonella in a sample from human beings, other animals, foods, or other products, and a method for detecting Salmonella.
BACKGROUND OF THE INVENTION
Diseases caused by infection of Salmonella (Salmonella infectious disease) are classified into a typhoidal type disease and an acute gastroenteritis type disease. In either type of disease, a significant test item to identify the diseases is detection of Salmonella in a sample such as blood, feces, and urine. The detection of Salmonella is a significant test item also to confirm the safety of foods or the like.
The most general method for detecting Salmonella is as follows:
A sample is firstly inoculated on a Hajna Tetrathionate broth culture medium or the like, and cultivation is carried out for 18-24 hours to proliferate bacteria before isolation cultivation on a DHL agar medium for 24 hours. Then, originated black colonies are cultured on a TSI agar and a LIM medium for 18-24 hours, and thereafter the primary identification test is carried out before a serological examination or the like to detect the existence of Salmonella.
A conventional detection method for Salmonella, mainly consisting of such a cultivation, has the following problems:
Firstly, an examination can not be performed after treatment with antibiotics or the like. Secondly, there is required a long time of more than several days before obtaining an examination result.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to reduce the time required for an examination by remarkably reducing the cultivation period. The reduction of examination time is important to perform a suitable treatment for a patient of Salmonella infectious disease, and to prevent Salmonella from spreading.
The present invention is based on the investigation that a base sequence having a formula (I) below is specific to bacteria of Salmonella genus, in which the base sequence is contained in the extensive base sequence of an ara C gene of Salmonella typhimurium reported in Gene 18, 157-163(1982) by P. Clarke et. al. The invention provides a method for detecting Salmonella in a sample by detecting a DNA having the base sequence of a formula (I) or a complementary formula (II) thereto.
A novel probe for detecting Salmonella of the present invention comprises:
a labeled substance, and
a DNA or RNA fragment which hybridizes with a base sequence having the following formula (I), or (II) being complementary to the formula (I).
5'-GCTCAGACGTATGGCGGTA-3' (I)
3'-CGAGTCTGCATACCGCCAT-5' (II)
The present invention also provides a method for detecting Salmonella in a sample, which comprises:
contacting said probe with a sample under the condition in which the probe can hybridize with a Salmonella DNA, and
detecting the existence of a DNA-DNA or DNA-RNA complex.
DETAILED DESCRIPTION OF THE INVENTION
The probe for detection comprises a moiety which recognizes the base sequence of a formula (I) or (II) to hybridize with it, and a labeled substance combined with the moiety.
That is, the DNA probe comprises a labeled substance and a DNA fragment which has a base sequence having the following formula (I) or (II).
5'-GCTCAGACGTATGGCGGTA-3' (I)
3'-CGAGTCTGCATACCGCCAT-5' (II)
On the other hand, the RNA probe comprises a labeled substance and a RNA fragment which has a base sequence having the following formula (I') or (II').
5'-GCUCAGACGUAUGGCGGUA-3' (I')
3'-CGAGUCUGCAUACCGCCAU-5' (II')
Although there may be used DNA or RNA which has the complementary base sequence to that of a formula (I) or (II) as the moiety for hybridization, DNA is preferably used due to stability as a reagent. Although the length of the probe DNA is not necessarily limited to that of base sequence complementary to the nineteen bases of formulae (I) and (II), unnecessary long probe DNAs are not preferable because they are liable to have increased binding affinity to bacteria DNAs other than Salmonella.
The probe DNA may be prepared by cleaving Salmonella DNAs with a restriction enzyme or the like, and by a chemical synthesis method such as a diester, triester, phosphite, phosphoramide method, or the like. The probe RNA is also prepared by the above conventional methods.
The labeled substance to be combined with the probe DNA or RNA, may be a radioisotope, a fluorescent agent, enzyme, luminescent agent, etc. These substances may be directly combined or indirectly combined through avidin or antibody with the probe DNA or RNA.
The probe of the present invention can be used in a colony hybridization method, or other detection methods in which hybridization is carried out. For detecting Salmonella, DNA obtained by lysis of subject bacteria is immobilized on a membrane of nitrocellulose or nylon, and then an excess of the probe of the present invention is added to the DNA to form a hybrid.
The bacteria may be broken by an alkali solution, surfactant, lytic enzyme or the like. The DNA from the bacteria can be immobilized on the membrane by baking at about 80° C. or by exposing the membrane to ultraviolet light. A hybridized probe is immobilized, and a probe not hybridized is removed by washing.
After washing, the labeled substance of the hybridized probe is detected. The detection method differs with each kind of labeled substances. The probe labeled by a radioisotope can be detected by a scintillation counter or other radiation measuring instruments, or an autoradiography method using exposure of a film. The amount of the hybridized DNA can be measured by a fluorescent measuring instrument when the probe contains a fluorescent substance, or by measuring enzyme activity when the probe is labeled with an enzyme.
EXAMPLE
Preparation of the DNA Probe
A sequence of 5'-GCTCAGACGTATGGCGGTA-3' was selected from the base sequence of an ara C gene in Salmonella typhimurium (P. Clarke et. al., Gene 18, 157-163(1982)). Then, oligonucleotide (probe I) having the same sequence as said gene and oligonucleotide (probe II) having a complementary sequence to said gene were prepared by chemical synthesis. That is, probe I and probe II have the base sequences of the following formulae:
5'-GCTCAGACGTATGGCGGTA-3' Probe I
3'-CGAGTCTGCATACCGCCAT-5' Probe II
Chemical synthesis was carried out by a triester method with a DNA synthesis instrument (Model NS-1 by Shimadzu Corporation). The synthesized DNA fragments were purified with a C 18 reverse-phase column. Each of the resulting DNA fragments was labeled with [γ- 32 P] ATP by polynucleotide kinase.
Colony Hybridization
Colony hybridization was carried out by using 4 strains of bacteria in Salmonella genus and 17 strains of bacteria in other genus to examine specificity of the DNA probes as follows.
Each nitrocellulose membrane sterilized by an autoclave was put onto an agar plate culture medium, and the test strains were grown on the membrane. According to the method of Mosley et. al. (J. Infect. Dis., 892-898(1980)), the bacteria were lysed with 0.5M solution of sodium hydroxide, and were neutralized and dried. Thereafter, the bacterial DNAs were immobilized on the nitrocellulose membrane at 80° C. Each membrane was reacted at 35° C. for one hour in a hybridization solution (6×SSC, 5 ×Denhardt's solution, 1 mM EDTA, 100 μg/ml of a salmon sperm DNA) including 10 6 cpm of the DNA probe per 1 cm 2 of the membrane, and then washed with 1×SSC (50° C. or 55° C.) for five minutes×three times. The membrane was dried, and then the formation of hybridization was examined with an autoradiography. The results are shown in Table 1.
As shown in Table 1, it is found that a probe I and a probe II, having a complementary base sequence to a probe I, is hybridized only with the bacteria in Salmonella genus, and is not reacted with other bacteria, at a washing temperature of 55° C.
TABLE 1______________________________________Effect of temperature of a washing solution ontohybridization of a DNA probe and bacteria DNAName of Number of Probe I Probe IItest strain strain 50° C. 55° C. 50° C. 55° C.______________________________________Salmonella enter- 1 + + + +itidisSalmonella typhi 2 + + + +Salmonella 1 + + + +typhimuriumEscherichia coli 2 ± - ± -Klebsiella pneu- 1 ± - ± -moniaeProteus vulgaris 1 - - - -Pseudomonas 1 ± - ± -aeruginasaShigella dysen- 2 ± - ± -teriaeShigella flexneri 1 ± - ± -Shigella sonnei 2 + - + -Vibrio cholerae 4 ± - ± -Vibrio 2 ± - ± -parahaemolyticusYersinia 1 ± - ± -enterocolitica______________________________________
EFFECTS OF THE INVENTION
The DNA and RNA probes of the present invention have a characteristic in that the probes react specifically with the Salmonella DNA, whereby the probes can easily detect Salmonella from a sample containing various kinds of bacteria. Therefore, the probes can identify Salmonella without needful cultivation for bacteria isolation in a conventional detection method, and shortens an examination period. The probes have an advantage that the causative bacteria of disease can be identified even after death of bacteria by antibiotics.
Further, the DNA probes of the present invention are characterized by consisting of 19 nucleotides having the identified sequence, and hence, the DNA probes have the following advantages in comparison with a current probe consisting of thousands of nucleotides: Firstly, the probes having a stable quality can be prepared since they can be easily prepared by chemical synthesis, and the cost of preparation thereof can be decreased since they are suitable for mass production. Secondly, a reaction time can be reduced since the probes can be processed in a higher concentration. Thirdly, since a whole sequence of each probe is identified, the probe has an advantage that functional alteration, such as alteration of the optimum washing temperature without alteration of specificity to bacteria, can be easily carried out by addition of other nucleotides or a certain modification in the base sequence. | A novel probe for detecting Salmonella comprises:
a labeled substance, and
a DNA or RNA fragment which hybridizes with a base sequence having the following formula (I), or (II) being complementary to the formula (I).
5'-GCTCAGACGTATGGCGGTA-3' (I)
3'-CGAGTCTGCATACCGCCAT-5' (II)
This invention also provides a method for detecting Salmonella by using the probe.
The probe reduces the time required for detecting Salmonella. | 8 |
The government has rights in this invention pursuant to Contract No. DE-AC04-76DP00789 awarded by the U.S. Department of Energy.
BACKGROUND OF THE INVENTION
This invention concerns location and orientation sensors. More particularly, this invention employs multiple pairs of transmitting and receiving electrodes to track features on a surface in multiple locations and orientations relative to the sensor based on pertubations in the electrical fields caused by a feature on a workpiece.
Large classes of maunfacturing operations require the precise tracking of a gap or seam between mating parts. These processes include welding, dispensing, edge finishing, and painting operations. A robot or other manipulator must be programmed to follow the trajectory of the joint to properly perform the operation. The vast majority of current manufacturing applications accomplishes this by precisely fixturing the mating parts and then "teaching" the location and orientation of the seam to the robot or positioner. In these open-loop techniques, the individual components are also typically overdesigned to prevent changes in the part geometry during the process, such as heat deformation during welding. This open-loop approach works well when the lot sizes are large and the cost of precise forming, machining, fixturing, and teaching can be amortized over many thousands of units. However, this approach is too costly and inflexible for small-volume or agile manufacturing operations.
Seam tracking sensors can provide error signals that the manipulator can use to accurately follow the desired seam in real-time, as the parts are being processed. These data are fed back to the controller which can modify the nominal trajectory to compensate for mismatch in the joint, misalignment of the fixture, and disortion of the workpiece. A wide variety of "disturbances" can be rejected by the control system, resulting in a useful processed part. Because of this, machining tolerances for the mating surfaces, fixture tolerances, and other process parameters can be relaxed, resulting in potentially large cost savings during the fabrication of individual components as well as the completed part.
One type of non-contacting sensor that has been used is an optical system that shines a light onto a liquid surface on the workpiece, typically a weld pool, and senses the harmonic ripples on the surface to give an indication of the liquid-solid interfaces below the top of the weld pool. These systems tend to be very expensive and, due to their optical nature, tend have problems with optical attenuation of the light source and the sensor because of the debris created by the manufacturing process. Also, they cannot provide orientation information.
The sensor system of this invention has been developed to permit the precise location and tracking of features on the surface of a workpiece. Specifically, it was developed to track the seams between workpieces in an application involving placing of brazing paste between the multiple tubes in a complexly curved rocket motor thrust chamber.
SUMMARY OF THE INVENTION
This sensor system uses impedance maeasurements between multiple pairs of electrodes to track and measure features on the surface of a workpiece. One embodiment uses capacitance variations and differential capacitances to permit the measurement and control of sensor lcoation and orientation with respect to the seams on the workpiece. This system comprises a specially designed arrangement of impedance sensing electrodes that are connected to appropriate signal conditioning electronics to measure the capacitive component of the impedance. Other embodiments can measure up to six degrees of freedom while tracking a linear feature on a workpiece by sensing impedance changes between pairs of electrodes.
The first embodiment of the system has four output signals that can be combined to provide tracking in the .increment.y and .increment.z lcoations and the .increment.p orientation (rotation about the y-axis) relative to a seam whose longitudinal axis is defined as the x-axis. This system has two pairs of rectangular electrodes, one on each side of a tab that extends down towards the workpiece. The tab is aligned with the x-axis of the seam, and the normals from each of the electrodes face outwards parallel to the y-axis of the seam. An oscillating signal is output from one electode in each pair with the other two electrodes sensing the fields. The field between the electrodes on one side of the tab will primarily sense in the sideways, y-axis, direction. The field between a transmitting electrode in one pair and a sensing electrode in the other pair will primarily sense in the downward, z-axis, direction. By subtracting field data from one of these downward-looking pairs of electrodes from the other, information about the rotation about the y-axis (.increment.p) can be obtained. Control over this orientation is important to keep the sensor and associated brazing paste dispensing system properly aligned relative to the z-axis as the system follows the curved contours of the workpiece. Addition of these two fields gives information about the height of the sensors (.increment.z) above the workpiece. If the field data from the pairs of the electrodes on each side is subtracted from each other, information relating to tracking in the y-direction may be obtained.
By adding further sensors and data processing to the system, information describing up to six degrees of freedom. Five degrees other than the feature axis on the workpiece that is being tracked are useful in tracking linear features in which the x-axis of the sensor is parallel to the linear feature. Six degrees of freedom are needed when the sensor is to track a "dot" feature such as a hole.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the four electrode seam tracking sensor.
FIG. 2 is the orientation diagram associated with FIG. 1.
FIG. 3 is a top view of the tab portion of the sensor following a seam in the workpiece.
FIG. 4 is the orientation diagram associated with FIG. 3.
FIG. 5 is an end view of the tab portion of the sensor following a seam in the workpiece.
FIG. 6 is the orientation diagram associated with FIG. 5.
FIG. 7 is a graph showing the differential sensor output in the downwards direction as a function of lateral distance across the seams in the workpiece.
FIG. 8 is an electrical schematic diagram of the sensor system.
FIG. 9 is a flowchart showing the sequence of steps used to perform the brazing paste dispensing operation.
FIG. 10 is a side view of the tab portion of the sensor system that will measure up to six degrees of freedom relative to the feature on the workpiece.
DETAILED DESCRIPTION OF THE INVENTION
The components and operations of this invention will be described in the context of a particular embodiment that was developed for a specific application. The following discussion should not be considered as limitative of the true scope of the invention which is set forth in the appended claims.
This embodiment of the capacitive tracking sensor was developed to track seams between tubes used to fabricate the thrust chamber for a rocket engine. The typical Atlas or Delta thrust chamber produced by Rocketdyne has 292 tubes approximately 230 cm long, while the Space Shuttle Main Engine nozzle contains over 1000 tubes. The tubes run longitudinally, carrying fuel along the sides of the thrust chamber during engine operation. The individual tubes are formed with a continuously-varying cross-section to improve fluid dynamics and define the overall chamber shape.
To manufacture a chamber, the loose tubes are first assembled into the final shape. The interstices between the tubes are then filled with nickel powder and silver-palladium alloy paste. In traditional practice these materials are dispensed manually at a fixed rate that is not adjusted to compensate for the varying cross-section of the tube interstice. Then the entire structure is furnace brazed. This currently used process requires many hours and costs tens of thousands of dollars. The manual application of the nickel powder and braze alloy is time-consuming and subject to inconsistencies. Manual rework would require refiring the entire nozzle to prevent localized stress concentrations. To prevent this the silver-palladium alloy paste is applied generously to avoid thin regions, and the excess is collected on the furnace floor. This excess results in higher raw material and recycling costs.
This braze filler paste dispensing operation is being automated with the use of the feature tracking sensor of this invention. There will be a significant reduction in the hours of labor and material costs through the use of an automatic positioning and precision metering system for dispensing braze filler mateials. Because of the size and flexibility of the unbrazed thrust chambers, traditional, preprogrammed paste dispensing paths are not adequate. The robot system will use different information from the feature tracking sensors to locate and track the tube interstices. Because of the use of sensor feedback, variations in the position of the chamber with respect to the robot will be accommodated with little or no manual teaching of the robot.
The sensor developed for this application is shown in FIG. 1. The sensor 10 comprises an inexpensive five layer PC board with one integrated circuit 16 for buffering and charge amplification. The sensing elements comprise four rectangular capacitor electrodes with one pair on each side of the tab extension 12 at the lower end of the sensor 10. The two electrodes shown in this view are numbered 1 and 2 with corresponding electrodes 3 and 4 on the opposite side of the tab 14 but not shown in this view. The electrode pairs are located just above the bottom edge 14 of the tab 12 to maximize their response to pertubations in the electric fields they produce by nearby structural features. The principles of capacitive sensing are described in a related patent application entitled "A Non-Contact Capacitance Based Image Sensing Method and System" U.S. Ser. No. 07/514,051 by J. L. Novak and J. J. Wiczer, assigned to the assignee of this invention. This reference is incorporated by reference in its entirety.
Power and output signals are carried by a ribbon connector 20 to remote signal conditioning electronics shown in FIG. 8. A different frequency input signal is input to each of electrodes 2 and 3 from remote oscillators via SMB coaxial connectors 18. The sensor 10 is mounted on a robot arm with fasteners through holes 22. FIG. 2 shows the orientation of the sensor relative to the seam feature. The pairs of electodes on each side of the tab 12 are aligned with the longitudinal or x-axis of the seam. The positive y-axis of the seam and the sensor is pointed into the paper while the z-axis is pointing downwards. The various rotational or orientational components about the x, y, and z axes are labelled r, p, and w respectively.
The sensor generates four electric fields that are perturbed by changes in the sensor position relative to a workpiece. Three of the sensing fields are indicated in FIG. 3 and 5. Changes in the electric field between the elecrode plates are detected as capacitance variations. The shape and extent of the electric fields are functions of the position and size of the electrodes. By varying the geometry of the electrode pairs, the field can be optimized for a particular application. For the seam tracking application, the size and placement of the electrodes has been optimized for locating and tracking the interstices associated with the typical rocket nozzle tubes.
FIG. 3 is a top view of the sensor tracking the seam between two tubes 30. The sensor tab 12 with the four electrodes 1, 2, 3 and 4 is shown. Electrodes 2 and 3 operate as transmitters, and electrodes 1 and 4 as receivers. The arrows on the field lines 32 and 34 indicate transmission direction but not necessarily field polarity. FIG. 5 is an end view of the sensor tab 12 and the tubes 50, showing electrodes 1 and 3 and the associated field lines 52. The fields between the electodes on one side extend primarily outward in the +y or -y direction, although there is a minor component in the z direction. Thus the 1-2 electrode pair and the 3-4 electrode pair are "side looking" (SL) sensors. The fields between electrodes 1-3 and 2-4 extend primarily downward in the +z direction. These will be referred to as the "downward looking" (DL) sensors. FIGS. 4 and 6 give orientation information for FIGS. 3 and 5 respectively.
Information about the rotation about the y-axis (.increment.p) can be obtained by subtracting the data from DL sensor 4-2 from that of DL sensor 1-3. All other influences on this sensor pair are common-mode and will be nulled by the subtraction. Control over this pitch rotation will keep the sensor correctly oriented relative to the normal to the plane of the workpiece.
Because of the geometry of the rocket nozzle, the tube interstices lie in a plane. By proper motion programming, .increment.r (roll rotation about the x-axis) and .increment.w (yaw rotation about the z-axis) can remain fixed and do not need to be sensed during the dispensing operation. A plane containing the axis of symmetry for the nozzle and the location of the interstice interior curved surface can be calculated, permitting predetermined rotation (if required) during travel. With .increment.r and .increment.w fixed with respect to the tube gap, the signal component corresponding to these perturbations will be constant. Thus, the differential signal between the SL sensors (1-2 minus 3-4) will provide deviations from true tracking in y, the differential signal between the DL sensors (1-3 minus 4-2) will indicate rotation about the y-axis (.increment.p), and the common mode signal from the DL sensors (1-3 plus 2-4) can be set to a fixed value to maintain a constant height (z) above the surface. However, other applications of this sensor might require different parameters to be sensed. Information regarding .increment.w, .increment.r, and .increment.x could be easily extracted as well as other combinations.
The sensor was tested using a fixture representing the workpiece containing the interstices to be located and tracked. A combustion chamber was simulated with a flat bundle of 3/8 inch OD tubes approximately 3 feet long for the following experiments. The sensor tab 12 was oriented parallel to the interstice axis (x-axis). Data was collected as the sensor was moved perpendicularly to the seam axis in the y and z directions.
Because the electric fields at the DL sensors extend primarily along the z-axis, these sensors exhibit a greater sensitivity to changes in this distance than the SL sensors. These senors are used to control the motion of the robot toward the chamber surface. The measured dynamic range for the common-mode DL sensor signal along the z-axis is approximately 70 mm. Calibration parameters were determined by collecting data as the sensor was moved away from the simulated chamber surface.
FIG. 7 shows a plot of the difference between the SL sensor signals as the sensor was scanned along the Y-axis of the tube bundle at distances from 0 to 4 mm above the surface. The numbers on the y-axis of the graph correspond to counts coming out of an analog to digital converter at the back end of the signal conditioning electronics described in more detail in conjunction with FIG. 8. The value of the difference signal goes to zero both at the centers of the interstices and at the tops of the tubes due to the symmetrical geometry at both locations. Plots of the sum of SL sensor signals, not shown, exhibit positive peaks at locations over the tops of the tubes and negative peaks at the interstices. The difference signal identifies the locations of symmetry, while the sum of the sensor signals identifies whether the location is a tube top or an interstice. This sensor information is used to precisely locate an interstice by directing the robot to move the sensor tip to zero the SL difference (i.e., balance the readings of the SL sensors) while maintaining a minimum value for the common-mode SL sensor signal.
FIG. 8 is an electrical schematic drawing of the sensor system. The two transmitting electrodes 2 and 3 mounted on tab 12 are driven at two different frequencies by oscillators 62 and 64. Using two frequencies allows continuous parallel sensing by the sensing electrodes 1 and 4 and their associated signal conditioning electronics 70, 80, 81, and 82 rather than having to time multiplex the signals if a single frequency with additional sensors were to be used.
The raw signal from electrode 1 contains information at the two frequencies of oscillators 62 and 64. This signal is buffered by charge amplifier 66 and is then fed into two signal processing sections 70 and 80. The four signal processing sections 70, 80, 81, and 82 are identical internally but are connected to different sensor and reference signals.
The sensor signal is fed into summer 71 along with the original oscillator signal which has been scaled using variable amplifier 72. Because the charge amplifier 66 inverts the sensor signal, the input to the wide bandwidth amplifier 73 can be adjusted to be zero when the sensor is in a fixed location relative to the workpiece by varying the output level of amp 74. This largely removes the system interference from the signal. When the sensor is in this reference position, most of the signal coming from the charge amplifier 66 is due to fixed and parasitic capacitances. By removing this constant signal from the output of the summer 71, the gain of the wide bandwidth amplifier 73 can be increased greatly, resulting in higher sensitivities.
The output of the wide bandwidth amplifier 73 goes to synchronous detector 76, both directly and through an inverter 75. The synchronous detector 76 is clocked by a clock generating circuit 74 that produces a clock signal from the original oscillator 62. The phase of this clock signal may be adjusted to compensate for any phase shifts that have occurred as a result of parasitic capacitances in the charge amplifier 66, the summer 71, the wide bandwidth amplifier 73, or the interconnections getween these stages. The phase may also be adjusted to permit operation of the sensor with nonmetallic materials or in situations where the feature to be tracked is surrounded by media other than air. For example, in some welding applications the parts to be welded lie beneath a layer of flux material. This material will result in a phase shift a the sensor which depends on the resistive and reactive components of the complex dielectric constant. Adjustment of the clock generating circuit 74 will permit accurate measurement of the electric field resulting from this configuration.
The output from the synchronous detector 76 is passed through a low-pass filter 77 and amplifier 78. The other branch of charge amplifier output 66 passes through an identical signal processing section 80 which is instead connected to oscillator 64. Thus the output of signal processing section 70 depends only on the electric field detected at electrode 1 due to oscillator 62 driving electrode 3, while the output of signal processing section 80 depends on the electric field at electrode 1 due to oscillator 64 driving electrode 2. Signal processing for electric fields detected at electrode 4 by charge amplifier 67 is performed in the same manner.
It should be noted that the signal processing techniques described in conjunction with FIG. 8 are very important to the successful operation of this embodiment. The variations in the electric fields due to changes in the location and orientation of the sensor with respect to the features are very small. Large amounts of parasitic capacitances and electrical interference tend to obscure the desired signal. By using the variable amplifier reference stage 72, this processing circuitry minimizes the effect of parasitic capacitances. The clock generating circuitry permits accurate adjustment of the phase of the detection signal, permitting compensation for phase shifts in the sensor or electronics as well as allowing the sensor to be used with nonmetallic materials or in dielectric media such as welding flux. In these cases, the sensor system measures the impedance, not only the capacitance between sensor electrodes. Each sensor signal would go to the signal processing stages with the clock generating circuits operating in quadrature to produce signals corresponding to the capacitive (reactive) and resistive parts of the complex impedance. Finally the synchronous detection circuitry 76 rejects all interference signals and noise which are not at the frequency of the oscillator 62 with the same phase (or in quadrature) as the output of the clock generating circuitry 74. This is especially important due to the typically large amounts of interference in manufacturing operations due to motors and other electrical equipment.
The conditioned signals output from 70, 80, 81, and 82 are then fed into a processor means 83 which adds or subtracts the sensed field signals to provide the location and orientation information for the sensor relative to the seam. The processing means also controls the motion of the robot arm 85 to which the sensor 10 and the tool 84 are attached as well as the sequence of steps necessary to lay down the brazing compound.
FIG. 9 is a diagram showing the sequence of steps involved in dispensing the brazing paste. The first step provides geometric information about the nozzle model to the processor 83. The second step locates the actual unbrazed tube assembly within the workcell and provides this information to the processor 83. The third step locks in to an individual seam at a known location. The next step uses the sensor to track all the seams in a sector of the nozzle. The next step calculates the geometry of the seam paths. The next step plays back the calculated paths while employing the tool to dispense the brazing paste. The next step is a decision point. If all of the seams on the inside of the nozzle are not completed, the sequence returns to the third step and locates a seam in an unfinished sector and proceeds from there. If the inside of the nozzle is complete, the sequence then restarts at the third step by beginning with the first seam sector on the outside of the nozzle. Once the outside of the nozzle is completed, the brazing paste dispensing operation is complete, and the nozzle moves on to the next step in its manufacture.
This sensor system uses differential measurements to "null out" variations due to improper seam tracking. This permits automatic compensation for relative changes in the shape and sizes of the gaps. The differential measurement also compensates for changes in temperature and the effects of small amounts of contamination on the probe. This sensor technology is inherently rugged, insensitive to lighting and surface contamination, and inexpensive, especially when compared to optical techniques such as structured lighting. This sensor will permit the robot to maintain relative orientation of the tool with respect to the interior nozzle surface, as well as the gaps.
The system described in the embodiment above can be readily extended into six degrees of freedom and is not limited to measuring only the .increment.y, .increment.z, and .increment.p parameters. Straightforward extension of the design principles utilized above can result in a sensor embodiment such as the one shown in FIG. 10. This sensor can be used to detect all three locations and the three orientations, that is perturbations in the .increment.x, .increment.y, .increment.z, .increment.r, .increment.p, and .increment.w directions and orientations. In addition, the signal processing sections described in conjunction with FIG. 8 could be extended to support four separate oscillators, permitting simultaneous collection of the twelve channels of sensor data. The perturbations would be measured using the electric fields given in Table 1 below.
FIG. 10 is an expanded version of the tab section shown in FIG. 1 with three more pads on each side of the tab 12, and its spatial orientation corresponds to that shown in FIG. 2. The pads on the printed circuit board are formed in the usual manner and serve as the electrodes which generate the electrical fields. Electrodes 101, 102, 103, 104, and 105 are on the side of the tab 12 facing the viewer. Electrodes 106, 107, 108, 109, and 110 are shown in parentheses to indicate that they are located on the opposite side of the tab 12 and directly behind electrodes 101, 102, 103, 103, and 105, respectively. The addition of electrodes 105 and 110 gives the capability to sense .increment.r, the roll about the x-axis (this is the feature axis).
TABLE 1______________________________________Direction Combination of Fields______________________________________Δx 101,106 minus 104,109Δy 102,103 minus 107,108Δz 102,107 plus 104,108Δr (105,101 plus 105,103) minus (110,107 plus 110,109)Δp 102,107 minus 103,108Δw (101,102 plus 108,109) minus (106,107 plus 103,104)______________________________________
Additionally, since the sensor can recognize ridges and protusions as well as seams, it can be readily converted to track these features if the associated manufacturing process requires this capability. Hence the feature can be either an indentation such as a seam or a protusion so long as the surfaces on either side of the feature are reasonably symmetric. In most sensor applications it will be desirable that the sensor and/or its associated robotic tool be oriented normal to the local workpiece surface. Certain applications such as grinding or polishing may require that the tool be oriented at a non-perpendicular angle relative to the local workpiece surface. Such applications are easily accomodated by modifications to the robotic controller. | Linear and other features on a workpiece are tracked by measuring the fields generated between electrodes arrayed in pairs. One electrode in each pair operates as a transmitter and the other as a receiver, and both electrodes in a pair are arrayed on a carrier. By combining and subtracting fields between electrodes in one pair and between a transmitting electrode in one pair and a receiving electrode in another pair, information describing the location and orientation of the sensor relative to the workpiece in up to six degrees of freedom may be obtained. Typical applications will measure capacitance, but other impedance components may be measured as well. The sensor is designed to track a linear feature axis or a protrusion or pocket in a workpiece. Seams and ridges can be tracked by this non-contact sensor. The sensor output is useful for robotic applications. | 6 |
PRIORITY
This application is a national phase filing of the Patent Cooperation Treaty (PCT) application # PCT/IB2013/055146 titled “COMPOSITIONS AND METHODS FOR THE TREATMENT OF MODERATE TO SEVERE PAIN” filed on Jun. 23, 2013 Published with WIPO Publication # WO/2014/006529, which further claims priority to parent application 2682/CHE/2012 filed on Jul. 3, 2012 in the country of India. The entire disclosure of the priority applications are relied on for all purposes and is incorporated into this application by reference.
FIELD OF THE INVENTION
This disclosure generally relates to compounds and compositions for the treatment of moderate to severe pain. More particularly, this invention relates to treating subjects with a pharmaceutically acceptable dose of compounds, crystals, enantiomers, stereoisomers, esters, salts, hydrates, prodrugs, or mixtures thereof.
BACKGROUND OF THE INVENTION
Pain is a subjective experience, influenced by physical, psychological, social, and spiritual factors. The concept of total pain acknowledges the importance of all these dimensions and that good pain relief is unlikely without attention to each aspect. Pain and diseases such as cancer are not synonymous: at least two thirds of patients experience pain at some time during the course of their illness, and most will need potent analgesics.
Moderate to severe pain is also associated with injury, inflammation, burning of seasonal allergies, eye pain, itchiness, bipolar disorder are a heterogeneous group of diseases of the nervous system, including the brain, spinal cord, and peripheral nerves that have much different aetiology. Many are hereditary; some are secondary to toxic or metabolic processes. Free radicals are highly reactive molecules or chemical species capable of independent existence. Generation of highly Reactive Oxygen Species (ROS) is an integral feature of normal cellular function like mitochondrial respiratory chain, phagocytosis and arachidonic acid metabolism. The release of oxygen free radicals has also been reported during the recovery phases from many pathological noxious stimuli to the cerebral tissues. Some of the pain associated neurological disorders include injury, post-operative pain, osteoarthritis, rheumatoid arthritis, multiple sclerosis, spinal cord injury, migraine, HIV related neuropathic pain, post herpetic neuralgia, diabetic neuropathy, cancer pain, fibromyalgia and lower back pain.
Managing acute pathology of often relies on the addressing underlying pathology and symptoms of the disease. There is currently a need in the art for new compositions to treatment of moderate to severe pain.
SUMMARY OF THE INVENTION
The present invention provides compounds, compositions containing these compounds and methods for using the same to treat, prevent and/or ameliorate the effects of the conditions such as moderate to severe pain.
The invention herein provides compositions comprising of formula I or pharmaceutical acceptable salts, hydrate, solvate, prodrug, enantiomer, or stereoisomer thereof. The invention also provides pharmaceutical compositions comprising one or more compounds of formula I or intermediates thereof and one or more of pharmaceutically acceptable carriers, vehicles or diluents. These compositions may be used in the treatment of moderate to severe pain and its associated complications.
In certain embodiments, the present invention relates to the compounds and compositions of formula I or pharmaceutically acceptable salts, hydrate, solvate, prodrug, enantiomer, or stereoisomer thereof,
Wherein,
R 1 represents H, D, —OCH 3 , —OCD 3 ,
a is independently 2, 3 or 7;
each b is independently 3, 5 or 6;
e is independently 1, 2 or 6;
c and d are each independently H, D, —OH, —OD, C 1 -C 6 -alkyl, —NH 2 or —COCH 3 ;
n is independently 1, 2, 3, 4 or 5.
In the illustrative embodiments, examples of compounds of formula I are as set forth below:
Herein the application also provides a kit comprising any of the pharmaceutical compositions disclosed herein. The kit may comprise instructions for use in the treatment of moderate to severe pain or its related complications.
The application also discloses a pharmaceutical composition comprising a pharmaceutically acceptable carrier and any of the compositions herein. In some aspects, the pharmaceutical composition is formulated for systemic administration, oral administration, sustained release, parenteral administration, injection, subdermal administration, or transdermal administration.
Herein, the application additionally provides kits comprising the pharmaceutical compositions described herein. The kits may further comprise instructions for use in the treatment of moderate to severe pain or its related complications.
The compositions described herein have several uses. The present application provides, for example, methods of treating a patient suffering from moderate to severe pain or its related complications manifested from metabolic conditions, severe diseases or disorders; Hepatology, Cancer, Hematological, Orthopedic, Cardiovascular, Renal, Skin, Neurological or Ocular complications.
BRIEF DESCRIPTION OF DRAWINGS
Example embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:
FIG. 1 shows the 13C-NMR spectrum for Formula I, according to one embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
As used herein, the following terms and phrases shall have the meanings set forth below. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art.
The compounds of the present invention can be present in the form of pharmaceutically acceptable salts. The compounds of the present invention can also be present in the form of pharmaceutically acceptable esters (i.e., the methyl and ethyl esters of the acids of formula I to be used as prodrugs). The compounds of the present invention can also be solvated, i.e. hydrated. The solvation can be affected in the course of the manufacturing process or can take place i.e. as a consequence of hygroscopic properties of an initially anhydrous compound of formula I (hydration).
Compounds that have the same molecular formula but differ in the nature or sequence of bonding of their atoms or the arrangement of their atoms in space are termed “isomers.” Isomers that differ in the arrangement of their atoms in space are termed “stereoisomers.” Diastereomers are stereoisomers with opposite configuration at one or more chiral centers which are not enantiomers. Stereoisomers bearing one or more asymmetric centers that are non-superimposable mirror images of each other are termed “enantiomers.” When a compound has an asymmetric center, for example, if a carbon atom is bonded to four different groups, a pair of enantiomers is possible. An enantiomer can be characterized by the absolute configuration of its asymmetric center or centers and is described by the R- and S-sequencing rules of Cahn, Ingold and Prelog, or by the manner in which the molecule rotates the plane of polarized light and designated as dextrorotatory or levorotatory (i.e., as (+) or (−)-isomers respectively). A chiral compound can exist as either individual enantiomer or as a mixture thereof. A mixture containing equal proportions of the enantiomers is called a “racemic mixture”.
As used herein, the term “metabolic condition” refers to an Inborn errors of metabolism (or genetic metabolic conditions) are genetic disorders that result from a defect in one or more metabolic pathways; specifically, the function of an enzyme is affected and is either deficient or completely absent.
The term “polymorph” as used herein is art-recognized and refers to one crystal structure of a given compound.
The phrases “parenteral administration” and “administered parenterally” as used herein refer to modes of administration other than enteral and topical administration, such as injections, and include without limitation intravenous, intramuscular, intrapleural, intravascular, intrapericardial, intraarterial, intrathecal, intracapsular, intraorbital, intracardiac, intradennal, intraperitoneal, transtracheal, subcutaneous, subcuticular, intra-articular, subcapsular, subarachnoid, intraspinal and intrastemal injection and infusion.
A “patient,” “subject,” or “host” to be treated by the subject method may mean either a human or non-human animal, such as primates, mammals, and vertebrates.
The phrase “pharmaceutically acceptable” is art-recognized. In certain embodiments, the term includes compositions, polymers and other materials and/or dosage forms which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of mammals, human beings and animals without excessive toxicity, irritation, allergic response, or other problem or complication, commensurate with a reasonable benefit/risk ratio.
The phrase “pharmaceutically acceptable carrier” is art-recognized, and includes, for example, pharmaceutically acceptable materials, compositions or vehicles, such as a liquid or solid filler, diluent, solvent or encapsulating material involved in carrying or transporting any subject composition, from one organ, or portion of the body, to another organ, or portion of the body. Each carrier must be “acceptable” in the sense of being compatible with the other ingredients of a subject composition and not injurious to the patient. In certain embodiments, a pharmaceutically acceptable carrier is non-pyrogenic. Some examples of materials which may serve as pharmaceutically acceptable carriers include: (1) sugars, such as lactose, glucose and sucrose; (2) starches, such as corn starch and potato starch; (3) cellulose, and its derivatives, such as sodium carboxymethyl cellulose, ethyl cellulose and cellulose acetate; (4) powdered tragacanth; (5) malt; (6) gelatin; (7) talc; (8) cocoa butter and suppository waxes; (9) oils, such as peanut oil, cottonseed oil, sunflower oil, sesame oil, olive oil, corn oil and soybean oil; (10) glycols, such as propylene glycol; (11) polyols, such as glycerin, sorbitol, mannitol and polyethylene glycol; (12) esters, such as ethyl oleate and ethyl laurate; (13) agar; (14) buffering agents, such as magnesium hydroxide and aluminum hydroxide; (15) alginic acid; (16) pyrogen-free water; (17) isotonic saline; (18) Ringer's solution; (19) ethyl alcohol; (20) phosphate buffer solutions; and (21) other non-toxic compatible substances employed in pharmaceutical formulations.
The term “prodrug” is intended to encompass compounds that, under physiological conditions, are converted into the therapeutically active agents of the present invention. A common method for making a prodrug is to include selected moieties that are hydrolyzed under physiological conditions to reveal the desired molecule. In other embodiments, the prodrug is converted by an enzymatic activity of the host animal.
The term “prophylactic or therapeutic” treatment is art-recognized and includes administration to the host of one or more of the subject compositions. If it is administered prior to clinical manifestation of the unwanted condition (e.g., disease or other unwanted state of the host animal) then the treatment is prophylactic, i.e., it protects the host against developing the unwanted condition, whereas if it is administered after manifestation of the unwanted condition, the treatment is therapeutic, (i.e., it is intended to diminish, ameliorate, or stabilize the existing unwanted condition or side effects thereof).
The term “predicting” as used herein refers to assessing the probability according to which a neurodegenerative condition or disorder such as Moderate to severe pain related diseases patient will suffer from abnormalities or complication and/or terminal platelet aggregation or failure and/or death (i.e. mortality) within a defined time window (predictive window) in the future. The mortality may be caused by the central nervous system or complication. The predictive window is an interval in which the subject will develop one or more of the said complications according to the predicted probability. The predictive window may be the entire remaining lifespan of the subject upon analysis by the method of the present invention.
The term “treating” is art-recognized and includes preventing a disease, disorder or condition from occurring in an animal which may be predisposed to the disease, disorder and/or condition but has not yet been diagnosed as having it; inhibiting the disease, disorder or condition, e.g., impeding its progress; and relieving the disease, disorder, or condition, e.g., causing regression of the disease, disorder and/or condition. Treating the disease or condition includes ameliorating at least one symptom of the particular disease or condition, even if the underlying pathophysiology is not affected, such as treating the neurological condition such as Moderate to severe pain of a subject by administration of an agent even though such agent does not treat the cause of the condition. The term “treating”, “treat” or “treatment” as used herein includes curative, preventative (e.g., prophylactic), adjunct and palliative treatment.
The phrase “therapeutically effective amount” is an art-recognized term. In certain embodiments, the term refers to an amount of a salt or composition disclosed herein that produces some desired effect at a reasonable benefit/risk ratio applicable to any medical treatment. In certain embodiments, the term refers to that amount necessary or sufficient to eliminate or reduce medical symptoms for a period of time. The effective amount may vary depending on such factors as the disease or condition being treated, the particular targeted constructs being administered, the size of the subject, or the severity of the disease or condition. One of ordinary skill in the art may empirically determine the effective amount of a particular composition without necessitating undue experimentation.
In certain embodiments, the pharmaceutical compositions described herein are formulated in a manner such that said compositions will be delivered to a patient in a therapeutically effective amount, as part of a prophylactic or therapeutic treatment. The desired amount of the composition to be administered to a patient will depend on absorption, inactivation, and excretion rates of the drug as well as the delivery rate of the salts and compositions from the subject compositions. It is to be noted that dosage values may also vary with the severity of the condition to be alleviated. It is to be further understood that for any particular subject, specific dosage regimens should be adjusted over time according to the individual need and the professional judgment of the person administering or supervising the administration of the compositions. Typically, dosing will be determined using techniques known to one skilled in the art.
Additionally, the optimal concentration and/or quantities or amounts of any particular salt or composition may be adjusted to accommodate variations in the treatment parameters. Such treatment parameters include the clinical use to which the preparation is put, e.g., the site treated, the type of patient, e.g., human or non-human, adult or child, and the nature of the disease or condition.
In certain embodiments, the dosage of the subject compositions provided herein may be determined by reference to the plasma concentrations of the therapeutic composition or other encapsulated materials. For example, the maximum plasma concentration (Cmax) and the area under the plasma concentration-time curve from time 0 to infinity may be used.
When used with respect to a pharmaceutical composition or other material, the term “sustained release” is art-recognized. For example, a subject composition which releases a substance over time may exhibit sustained release characteristics, in contrast to a bolus type administration in which the entire amount of the substance is made biologically available at one time. For example, in particular embodiments, upon contact with body fluids including blood, spinal fluid, mucus secretions, lymph or the like, one or more of the pharmaceutically acceptable excipients may undergo gradual or delayed degradation (e.g., through hydrolysis) with concomitant release of any material incorporated therein, e.g., an therapeutic and/or biologically active salt and/or composition, for a sustained or extended period (as compared to the release from a bolus). This release may result in prolonged delivery of therapeutically effective amounts of any of the therapeutic agents disclosed herein.
The phrases “systemic administration,” “administered systemically,” “peripheral administration” and “administered peripherally” are art-recognized, and include the administration of a subject composition, therapeutic or other material at a site remote from the disease being treated. Administration of an agent for the disease being treated, even if the agent is subsequently distributed systemically, may be termed “local” or “topical” or “regional” administration, other than directly into the central nervous system, e.g., by subcutaneous administration, such that it enters the patient's system and, thus, is subject to metabolism and other like processes.
The phrase “therapeutically effective amount” is an art-recognized term. In certain embodiments, the term refers to an amount of a salt or composition disclosed herein that produces some desired effect at a reasonable benefit/risk ratio applicable to any medical treatment. In certain embodiments, the term refers to that amount necessary or sufficient to eliminate or reduce medical symptoms for a period of time. The effective amount may vary depending on such factors as the disease or condition being treated, the particular targeted constructs being administered, the size of the subject, or the severity of the disease or condition. One of ordinary skill in the art may empirically determine the effective amount of a particular composition without necessitating undue experimentation.
The present disclosure also contemplates prodrugs of the compositions disclosed herein, as well as pharmaceutically acceptable salts of said prodrugs.
This application also discloses a pharmaceutical composition comprising a pharmaceutically acceptable carrier and the composition of a compound of Formula I may be formulated for systemic or topical or oral administration. The pharmaceutical composition may be also formulated for oral administration, oral solution, injection, subdermal administration, or transdermal administration. The pharmaceutical composition may further comprise at least one of a pharmaceutically acceptable stabilizer, diluent, surfactant, filler, binder, and lubricant.
In many embodiments, the pharmaceutical compositions described herein will incorporate the disclosed compounds and compositions (Formula I) to be delivered in an amount sufficient to deliver to a patient a therapeutically effective amount of a compound of formula I or composition as part of a prophylactic or therapeutic treatment. The desired concentration of formula I or its pharmaceutical acceptable salts will depend on absorption, inactivation, and excretion rates of the drug as well as the delivery rate of the salts and compositions from the subject compositions. It is to be noted that dosage values may also vary with the severity of the condition to be alleviated. It is to be further understood that for any particular subject, specific dosage regimens should be adjusted over time according to the individual need and the professional judgment of the person administering or supervising the administration of the compositions. Typically, dosing will be determined using techniques known to one skilled in the art.
Additionally, the optimal concentration and/or quantities or amounts of any particular compound of formula I may be adjusted to accommodate variations in the treatment parameters. Such treatment parameters include the clinical use to which the preparation is put, e.g., the site treated, the type of patient, e.g., human or non-human, adult or child, and the nature of the disease or condition.
The concentration and/or amount of any compound of formula I may be readily identified by routine screening in animals, e.g., rats, by screening a range of concentration and/or amounts of the material in question using appropriate assays. Known methods are also available to assay local tissue concentrations, diffusion rates of the salts or compositions, and local blood flow before and after administration of therapeutic formulations disclosed herein. One such method is microdialysis, as reviewed by T. E. Robinson et al., 1991, microdialysis in the neurosciences, Techniques, volume 7, Chapter 1. The methods reviewed by Robinson may be applied, in brief, as follows. A microdialysis loop is placed in situ in a test animal. Dialysis fluid is pumped through the loop. When compounds with formula I such as those disclosed herein are injected adjacent to the loop, released drugs are collected in the dialysate in proportion to their local tissue concentrations. The progress of diffusion of the salts or compositions may be determined thereby with suitable calibration procedures using known concentrations of salts or compositions.
In certain embodiments, the dosage of the subject compounds of formula I provided herein may be determined by reference to the plasma concentrations of the therapeutic composition or other encapsulated materials. For example, the maximum plasma concentration (Cmax) and the area under the plasma concentration-time curve from time 0 to infinity may be used.
Generally, in carrying out the methods detailed in this application, an effective dosage for the compounds of Formulas I is in the range of about 0.01 mg/kg/day to about 100 mg/kg/day in single or divided doses, for instance 0.01 mg/kg/day to about 50 mg/kg/day in single or divided doses. The compounds of Formulas I may be administered at a dose of, for example, less than 0.2 mg/kg/day, 0.5 mg/kg/day, 1.0 mg/kg/day, 5 mg/kg/day, 10 mg/kg/day, 20 mg/kg/day, 30 mg/kg/day, or 40 mg/kg/day. Compounds of Formula I may also be administered to a human patient at a dose of, for example, between 0.1 mg and 1000 mg, between 5 mg and 80 mg, or less than 1.0, 9.0, 12.0, 20.0, 50.0, 75.0, 100, 300, 400, 500, 800, 1000, 2000, 5000 mg per day. In certain embodiments, the compositions herein are administered at an amount that is less than 95%, 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, or 10% of the compound of formula I required for the same therapeutic benefit.
An effective amount of the compounds of formula I described herein refers to the amount of one of said salts or compositions which is capable of inhibiting or preventing a disease. For example Moderate to severe pain or any other medical condition.
An effective amount may be sufficient to prohibit, treat, alleviate, ameliorate, halt, restrain, slow or reverse the progression, or reduce the severity of a complication resulting from nerve damage or demyelization and/or elevated reactive oxidative-nitrosative species and/or abnormalities in neurotransmitter homeostasis's, in patients who are at risk for such complications. As such, these methods include both medical therapeutic (acute) and/or prophylactic (prevention) administration as appropriate. The amount and timing of compositions administered will, of course, be dependent on the subject being treated, on the severity of the affliction, on the manner of administration and on the judgment of the prescribing physician. Thus, because of patient-to-patient variability, the dosages given above are a guideline and the physician may titrate doses of the drug to achieve the treatment that the physician considers appropriate for the patient. In considering the degree of treatment desired, the physician must balance a variety of factors such as age of the patient, presence of preexisting disease, as well as presence of other diseases.
The compositions provided by this application may be administered to a subject in need of treatment by a variety of conventional routes of administration, including orally, topically, parenterally, e.g., intravenously, subcutaneously or intramedullary. Further, the compositions may be administered intranasally, as a rectal suppository, or using a “flash” formulation, i.e., allowing the medication to dissolve in the mouth without the need to use water. Furthermore, the compositions may be administered to a subject in need of treatment by controlled release dosage forms, site specific drug delivery, transdermal drug delivery, patch (active/passive) mediated drug delivery, by stereotactic injection, or in nanoparticles.
The compositions may be administered alone or in combination with pharmaceutically acceptable carriers, vehicles or diluents, in either single or multiple doses. Suitable pharmaceutical carriers, vehicles and diluents include inert solid diluents or fillers, sterile aqueous solutions and various organic solvents. The pharmaceutical compositions formed by combining the compositions and the pharmaceutically acceptable carriers, vehicles or diluents are then readily administered in a variety of dosage forms such as tablets, powders, lozenges, syrups, injectable solutions and the like. These pharmaceutical compositions can, if desired, contain additional ingredients such as flavorings, binders, excipients and the like. Thus, for purposes of oral administration, tablets containing various excipients such as L-arginine, sodium citrate, calcium carbonate and calcium phosphate may be employed along with various disintegrates such as starch, alginic acid and certain complex silicates, together with binding agents such as polyvinylpyrrolidone, sucrose, gelatin and acacia. Additionally, lubricating agents such as magnesium stearate, sodium lauryl sulfate and talc are often useful for tabletting purposes. Solid compositions of a similar type may also be employed as fillers in soft and hard filled gelatin capsules. Appropriate materials for this include lactose or milk sugar and high molecular weight polyethylene glycols. When aqueous suspensions or elixirs are desired for oral administration, the essential active ingredient therein may be combined with various sweetening or flavoring agents, coloring matter or dyes and, if desired, emulsifying or suspending agents, together with diluents such as water, ethanol, propylene glycol, glycerin and combinations thereof. The compounds of formula I may also comprise enterically coated comprising of various excipients, as is well known in the pharmaceutical art.
For parenteral administration, solutions of the compositions may be prepared in (for example) sesame or peanut oil, aqueous propylene glycol, or in sterile aqueous solutions may be employed. Such aqueous solutions should be suitably buffered if necessary and the liquid diluent first rendered isotonic with sufficient saline or glucose. These particular aqueous solutions are especially suitable for intravenous, intramuscular, subcutaneous and intraperitoneal administration. In this connection, the sterile aqueous media employed are all readily available by standard techniques known to those skilled in the art.
The formulations, for instance tablets, may contain e.g. 10 to 100, 50 to 250, 150 to 500 mg, or 350 to 800 mg e.g. 10, 50, 100, 300, 500, 700, 800 mg of the compounds of formula I disclosed herein, for instance, compounds of formula I or pharmaceutical acceptable salts of a compounds of Formula I.
Generally, a composition as described herein may be administered orally, or parenterally (e.g., intravenous, intramuscular, subcutaneous or intramedullary). Topical administration may also be indicated, for example, where the patient is suffering from gastrointestinal disorder that prevent oral administration, or whenever the medication is best applied to the surface of a tissue or organ as determined by the attending physician. Localized administration may also be indicated, for example, when a high dose is desired at the target tissue or organ. For buccal administration the active composition may take the form of tablets or lozenges formulated in a conventional manner.
The dosage administered will be dependent upon the identity of the neurological disease; the type of host involved, including its age, health and weight; the kind of concurrent treatment, if any; the frequency of treatment and therapeutic ratio.
Illustratively, dosage levels of the administered active ingredients are: intravenous, 0.1 to about 200 mg/kg; intramuscular, 1 to about 500 mg/kg; orally, 5 to about 1000 mg/kg; intranasal instillation, 5 to about 1000 mg/kg; and aerosol, 5 to about 1000 mg/kg of host body weight.
Expressed in terms of concentration, an active ingredient can be present in the compositions of the present invention for localized use about the cutis, intranasally, pharyngolaryngeally, bronchially, intravaginally, rectally, or ocularly in a concentration of from about 0.01 to about 50% w/w of the composition; preferably about 1 to about 20% w/w of the composition; and for parenteral use in a concentration of from about 0.05 to about 50% w/v of the composition and preferably from about 5 to about 20% w/v.
The compositions of the present invention are preferably presented for administration to humans and animals in unit dosage forms, such as tablets, capsules, pills, powders, granules, suppositories, sterile parenteral solutions or suspensions, sterile non-parenteral solutions of suspensions, and oral solutions or suspensions and the like, containing suitable quantities of an active ingredient. For oral administration either solid or fluid unit dosage forms can be prepared.
As discussed above, the tablet core contains one or more hydrophilic polymers. Suitable hydrophilic polymers include, but are not limited to, water swellable cellulose derivatives, polyalkylene glycols, thermoplastic polyalkylene oxides, acrylic polymers, hydrocolloids, clays, gelling starches, swelling cross-linked polymers, and mixtures thereof. Examples of suitable water swellable cellulose derivatives include, but are not limited to, sodium carboxymethylcellulose, cross-linked hydroxypropylcellulose, hydroxypropyl cellulose (HPC), hydroxypropylmethylcellulose (HPMC), hydroxyisopropylcellulose, hydroxybutylcellulose, hydroxyphenylcellulose, hydroxyethylcellulose (HEC), hydroxypentylcellulose, hydroxypropylethylcellulose, hydroxypropylbutylcellulose, and hydroxypropylethylcellulose, and mixtures thereof. Examples of suitable polyalkylene glycols include, but are not limited to, polyethylene glycol. Examples of suitable thermoplastic polyalkylene oxides include, but are not limited to, poly(ethylene oxide). Examples of suitable acrylic polymers include, but are not limited to, potassium methacrylatedivinylbenzene copolymer, polymethylmethacrylate, high-molecular weight crosslinked acrylic acid homopolymers and copolymers such as those commercially available from Noveon Chemicals under the tradename CARBOPOL™. Examples of suitable hydrocolloids include, but are not limited to, alginates, agar, guar gum, locust bean gum, kappa carrageenan, iota carrageenan, tara, gum arabic, tragacanth, pectin, xanthan gum, gellan gum, maltodextrin, galactomannan, pusstulan, laminarin, scleroglucan, gum arabic, inulin, pectin, gelatin, whelan, rhamsan, zooglan, methylan, chitin, cyclodextrin, chitosan, and mixtures thereof. Examples of suitable clays include, but are not limited to, smectites such as bentonite, kaolin, and laponite; magnesium trisilicate; magnesium aluminum silicate; and mixtures thereof. Examples of suitable gelling starches include, but are not limited to, acid hydrolyzed starches, swelling starches such as sodium starch glycolate and derivatives thereof, and mixtures thereof. Examples of suitable swelling cross-linked polymers include, but are not limited to, cross-linked polyvinyl pyrrolidone, cross-linked agar, and cross-linked carboxymethylcellulose sodium, and mixtures thereof.
The carrier may contain one or more suitable excipients for the formulation of tablets. Examples of suitable excipients include, but are not limited to, fillers, adsorbents, binders, disintegrants, lubricants, glidants, release-modifying excipients, superdisintegrants, antioxidants, and mixtures thereof.
Suitable binders include, but are not limited to, dry binders such as polyvinyl pyrrolidone and hydroxypropylmethylcellulose; wet binders such as water-soluble polymers, including hydrocolloids such as acacia, alginates, agar, guar gum, locust bean, carrageenan, carboxymethylcellulose, tara, gum arabic, tragacanth, pectin, xanthan, gellan, gelatin, maltodextrin, galactomannan, pusstulan, laminarin, scleroglucan, inulin, whelan, rhamsan, zooglan, methylan, chitin, cyclodextrin, chitosan, polyvinyl pyrrolidone, cellulosics, sucrose, and starches; and mixtures thereof. Suitable disintegrants include, but are not limited to, sodium starch glycolate, cross-linked polyvinylpyrrolidone, cross-linked carboxymethylcellulose, starches, microcrystalline cellulose, and mixtures thereof.
Suitable lubricants include, but are not limited to, long chain fatty acids and their salts, such as magnesium stearate and stearic acid, talc, glycerides waxes, and mixtures thereof. Suitable glidants include, but are not limited to, colloidal silicon dioxide. Suitable release-modifying excipients include, but are not limited to, insoluble edible materials, pH-dependent polymers, and mixtures thereof.
Suitable insoluble edible materials for use as release-modifying excipients include, but are not limited to, water-insoluble polymers and low-melting hydrophobic materials, copolymers thereof, and mixtures thereof. Examples of suitable water-insoluble polymers include, but are not limited to, ethylcellulose, polyvinyl alcohols, polyvinyl acetate, polycaprolactones, cellulose acetate and its derivatives, acrylates, methacrylates, acrylic acid copolymers, copolymers thereof, and mixtures thereof. Suitable low-melting hydrophobic materials include, but are not limited to, fats, fatty acid esters, phospholipids, waxes, and mixtures thereof. Examples of suitable fats include, but are not limited to, hydrogenated vegetable oils such as for example cocoa butter, hydrogenated palm kernel oil, hydrogenated cottonseed oil, hydrogenated sunflower oil, and hydrogenated soybean oil, free fatty acids and their salts, and mixtures thereof. Examples of suitable fatty acid esters include, but are not limited to, sucrose fatty acid esters, mono-, di-, and triglycerides, glyceryl behenate, glyceryl palmitostearate, glyceryl monostearate, glyceryl tristearate, glyceryl trilaurylate, glyceryl myristate, GlycoWax-932, lauroyl macrogol-32 glycerides, stearoyl macrogol-32 glycerides, and mixtures thereof. Examples of suitable phospholipids include phosphotidyl choline, phosphotidyl serene, phosphotidyl enositol, phosphotidic acid, and mixtures thereof. Examples of suitable waxes include, but are not limited to, carnauba wax, spermaceti wax, beeswax, candelilla wax, shellac wax, microcrystalline wax, and paraffin wax; fat-containing mixtures such as chocolate, and mixtures thereof. Examples of super disintegrants include, but are not limited to, croscarmellose sodium, sodium starch glycolate and cross-linked povidone (crospovidone). In one embodiment the tablet core contains up to about 5 percent by weight of such super disintegrant.
Examples of antioxidants include, but are not limited to, tocopherols, ascorbic acid, sodium pyrosulfite, butylhydroxytoluene, butylated hydroxyanisole, edetic acid, and edetate salts, and mixtures thereof. Examples of preservatives include, but are not limited to, citric acid, tartaric acid, lactic acid, malic acid, acetic acid, benzoic acid, and sorbic acid, and mixtures thereof.
In one embodiment, the immediate release coating has an average thickness of at least 50 microns, such as from about 50 microns to about 2500 microns; e.g., from about 250 microns to about 1000 microns. In embodiment, the immediate release coating is typically compressed at a density of more than about 0.9 g/cc, as measured by the weight and volume of that specific layer.
In one embodiment, the immediate release coating contains a first portion and a second portion, wherein at least one of the portions contains the second pharmaceutically active agent. In one embodiment, the portions contact each other at a center axis of the tablet. In one embodiment, the first portion includes the first pharmaceutically active agent and the second portion includes the second pharmaceutically active agent.
In one embodiment, the first portion contains the first pharmaceutically active agent and the second portion contains the second pharmaceutically active agent. In one embodiment, one of the portions contains a third pharmaceutically active agent. In one embodiment one of the portions contains a second immediate release portion of the same pharmaceutically active agent as that contained in the tablet core.
In one embodiment, the outer coating portion is prepared as a dry blend of materials prior to addition to the coated tablet core. In another embodiment the outer coating portion is included of a dried granulation including the pharmaceutically active agent.
Formulations with different drug release mechanisms described above could be combined in a final dosage form containing single or multiple units. Examples of multiple units include multilayer tablets, capsules containing tablets, beads, or granules in a solid or liquid form. Typical, immediate release formulations include compressed tablets, gels, films, coatings, liquids and particles that can be encapsulated, for example, in a gelatin capsule. Many methods for preparing coatings, covering or incorporating drugs, are known in the art.
The immediate release dosage, unit of the dosage form, i.e., a tablet, a plurality of drug-containing beads, granules or particles, or an outer layer of a coated core dosage form, contains a therapeutically effective quantity of the active agent with conventional pharmaceutical excipients. The immediate release dosage unit may or may not be coated, and may or may not be admixed with the delayed release dosage unit or units (as in an encapsulated mixture of immediate release drug-containing granules, particles or beads and delayed release drug-containing granules or beads).
Extended release formulations are generally prepared as diffusion or osmotic systems, for example, as described in “Remington—The Science and Practice of Pharmacy”, 20th. Ed., Lippincott Williams & Wilkins, Baltimore, Md., 2000). A diffusion system typically consists of one of two types of devices, reservoir and matrix, which are wellknown and described in die art. The matrix devices are generally prepared by compressing the drug with a slowly dissolving polymer carrier into a tablet form.
An immediate release portion can be added to the extended release system by means of either applying an immediate release layer on top of the extended release core; using coating or compression processes or in a multiple unit system such as a capsule containing extended and immediate release beads.
Delayed release dosage formulations are created by coating a solid dosage form with a film of a polymer which is insoluble in the acid environment of the stomach, but soluble in the neutral environment of small intestines. The delayed release dosage units can be prepared, for example, by coating a drug or a drug-containing composition with a selected coating material. The drug-containing composition may be a tablet for incorporation into a capsule, a tablet for use as an inner core in a “coated core” dosage form, or a plurality of drug-containing beads, particles or granules, for incorporation into either a tablet or capsule.
A pulsed release dosage form is one that mimics a multiple dosing profile without repeated dosing and typically allows at least a twofold reduction in dosing frequency as compared to the drug presented as a conventional dosage form (e.g., as a solution or prompt drug-releasing, conventional solid dosage form). A pulsed release profile is characterized by a time period of no release (lag time) or reduced release followed by rapid drug release.
Each dosage form contains a therapeutically effective amount of active agent. In one embodiment of dosage forms that mimic a twice daily dosing profile, approximately 30 wt. % to 70 wt. %, preferably 40 wt. % to 60 wt. %, of the total amount of active agent in the dosage form is released in the initial pulse, and, correspondingly approximately 70 wt. % to 3.0 wt. %, preferably 60 wt. % to 40 wt. %, of the total amount of active agent in the dosage form is released in the second pulse. For dosage forms mimicking the twice daily dosing profile, the second pulse is preferably released approximately 3 hours to less than 14 hours, and more preferably approximately 5 hours to 12 hours, following administration.
Another dosage form contains a compressed tablet or a capsule having a drug-containing immediate release dosage unit, a delayed release dosage unit and an optional second delayed release dosage unit. In this dosage form, the immediate release dosage unit contains a plurality of beads, granules particles that release drug substantially immediately following oral administration to provide an initial dose. The delayed release dosage unit contains a plurality of coated beads or granules, which release drug approximately 3 hours to 14 hours following oral administration to provide a second dose.
For purposes of transdermal (e.g., topical) administration, dilute sterile, aqueous or partially aqueous solutions (usually in about 0.1% to 5% concentration), otherwise similar to the above parenteral solutions, may be prepared.
Methods of preparing various pharmaceutical compositions with a certain amount of one or more compounds of formula I or other active agents are known, or will be apparent in light of this disclosure, to those skilled in this art. For examples of methods of preparing pharmaceutical compositions, see Remington's Pharmaceutical Sciences, Mack Publishing Company, Easton, Pa., 19th Edition (1995).
In addition, in certain embodiments, subject compositions of the present application maybe lyophilized or subjected to another appropriate drying technique such as spray drying. The subject compositions may be administered once, or may be divided into a number of smaller doses to be administered at varying intervals of time, depending in part on the release rate of the compositions and the desired dosage.
Formulations useful in the methods provided herein include those suitable for oral, nasal, topical (including buccal and sublingual), rectal, vaginal, aerosol and/or parenteral administration. The formulations may conveniently be presented in unit dosage form and may be prepared by any methods well known in the art of pharmacy. The amount of a subject composition which may be combined with a carrier material to produce a single dose may vary depending upon the subject being treated, and the particular mode of administration.
Methods of preparing these formulations or compositions include the step of bringing into association subject compositions with the carrier and, optionally, one or more accessory ingredients. In general, the formulations are prepared by uniformly and intimately bringing into association a subject composition with liquid carriers, or finely divided solid carriers, or both, and then, if necessary, shaping the product.
The compounds of formula I described herein may be administered in inhalant or aerosol formulations. The inhalant or aerosol formulations may comprise one or more agents, such as adjuvants, diagnostic agents, imaging agents, or therapeutic agents useful in inhalation therapy. The final aerosol formulation may for example contain 0.005-90% w/w, for instance 0.005-50%, 0.005-5% w/w, or 0.01-1.0% w/w, of medicament relative to the total weight of the formulation.
In solid dosage forms for oral administration (capsules, tablets, pills, dragees, powders, granules and the like), the subject composition is mixed with one or more pharmaceutically acceptable carriers and/or any of the following: (1) fillers or extenders, such as starches, lactose, sucrose, glucose, mannitol, and/or silicic acid; (2) binders, such as, for example, carboxymethylcellulose, alginates, gelatin, polyvinyl pyrrolidone, sucrose and/or acacia; (3) humectants, such as glycerol; (4) disintegrating agents, such as agar-agar, calcium carbonate, potato or tapioca starch, alginic acid, certain silicates, and sodium carbonate; (5) solution retarding agents, such as paraffin; (6) absorption accelerators, such as quaternary ammonium compounds; (7) wetting agents, such as, for example, acetyl alcohol and glycerol monostearate; (8) absorbents, such as kaolin and bentonite clay; (9) lubricants, such a talc, calcium stearate, magnesium stearate, solid polyethylene glycols, sodium lauryl sulfate, and mixtures thereof; and (10) coloring agents. In the case of capsules, tablets and pills, the pharmaceutical compositions may also comprise buffering agents. Solid compositions of a similar type may also be employed as fillers in soft and hard-filled gelatin capsules using lactose or milk sugars, as well as high molecular weight polyethylene glycols and the like.
Liquid dosage forms for oral administration include pharmaceutically acceptable emulsions, microemulsions, solutions, suspensions, syrups and elixirs. In addition to the subject compositions, the liquid dosage forms may contain inert diluents commonly used in the art, such as, for example, water or other solvents, solubilizing agents and emulsifiers, such as ethyl alcohol, isopropyl alcohol, ethyl carbonate, ethyl acetate, benzyl alcohol, benzyl benzoate, propylene glycol, 1,3-butylene glycol, oils (in particular, cottonseed, corn, peanut, sunflower, soybean, olive, castor, and sesame oils), glycerol, tetrahydrofuryl alcohol, polyethylene glycols and fatty acid esters of sorbitan, and mixtures thereof.
Suspensions, in addition to the subject compositions, may contain suspending agents such as, for example, ethoxylated isostearyl alcohols, polyoxyethylene sorbitol, and sorbitan esters, microcrystalline cellulose, aluminum metahydroxide, bentonite, agar-agar and tragacanth, and mixtures thereof.
Formulations for rectal or vaginal administration may be presented as a suppository, which may be prepared by mixing a subject composition with one or more suitable non-irritating carriers comprising, for example, cocoa butter, polyethylene glycol, a suppository wax, or a salicylate, and which is solid at room temperature, but liquid at body temperature and, therefore, will melt in the appropriate body cavity and release the encapsulated compound(s) and composition(s). Formulations which are suitable for vaginal administration also include pessaries, tampons, creams, gels, pastes, foams, or spray formulations containing such carriers as are known in the art to be appropriate.
Dosage forms for transdermal administration include powders, sprays, ointments, pastes, creams, lotions, gels, solutions, patches, and inhalants. A subject composition may be mixed under sterile conditions with a pharmaceutically acceptable carrier, and with any preservatives, buffers, or propellants that may be required. For transdermal administration, the complexes may include lipophilic and hydrophilic groups to achieve the desired water solubility and transport properties.
The ointments, pastes, creams and gels may contain, in addition to subject compositions, other carriers, such as animal and vegetable fats, oils, waxes, paraffins, starch, tragacanth, cellulose derivatives, polyethylene glycols, silicones, bentonites, silicic acid, talc and zinc oxide, or mixtures thereof. Powders and sprays may contain, in addition to a subject composition, excipients such as lactose, talc, silicic acid, aluminum hydroxide, calcium silicates and polyamide powder, or mixtures of such substances. Sprays may additionally contain customary propellants, such as chlorofluorohydrocarbons and volatile unsubstituted hydrocarbons, such as butane and propane.
Methods of delivering a composition or compositions via a transdermal patch are known in the art. Exemplary patches and methods of patch delivery are described in U.S. Pat. Nos. 6,974,588, 6,564,093, 6,312,716, 6,440,454, 6,267,983, 6,239,180, and 6,103,275.
In another embodiment, a transdermal patch may comprise: a substrate sheet comprising a composite film formed of a resin composition comprising 100 parts by weight of a polyvinyl chloride-polyurethane composite and 2-10 parts by weight of a styrene-ethylene-butylene-styrene copolymer, a first adhesive layer on the one side of the composite film, and a polyalkylene terephthalate film adhered to the one side of the composite film by means of the first adhesive layer, a primer layer which comprises a saturated polyester resin and is formed on the surface of the polyalkylene terephthalate film; and a second adhesive layer comprising a styrene-diene-styrene block copolymer containing a pharmaceutical agent layered on the primer layer. A method for the manufacture of the above-mentioned substrate sheet comprises preparing the above resin composition molding the resin composition into a composite film by a calendar process, and then adhering a polyalkylene terephthalate film on one side of the composite film by means of an adhesive layer thereby forming the substrate sheet, and forming a primer layer comprising a saturated polyester resin on the outer surface of the polyalkylene terephthalate film.
Another type of patch comprises incorporating the drug directly in a pharmaceutically acceptable adhesive and laminating the drug-containing adhesive onto a suitable backing member, e.g. a polyester backing membrane. The drug should be present at a concentration which will not affect the adhesive properties, and at the same time deliver the required clinical dose.
Transdermal patches may be passive or active. Passive transdermal drug delivery systems currently available, such as the nicotine, estrogen and nitroglycerine patches, deliver small-molecule drugs. Many of the newly developed proteins and peptide drugs are too large to be delivered through passive transdermal patches and may be delivered using technology such as electrical assist (iontophoresis) for large-molecule drugs.
Iontophoresis is a technique employed for enhancing the flux of ionized substances through membranes by application of electric current. One example of an iontophoretic membrane is given in U.S. Pat. No. 5,080,646 to Theeuwes. The principal mechanisms by which iontophoresis enhances molecular transport across the skin are (a) repelling a charged ion from an electrode of the same charge, (b) electroosmosis, the convective movement of solvent that occurs through a charged pore in response the preferential passage of counter-ions when an electric field is applied or (c) increase skin permeability due to application of electrical current.
In some cases, it may be desirable to administer in the form of a kit, it may comprise a container for containing the separate compositions such as a divided bottle or a divided foil packet. Typically the kit comprises directions for the administration of the separate components. The kit form is particularly advantageous when the separate components are preferably administered in different dosage forms (e.g., oral and parenteral), are administered at different dosage intervals, or when titration of the individual components of the combination is desired by the prescribing physician.
An example of such a kit is a so-called blister pack. Blister packs are well known in the packaging industry and are widely used for the packaging of pharmaceutical unit dosage forms (tablets, capsules, and the like). Blister packs generally consist of a sheet of relatively stiff material covered with a foil of a plastic material that may be transparent. During the packaging process recesses are formed in the plastic foil. The recesses have the size and shape of the tablets or capsules to be packed. Next, the tablets or capsules are placed in the recesses and the sheet of relatively stiff material is sealed against the plastic foil at the face of the foil which is opposite from the direction in which the recesses were formed. As a result, the tablets or capsules are sealed in the recesses between the plastic foil and the sheet. In some embodiments the strength of the sheet is such that the tablets or capsules can be removed from the blister pack by manually applying pressure on the recesses whereby an opening is formed in the sheet at the place of the recess. The tablet or capsule can then be removed via said opening.
Methods and compositions for the treatment of moderate to severe pain. Among other things, herein is provided a method of treating moderate to severe pain, comprising administering to a patient in need thereof a therapeutically effective amount of compound of Formula I:
Wherein,
R 1 represents H, D, —OCH 3 , —OCD 3 ,
R 2 represents
a is independently 2, 3 or 7;
each b is independently 3, 5 or 6;
e is independently 1, 2 or 6;
c and d are each independently H, D, —OH, —OD, C 1 -C 6 -alkyl, —NH 2 or —COCH 3 ;
n is independently 1, 2, 3, 4 or 5.
Methods for Using Compounds of Formula I:
The invention also includes methods for treating pain, pain due to injury, post-operative pain, osteoarthritis, rheumatoid arthritis, multiple sclerosis, spinal cord injury, migraine, HIV related neuropathic pain, post herpetic neuralgia, diabetic neuropathy, bipolar depression, depression, stress, cancer pain, fibromyalgia and lower back pain or any other medical condition related to severe pain.
Methods of Making
Examples of synthetic pathways useful for making compounds of formula I are set forth in example below and generalized in scheme 1 and scheme 2:
Step-1: Synthesis of Compound 2:
To a mechanically stirred solution of 2,6-dichloroaniline 1 (76 g, 0.047 mol) in 60 mL of glacial acetic acid is added dropwise acetyl chloride (36 mL, 0.5 mol). After the addition is complete, the reaction mixture is heated at 90° C. for 20 minutes. The solution is poured into ice water (500 mL), forming a white precipitate. The solids are filtered, washed with water and dried to give the product 2 (91.8 g, 96%, white solid, m.p. 179-180° C., lit. m.p. 180-181° C. from glacial acetic acid).
Step-2: Synthesis of Compound 4:
15 g of compound 2 are dissolved in 150 ml of bromobenzene 3, Five and a half grams of calcinated potassium carbonate and 0.5 g of copper powder are added The mixture is refluxed for 4 days the water formed being removed by a water separator cooled and subjected to steam distillation The residue is extracted with 200 ml of ether The ether solution is filtered through Hyflo and the residue is concentrated to dryness under 11 torr. The residue is dissolved in 60 ml of ethanolic potassium hydroxide and the solution is refluxed for 3 hours. The solution is then concentrated to dryness at 40 under 11 torr. Ten milliliters of water are added to the residue which is then extracted with 100 ml of ether. The ether solution is removed and extracted with 20 ml of water. The ether solution is then dried with sodium sulfate and concentrated to dryness under 11 torr. The residue was distilled under high vacuum to yield compound 4 as yellow oil at 115° C./0.01 torr.
Step-3:
Synthesis of compound 6:
4 g of compound 4 and 40 ml of freshly distilled chloroacetyl chloride 5 were refluxed for 1 hour. The dark solution was evaporated under 11 torr at a bath temperature of 50° C. The residue was dissolved in 70 ml of ethyl acetate/ether 1:1. This solution was extracted with 10 ml of 2 N potassium bicarbonate solution and 10 ml of water dried over sodium sulfate and evaporated under 11 torr. The compound 6 was recrystallised from methanol MP 143° C.
Step-4: Synthesis of Compound 7:
4 g of compound 6 and 4 g of aluminium chloride are well mixed and heated for 2 hours at 160° C. The melt was cooled and poured onto about 50 g of ice while still warm. The oil which separates was dissolved in 50 ml of chloroform. The chloroform solution was washed with 10 ml of water dried over sodium sulfate and concentrated under 11 torr. The residue was distilled. Compound 7 obtained was crystallised from methanol MP 126° C.
Step-5: Synthesis of Compound 8:
A solution of 40 g of compound 7 in 280 ml of 1 N sodium hydroxide solution and 420 ml of ethanol was refluxed for 2 hours. The clear solution was cooled and the ethanol was distilled off at a bath temperature of 40 under 11 torr. The aqueous residue was extracted with 100 ml of ether. The ether was removed and the aqueous solution was cooled by the addition of ice about 50 g and external cooling to 5° C. 2 N of hydrochloric acid was then added while stirring until the pH of the solution was about 6. The precipitated acid was taken up in 400 ml of ether, the ether solution was separated and the aqueous solution was again extracted with 200 ml of ether. The ether solutions are washed with 50 ml of water combined dried over sodium sulfate and concentrated under 11 torr without heating. After adding petroleum ether to the concentrated ethereal solution the compound 8 crystallizes. After recrysallisation from ether/petroleum ether it melts at 156-158° C.
Step-6: Synthesis of Compound 10:
Compound 8 (10 mmol) and 5 ml of SOCl 2 were refluxed for 2 h to get acid chloride. Excess SOCl 2 was distilled off and the acid chloride was directly used. Compound 9 was suspended in DCM at 0° C. and added DIPEA (12 mmol). The reaction mixture was stirred for 30 min and then added acid chloride in DCM to the reaction mixture dropwise at 0° C. The reaction mixture was stirred at room temperature for 4 h. After completion of the reaction, the reaction mixture was diluted with DCM and added water. The layers were separated and the organic layer was washed with saturated NaHCO 3 and evaporated to get the residue. The residue was purified through column to get compound 10. M.F: C 22 H 23 C 12 NO 3 S 2 ; Mol. Wt.: 483.05; Elemental Analysis: C, 54.54; H, 4.79; Cl, 14.64; N, 2.89; 0, 9.91; S, 13.24.
Step 1: Synthesis of [2-(2,6-Dichloro-phenylamino)-phenyl]-acetic acid] (2)
To a stirred solution of 1-(2,6-Dichloro-phenyl)-1,3-dihydro-indol-2-one 1 (10 g, 0.03 mol) in toluene (340 mL) was added aq. NaOH (2N, 34 mL)) at rt. The resulting mixture was stirred at 90° C. for 16 h. After completion, clear solution was cooled in an ice bath and acidified with con. HCl. The precipitated solid was filtered, washed with ethanol and dried under reduced pressure to get 9.0 g (84.4% yield) of Compound 2 as an off white solid. Used in the next step without any further purification; Mass: 294.1 (M−H); 1 H-NMR (400 MHz, DMSO): 12.70 (s, 1H), 7.53-7.51 (d, J=8.0 Hz, 2H), 7.24-7.16 (m, 3H), 7.08-7.03 (m, 1H), 6.87-6.83 (m, 1H), 6.28-6.26 (d, J=7.8 Hz, 1H), 3.69 (s, 2H); 13 C-NMR (400 MHz; DMSO): 173.86, 142.66, 137.11, 130.89, 130.04, 129.17, 127.51, 125.56, 123.89, 120.76, 115.95, 37.74.
Step 2: Synthesis of [2-(2,6-Dichloro-phenylamino)-phenyl]-acetic acid 2-tert-butoxycarbonylamino-ethyl ester (4)
To a stirred solution of [2-(2,6-Dichloro-phenylamino)-phenyl]-acetic acid] 2 (4.0 g, 0.01 mol, 1 eq) and N-BOC-Ethanolamine (2.39 g, 0.01 mol) in DCM (70 mL) was added DMAP (0.16 g, 0.001 mol) at rt. To this mixture was added DCC (5.5 g, 0.02 mol) in DCM (30 mL) drop-wise at 0-5° C. and resulting mixture was stirred at room temperature for 1 h. Reaction was monitored by TLC. After completion, reaction mixture was filtered and the solvent was removed under reduced pressure. Residue was dissolved in water (100 mL) and extracted with DCM (2×50 mL). Combined organic layer was dried over anhydrous Na 2 SO 4 and evaporated under reduced pressure to obtained crude compound which was washed with hexane (2×20 mL), dried to get 6.0 g crude of Compound 4 and cyclized compound 1 as an off white solid. This mixture was used in the next step without any further purification: Mass: 439.3 (M + +H).
Step 3: Synthesis of [2-(2,6-Dichloro-phenylamino)-phenyl]-acetic acid 2-amino-ethyl ester (5)
To a stirred solution of [2-(2,6-Dichloro-phenylamino)-phenyl]-acetic acid 2-tert-butoxycarbonylamino-ethyl ester 4 (5.3 g, 0.01 mol) in DCM (50 mL) was added TFA (5.3 mL) at 0° C. The resulting mixture was stirred at room temperature for 16 h. Reaction was monitored by TLC. After completion, reaction mixture was concentrated under reduced pressure. The residue was neutralized with aq sodium bicarbonate and extracted with DCM (2×50 mL). Combined organic layer was dried over anhy Na 2 SO 4 and evaporated under reduced pressure. Crude compound was purified by silica gel column chromatography using methanol and DCM (5:95) to get 1.0 g (24.4% Yield) Compound-5 as a brown solid; Mass: 339.0 (M + +H).
Step 4: Synthesis of [2-(2,6-Dichloro-phenylamino)-phenyl]-acetic acid 2-[3-((R)-2,4-dihydroxy-3,3-dimethyl-butyrylamino)-propionylamino]-ethyl ester (CLX-SYN-G18-C01)
To a stirred solution of 3-((R)-2,4-Dihydroxy-3,3-dimethyl-butyrylamino)-propionic acid 6 (0.2 g, 0.0007 mol, 1 eq) in DMF (4 mL) was added triethyl amine (0.31 g, 0.003 mol), EDC.HCl (0.22 g, 0.001 mol), HOBt (0.15 g, 0.001 mol) and [2-(2,6-Dichloro-phenylamino)-phenyl]-acetic acid 2-amino-ethyl ester 5 (0.26 g, 0.0007 mol, 1 eq) at rt. The resulting mixture was stirred at room temperature for 16 h. Reaction was monitored by TLC. After completion, reaction mixture was diluted with water (10 mL) and extracted with ethyl acetate (2×20 mL). Combined organic layer was dried over anhydrous Na 2 SO 4 and evaporated under reduced pressure and purified by silica gel column chromatography using Methanol and DCM (3:97) to get 0.11 g (26.4% Yield) of CLX-SYN-G18-C01 as an off white solid; Mass: 539.9 [M+H].
EQUIVALENTS
The present disclosure provides among other things compositions and methods for treating moderate to moderate to severe pain and their complications. While specific embodiments of the subject disclosure have been discussed, the above specification is illustrative and not restrictive. Many variations of the systems and methods herein will become apparent to those skilled in the art upon review of this specification. The full scope of the claimed systems and methods should be determined by reference to the claims, along with their full scope of equivalents, and the specification, along with such variations.
INCORPORATION BY REFERENCE
All publications and patents mentioned herein, including those items listed above, are hereby incorporated by reference in their entirety as if each individual publication or patent was specifically and individually indicated to be incorporated by reference. In case of conflict, the present application, including any definitions herein, will control. | The invention relates to the compounds of formula I or its pharmaceutical acceptable salts, as well as polymorphs, solvates, enantiomers, stereoisomers and hydrates thereof. The pharmaceutical compositions comprising an effective amount of compounds of formula I; and methods for treating or preventing moderate to severe pain, may be formulated for oral, buccal, rectal, topical, transdermal, transmucosal, intravenous, parenteral administration, syrup, or injection. Such compositions may be used to treatment of muscle pain, spasticity, neuropathic pain, fibromyalgia, post-operative pain, muscle spasticity, headache, chronic pain, sub-chronic pain and local pain. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to processes for the production of antistatic filaments using specific apparati for carrying out these processes. The apparatus which is most preferred is classified under coating apparatus having a solid applicator which supports strand form work. The applicator is movably mounted, rotates, and utilizes force or fountain feed.
2. Description of the Prior Art
The closest prior art patents with respect to the present invention are U.S. Pat. No. 3,823,035 and U.S. Pat. No. 4,255,487, and U.S. Pat. No. 4,545,835 which are hereby incorporated by reference. These patents describe broad, generalized processes for making antistatic filaments which are virtually identical to the filaments made by the process of the present invention. However, these processes differ from the process of the instant invention in that different mixes are applied and different mix application means are utilized, as described in detail below.
Other patents which are much more distantly related to the present invention include: U.S. Pat. No. 3,582,445; U.S. Pat. No. 3,040,703; U.S. Pat. No. 3,749,055; U.S. Pat. No. 2,269,150; U.S. Pat. No. 2,380,422; U.S. Pat. No. 3,971,202 and U.S. Pat. No. 3,401,542. Most of these patents described filament coating means which are closely related to the coating means described herein.
BRIEF SUMMARY OF THE INVENTION
The present invention pertains to an improved process for making conductive textile fiber by suffusing a dispersion of finely-divided, electrically-conductive particles into a non-conductive, filamentary polymer substrate. The particles are applied to the substrate in an amount sufficient to render the electrical resistance of the textile not more than about 10 9 ohms/cm in a liquid which is a solvent for the substrate but does not react with the electrically conductive particles. The solvent is removed from the substrate after a desired degree of penetration has taken place in the annular region located at the periphery of the filament and before the structural integrity of the substrate has been destroyed. The improvement found in the present invention comprises: applying a mix to the nonconductive filamentary substrate with a grooved, roll-type mix applicator, the mix being comprised of a dispersion of electrically conductive particles in a liquid solvent wherein the liquid solvent will dissolve the substrate and will flash evaporate at 150° C., and wherein the solvent is a mixture of formic acid and member selected from the group consisting of:
(a) an amide;
(b) a carboxylic acid;
(c) an alcohol;
(d) an ester;
(e) a ketone;
(f) an ether; and
(g) a hydrocarbon.
The improved process of the present invention allows one to produce a conductive textile fiber at a considerably greater speed and with a shorter evaporation tube than the processes exemplified in U.S. Pat. No. 3,823,035, U.S. Pat. No. 4,255,487 and U.S. Pat. No. 4,545,835. Furthermore, the mix utilized in the present invention provides a combination of volatility, surface tension, and viscosity which not only permits the carrying out of the process at high speeds but also allows the use of a roll-type mix applicator. The roll-type applicator is advantageous in that its use in turn permits the passage of slubs, knots, etc. found in the feed yarns without disruption of the process: e.g. a "transfer tail" on a feed yarn parkage may be tied to the leading end of another feed yarn package, so that a constant supply of feed yarn may be maintained. Knots and slubs create severe problems in the "orifice" processes described in U.S. Pat. No. 4,545,835.
It is an object of the present invention to provide an improved mix for the production of a conductive textile fiber so that the conductive textile fiber may be made at higher speeds than ever before.
It is an object of the present invention to provide an improved mix for the production of a conductive textile fiber so that a roll-type mix-applicator may be utilized in a commercial process in order that a slubby and/or knotty supply of feed yarn may be processed continuously without disruption of the process.
It is a further object of the present invention to enable a high-speed, substantially horizonal process for making a conductive textile fiber.
It is a further object of the present invention to enable the production of a supported conductive textile yarn at high speeds, i.e. speeds greater than 2000 m/min., the supported yarn being comprised of a conductive textile fiber being interlaced with a plurality of support strands.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal schematic of the improved process of the present invention.
FIG. 2 is a cross-sectional view of a roll-type mix applicator to be used in the present invention.
FIG. 3 is a longitudinal schematic of a second embodiment of the improved process of the present invention.
FIG. 4 is a longitudinal perspective view of a grooved roller to be used in the process of the present invention.
FIG. 5 is an enlarged sectional view of a portion of the grooved roller illustrated in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrate a schematic of a preferred mode of carrying out the process of the present invention. A bobbin (1) of a nonconductive filamentary polymer substrate (2) is positioned below a pigtail guide (3). The filamentary substrate (2) could be, for example a 20 denier nylon 6 monofilament. The substrate (2) then travels downward and underneath a fixed guide bar (4), following which the yarn is directed upward and into the groove (5) (shown only in FIGS. 4 and 5) of a grooved roll-type coating applicator (6). An improved mix (7) is held in a holding tank (8) and is pumped upward (via pump 9) to a "head tank" (10) via a pump conduit (11). The mix (7) is pumped into the head tank (10) at such a rate that the head tank is filled to the point of continuously overflowing back into the holding tank (8) via a return conduit (12). The head tank (10) therefore maintains a constant level (14) of mix (7) therein, and the head tank (10) therefore supplies a constant and continuous pressure of mix to the mix applicator (6), via supply conduit (13). The mix (7) goes into the applicator (6), the mix then being forced up into the grooves (5) (shown only in FIGS. 4 and 5) which are on a grooved roller member (15) which is the most critical element of the roll-type mix applicator (6). The Inner Surface of the Stator (40) (see FIG. 2) keeps the mix (7) confined to the grooves (5) on the roller member. The substrate is forwarded at a speed of at least 500 meters per minute by a pair of drive rollers (17) and (18), while the surface speed of the roller member (15) remains about 12 meters per minute. The roller (15) is driven by a motor (41). The substrate (2) continuously sweeps away the mix in the groove as the mix is being brought to a point at which the substrate (2) makes initial contact with the groove. After the substrate (2) has left the surface of the grooved roller members (15), the now mix-coated substrate (2') enters the upstream end of the evaporation tube (19). The mix (7) suffuses into the mix-coated substrate (2') as the substrate (2') enters and travels through the evaporation tube (19). The volatile components within the mix flash off of the coated substrate (2') as the coated substrate is subjected to hot counter-current airflow. The airflow is counter-current to the direction of yarn travel, as indicated by "wavy" arrows in FIG. 1. The hot airflow is created by a compressor (20) in conjunction with an electrical heater (21), the hot compressed air being forced around an interior tube (22), the interior tube (22) being within the evaporation tube (19). The interior tube (22) creates a venturi effect which draws outside air into the upstream end of the evaporation tube (19). Coupled with compressor (20) is an exhaust fan (23) and exhaust duct (24) which carries the solvent laden air from the drying tube (19) to an external destination, i.e., solvent gases are directed outside of the building which houses the process, or to a trap (not shown) for recovery. The downstream end of the drying tube (19) has a small slit (approximately 0.25 inches wide) which is bounded by cylindrical bars (25) which provide a smooth, wear-resistant surface should the substrate (2') ever get out of a lignment. In FIG. 1 the direction of hot air flow is indicated by "wavy" arrows. The direction of yarn flow is indicated by the "straight" arrows and the arrows indicating the direction of rotation of feed rolls (17) and (18). After the largely solvent-free substrate (2') is forwarded past the guide bars (25), the substrate (2') then passes several times around feed rolls (18) and (17), and then travels past two pairs of guide bars (26) and (27) which are oriented 90° from one another, causing the substrate to be properly aligned before being taken up by a winder (28) which forms a bobbin (29).
FIG. 3 illustrates an alternative embodiment of the process of the present invention, wherein the filamentary polymer substrate (2) is processed exactly as in FIG. 1, except that a support yarn (30) is fed into the evaporation tube (19) alongside, but slightly spaced from, the coated filamentary substrate (2') which has passed through the groove of the roller member (15). The support yarn (30) does not come into contact with mix 7 (i.e. the mix-control substrate (2')) until after substantially complete evaporation of solvents from the coated substrate (2'). The support yarn (30) contacts the filamentary substrate (2') shortly before (or even at) the point at which the substrate (2') contacts the first feed roll (17). From here the combined substrate (2') and support yarn (30) proceed exactly as illustrated in FIG. 1 except that the substrate (2') is interlaced with the support yarn (30) by an interlacer (31) which is positioned between the two pairs of alignment guides (26) and (27). The interlacer (31) is most preferably supplied with a source of compressed air from a compressor (32). The direction of gaseous flow is shown by the arrows in the vicinity of compressor (32) and interlacer (31). The interlaced combination of the substrate (2') and the support yarn (30) is then wound up onto a bobbin.
It has been unexpectedly found that a particular group of mix formulations is highly advantageous in the use of the roll coater in the process of the present invention. The mix formulations have been found to provide advantages in carrying out the process of the present invention in enabling a higher yarn throughput speed and/or shorter drying tube length, due to higher volatility of the solvent compounds while enabling the use of a roll-type mix applicator for extended periods, which enables process advantages in that a process which is closer to being completely continuous can be performed.
Some of the solvents which may be used in the present invention are flammable. Use of these solvents requires the presence of relatively expensive explosion-proof equipment. However, many of these flammable solvents have desirable volatility characteristics in that they are very easily evaporated.
Several of the solvents are not flammable, and for this reason are most preferred. Examples of these solvents are acetic acid, dimethylformaide and dimethylacetamide. If one of the most preferred solvents is utilized, it is also most preferred that the solvent mixture comprises between 20% and 40% formic acid. Furthermore, when carrying out the process on monofilaments which are between 7 denier and 20 denier, it is most preferred that the mixture comprises between 20% and 30% formic acid. If the process is being carried out on monofilaments between 20 denier and 120 denier, it is most preferred that the solvent mixture comprises between 30% and 40% formic acid.
Preferably the mix further comprises between 0.1% and 5% of a dissolved polymer which is compatible with the polymer from which the polymeric substrate is made. As used herein, the phrase "compatible polymers" is defined as polymers which are mutually soluble in the same solvent. For example, a nylon 6,6 polymeric substrate has been sucessfully coated with a mix which utilized dissolved nylon 6 polymer.
Most preferably the mix comprises between 0.1% and 5% of a "corresponding polymer", i.e., the polymer dissolved in the mix is the same chemical species as the polymer from which the polymeric substrate is made. The most preferred polymeric substrate is made of nylon 6 polymer, and of course the most preferred polymer for the mix is therefore nylon 6 polymer.
The roll coater is preferably designed in order to apply a consistently uniform amount of mix to the substrate over a long period of time, without leaking mix and without allowing the mix to dry on the roller. As shown in FIG. 2, a preferred roll coater is comprised of a grooved roller member (15), a stator member (40), and a motor (41) for rotation of the roller member (15). The roller (15) preferably has a Rulon™ surface. Rulon™ is a fiberglass-reinforced polytetrafluoroethylene composite, and has proven to be very wear-resistant in the processes described herein. The stator (40) is preferably made of a hard metal such as stainless steel. As shown in FIGS. 1 and 3 there is a constant flow of mix being supplied to the grooved roll-coater. The mix travels through stator support block (42) (shown in FIG. 2), up through the stator member (40) itself, and finally into the groove of the grooved roller member (15), and is finally swept onto the traveling filamentary substrate (not shown in FIG. 2).
FIG. 2 represents a cross-sectional view of the mix applicator (6) utilized in the process of the present invention. A motor (41) is supported by an upper section (47) of a rigid structural assembly. The motor (41) in turn supports and rotates the grooved roller member (15). A pneumatic cylinder (43) is attached to a lower section (48) of the rigid structural assembly. The cylinder (43) has a piston (45) which is attached to a stator support block (42). The stator support block in turn is attached to the steel stator member (40). In the examples below, the piston usually exerts about 15 pounds of force on the stator support block (see arrows 46) which the stator member (40) then exerts on the roller member (15). The surfaces of the stator member (40) and the roller member (15) are smooth so that mix (7) which flows through the stator support block (42) and the stator member (40) is prevented from accumulating on the main surface of roller member 15 i.e. the mix is allowed to go only into grooves (5) (see FIGS. 4 and 5) of the roller members (15). Compressed air is supplied to the pneumatic cylinder (43) via line (44).
The roll coater (6) should be designed as that the mix is not actively forced through the groove, but rather just flows into the groove. If the groove is too large or the head pressure is too high, the mix will be literally forced "through" the groove and may even "squirt" out of the groove, both which are highly undesirable. If the groove size is too small, the roll coater may have to be rotated so fast that the mix will be slung out of the groove by centrifugal force. Thus the groove size, mix pressure, and mix viscosity are important process parameters. Optimizing these parameters for any given system can easily be accomplished from a review of the examples herein together with applying ordinary engineering principles concerning fluid flow.
FIG. 4 illustrates a longitudinal perspective view of the roller member (15). The particular roller member illustrated in FIG. 4 has 6 grooves (5) therein. Also illustrated in FIG. 4 are certain parameters related to the roller member, such as (a) GS: groove spacing; (b) D: roller diameter; (c) L: roller length.
FIG. 5 is an enlarged view of a small portion of the roller member (15). Surfaces (5) define a groove which has an apex angle of 60°, as illustrated. FIG. 5 also defines the parameters of (a) GD: groove depth; (b) GW: groove width. It has been conceived that the groove depth may range from 0.010 inches to 0.030 inches.
In the process of using the roll coater, the traveling substrate continuously sweeps the mix-filled groove substantially clean as the groove carries mix up to the point at which the traveling substrate comes into contact with the roller. The surface speed of the roller together with the cross sectional area of the groove determine the amount of mix available for the traveling substrate to pick up. The roller should not have so small a diameter that a high RPM is necessary, as the certrifugal forces on the mix can become so high that the roller will sling the mix from the roll. In addition, the cross-sectional area of the groove should be sized so that a suitable amount of mix will be supplied to the substrate. The cross-sectional shape of the groove is generally in the shape of a "V". It has been conceived that the apex angle of the "V" may vary greatly, and it has been proven that the "V" may have an apex angle that can vary from 60° to 90°. For filaments of 150 denier to 2000 denier a 90° angle is preferred while for filaments of 5 denier to 150 denier a 60° angle is preferred. It has been conceived that an apex angle between 50° and 100° will be operable. However, it has been conceived that any groove shape may be utilized so long as it does not tend to grab the yarn and so long as it makes enough mix available to the yarn. Preferred roller rotation rates, roller diameters, groove shapes, and groove sizes are given in the Examples below. It has been conceived that the diameter of the grooved roller may vary from 0.75 inches to 3.0 inches.
The process of the present invention has been carried out utilizing filaments having deniers from 7 to 2000. However, it has been conceived that the process is operable over the denier range of 5 to 5000.
The evaporation tube has a counter-current flow of hot air therethrough. The evaporation tube most preferably has an inside diameter of between 1 inch and 3 inches and may have a length between 3 and 100 feet, but most preferably is between 10 and 20 feet in length, and most preferably is about fifteen feet in length. The hot air supplied to the evaporation tube preferably has a temperature between 100° C. and 200° C.
The air interlacer (31) utilized to entangle the support yarn (30) with the substrate (2), as shown schematically in FIG. 3, has a straight, round yarn throughput hole with a diameter of 0.125 inches. The interlacer has a fluid jet orifice which intersects the throughput hole at 90°. The round fluid jet orifice has a diameter of 0.0625 inches. Air pressures from 40 psig to 100 psig are operable.
EXAMPLE I
Prior Art
A cold-stretched 15 denier nylon 6 monofilament having a circular cross-sectional diameter of 42 microns was continuously directed at a rate of 400 meters per minute from a source of supply through the interface of two opposing surfaces of a polyester pad which was kept saturated with:
______________________________________(a) carbon black (30 millimicrons) 5%; and(b) powdered nylon 6 substrate 5%; and(c) formic acid (80%, aqueous;) 72%; and(d) water 18%______________________________________
Thereupon, the filament was conducted into and through a 20 foot-long, substantially horizontally positioned elongated chamber in which the air at room temperature was continuously exchanged by means of air jets and exhaust openings. Removal of the volatile formic acid was thereby accomplished, and the filament was substantially dry. After exiting the elongated chamber, the filament was continuously wound onto a package at a rate of 400 meters per minute.
After 1-2 hours of continuous processing, the pad was observed to be scraping (actually doctoring) off the vast majority of the mix from the filament. Investigation into this phenomena revealed that the mix-saturated pad exposed the mix to the air in the vicinity of the point at which the filament exited the pad. The formic acid had evaporated from the mix at this point, causing the nylon 6 to precipitate out of the solution. This nylon 6 formed an effective surface for virtually complete doctoring of mix from the surface of the mix-coated filament. The solution to this problem was to frequently replace the polyester pads which was inconvenient, time, consuming, and expensive.
EXAMPLE II
Comparative
The process illustrated in FIG. 1 was carried out using a 20 denier nylon 6 monofilament. The monofilament was offwound from a pirn at a rate of 2500 meters per minute. As the monofilament was offwound it traveled up to a pigtail guide and then proceeded down and underneath a guide bar and then up and into contact with the mix-filled groove of the roll-type mix applicator as shown in FIG. 1. The mix comprised:
______________________________________(a) carbon black (30 millimicrons) 5%; and(b) powdered nylon 6 polymer 5%; and(c) formic acid 72%; and(d) water 18%______________________________________
The roller had a diameter of 1 inch, and the V-shaped groove had a maximum width of 0.023 inches and a depth of approximately 0.020 inches. The roller had a steel core and a Rulon™ outer layer which was 0.125 inches thick. The roller was rotated at approximately 150 rpm. The monofilament was processed satisfactorily for up to 10 minutes, after which time the monofilament would consistently break in the drying tube. The evaporation tube had counter current airflow forced therethrough, as indicated in FIGS. 1 and 3. The evaporation tube was substantially horizontally positioned. The air had a temperature of approximately 150° C. The evaporation tube had an inside diameter of 2.5 inches, and the hot air was forced through the tube at a rate of 700 feet per minute. A careful examination of the product revealed that there was an extremely uneven deposition of the mix on the strand. It was surmised that the acid in the mix would dissolve the strand to a degree which would result in strand breakage due to the fact that surprisingly the mix was found to have been applied very heavily on distinct areas of the surface of the strand. The excess acid in these areas was believed to have caused excessive strand weakening.
EXAMPLE III
The process was carried out exactly as described in Example II, except that the mix contained:
______________________________________(a) carbon black (30 millimicrons) 3.8%; and(b) powdered nylon 6 2.3%; and(c) formic acid 21.1%; and(d) acetic acid 72.8%.______________________________________
The process was run continuously for more than 24 hours, during which time the roll-coater tolerated the passage of slubs and knots due to transfer tailing of the monofilament. Surprisingly, the monofilament was evenly coated with the mix and the roller did not have any buildup of mix thereon. The resulting resistance of the filament was about 5×10 5 ohms/cm. The product was considered to be of excellent quality for antistatic textile purposes.
EXAMPLE IV
The process was carried out similarly to the process described in Example III except that a 7 denier nylon 6 monofilamentary polymeric substrate was subjected to the mix. The roller rotated at about 100 rpm. A 20 denier/8 filament support yarn was directed through the drying tube as shown in FIG. 3. The substrate first touched the support yarn at the first feed roll. Both yarns were forwarded at about 2500 meters/minute. After both yarns passed through the feed rolls they went through a guide and are then interlaced together. The interlacer has a circular yarn throughput hole with a diameter of 0.125 inches and a length of 1.25 inches. The air jet orifice has a diameter of 0.0625 inches. The axis of the jet orifice hole intersects the axis of the yarn throughput hole at an angle of 90 degrees. The air jet orifice is supplied with 90 psi of compressed air. The interlaced product is then wound up at 2500 meters per minute. Just as in Example III, the process is performed satisfactorily for more than 24 hours, uninterrupted.
EXAMPLE V
A process was carried out substantially as shown in FIG. 1 except that instead of running only 1 monofilamentary substrate through the evaporation tube, ten 15-denier monofilaments were simultaneously coated on 1 roll coater and sent through a single evaporation tube. The roller was exactly as described in Example II except that it had 10 grooves thereon which were spaced 1/4" apart. The roller rotated at 100 rpm. The mix was exactly as used in Example III. The monofilaments were forwarded at a speed of 1500 meters per minute. The resulting filaments are interlaced together by the same interlacing process described in Example IV. The interlaced product is then wound up at 1500 meters per minute. Just as in Example III, the process runs uninterrupted for more than 24 hours.
EXAMPLE VI
A 2000 denier nylon 6,6 monofilamentary substrate was forwarded at a speed of approximately 600 feet per minute in a process similar to the process described in Example III. However, the roll coater has a groove which had a depth of 0.025 inches, and the groove had a maximum width of 0.050 inches (i.e. the surfaces forming the sides of the groove met at a 90° angle). The mix used was the same as in Example III. The counter-current air which was forced through the evaporation tube had a temperature of approximately 200° C. The rate of flow of air through the evaporation tube was 600 feet per minute, and the inside diameter of the evaporation tube was 2.5 inches. The 2000 denier substrate was processed continuously for a period of 1.5 hours without interruption. The resulting 2000 denier antistatic/conductive product had a resistance of 10,000 ohms per centimeter and was considered excellent for applications requiring an antistatic filament of this size. | This process for making antistatic filaments utilizes a specific mixture of compounds in order to suffuse electrically conductive particles into a filamentary polymeric substrate by forwarding the substrate through a grooved roll-type mix applicator. The mixture comprises a dispersion of the electrically conductive particles in liquid solvent which is a mixture of formic acid and a member selected from the group consisting of an amide, a carboxylic acid other than formic acid, an alcohol, an ester, a ketone, an ether, and a hydrocarbon. The process provides advantages over the prior art in permitting the use of high processing speeds, enabling easy stringup, and allowing the use of knotty and/or slubby filamentary substrates. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This invention is a continuation-in-part of U.S. patent application Ser. No. 12/616,560, entitled “Aroma diffusing night lamp system”, filed on Nov. 11, 2009 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to scent releasing devices and more specifically, to an aroma diffusing night lamp system that combines a night lamp unit and an aroma diffuser unit together and that uses an angle-adjustable electric plug to obtain the necessary working power supply.
2. Description of the Related Art
Conventional night lamp does not allow adjustment of the angular position of the two parallel metal prongs of their electric plugs to fit different indoor installation requirements.
There are night lamps with an added aroma diffusing function. These night lamps combine an angle-adjustable night lamp unit and an aroma diffuser unit. When the night lamp unit of a night lamp is connected to a city power supply outlet, the radiating heat from the night lamp unit heats an aromatic substance, for example, essential oil in the aroma diffuser unit into vapor, providing a romantic atmosphere and enhancing the value of use of the night lamp.
Although conventional aroma diffusing night lamps allow adjustment of the installation angle of the night lamp unit, their angle-adjustable structure wear quickly with use or is difficult to adjust to the accurate angle. After installation, the applied essential oil may fall from the lampshade accidentally.
Further, regular aroma diffusing night lamps commonly use an incandescent lamp bulb to emit light and to heat the supplied aromatic substance. The heating efficiency of an incandescent lamp is low. Further, the aroma diffuser unit of a regular aroma diffusing night lamp is less stable. In consequence, a gap may be produced in the electric conducting structure, affecting the performance of electric conductivity. Further, regular aroma diffusing night lamps have no means to seal the electric conducting component parts. If the aromatic fluid leaks out, a short circuit accident may occur.
Further, the angle adjustment structures of conventional angle adjustable aroma diffusing nigh lamps are commonly not very stable. After adjustment of the desired angle, the aroma diffuser unit may be biased relative to the night lamp unit accidentally.
Further, some known aroma diffusing nigh lamps use a lampshade prepared from a light-transmissive heat-resisting hard material such as ceramic or glass. During installation, small retaining and/or fastening members are used to affix the lampshade in place. The use of these retaining and/or fastening members may cause the lampshade to break, shortening the night lamp lifespan and threatening user safety.
SUMMARY OF THE INVENTION
The present invention has been accomplished to provide an aroma diffusing night lamp system with an angle-adjustable electric plug, which eliminates the drawbacks of the aforesaid prior art designs.
To achieve this and other objects of the present invention, an aroma diffusing night lamp system comprises a night lamp unit and an aroma diffuser unit. The night lamp unit comprises a lamp socket, a light emitting device mounted in the lamp socket, an electric plug coupled and rotatable relative to the lamp socket and adapted for electrically connecting the lamp socket to an external city power supply outlet, and a safety lampshade surrounding the light emitting device. The aroma diffuser unit comprises an electrically insulative heater holder mounted in the safety lampshade of the night lamp unit, a heater carried in thee electrically insulative heater holder and electrically connected to the electric socket of the night lamp unit by power wires and an outer lampshade mounted on the lamp socket and surrounding the safety lampshade. The outer lampshade defines a top trough for holding an aromatic substance. The top tough has the bottom wall thereof kept in contact with the heater and adapted for transferring heat energy from the heater to the aromatic substance carried in the top trough to heat the aromatic substance into vapor.
In one embodiment of the present invention, the light emitting device comprises at least one light emitting diode.
In one embodiment of the present invention, the heater is a cement resistor.
Further, the electric plug comprises an electric plug body having a cylindrical rear side, a gear wheel fixedly located on the cylindrical rear side of the electric plug body, a first gear wheel cover and a second gear wheel cover. The first gear wheel cover has two arched arms and an arched groove defined by the two arched arms thereof. The second gear wheel cover has two arched arms and an arched groove defined by the two arched arms thereof. The arched arms of the first gear wheel cover are respectively abutted against the arched arms of the second gear wheel cover around the cylindrical rear side of the electric plug body to keep the arched grooves of the first gear wheel cover and the second gear wheel cover in friction engagement with the gear wheel.
Further, the lamp socket comprises two socket shells fastened together and a damping spring leaf mounted in one socket shell for securing the gear wheel of the electric plug. One socket shell has a round hole for receiving a part of the gear wheel of the electric plug, and a locating groove formed in the round hole for receiving the damping spring leaf. The damping spring leaf is positioned in the locating groove and stopped against a part of the gear wheel of the electric plug. Further, the damping spring leaf has a W-shaped configuration and a protruding damping portion located on the middle part thereof. The locating groove in the round hole of one socket shell is configured to fit the W-shaped configuration of the damping spring leaf.
The aroma diffuser unit further comprises a first top cover, a second top cover and at least one elastic member. The first top cover has at least one vertically extending groove. The second top cover has at least one vertically extending groove. The first top cover and the second top cover are abutted together such that each vertically extending groove of the first top cover is coupled to one respective vertically extending groove of the second top cover to form one vertical through hole. The first top cover and the second top cover are mounted in between the safety lampshade of the night lamp unit and the electrically insulative heater holder of the aroma diffuser. The at least one elastic member is respectively inserted into the at least one vertical through hole in between the first top cover and the second top cover. The electrically insulative heater holder has at least one foot member extended from the bottom side thereof and inserted into the at least one vertical through holes in between the first top cover and the second top cover and supported on the at least one elastic member.
The night lamp unit further comprises a retainer mounted on the electric socket to secure the outer lampshade to the electric socket. The retainer has a bottom ring mounted on the top side of the electric socket and a plurality of retaining pawls upwardly extended from the bottom ring and equiangularly spaced from one another for securing the outer lampshade.
Further, each retaining pawl of the retainer has a hooked portion, a top slope located on the top side of the hooked portion and a recessed portion located on the bottom side of the hooked portion.
Further, the electric plug has a plurality of triangular retaining blocks equiangularly spaced around the cylindrical rear side thereof. The gear wheel is a gear ring, having a plurality of triangular retaining grooves equiangularly arranged on the inner diameter thereof and respectively forced into engagement with the triangular retaining blocks of the electric plug.
Thus, subject to the use of the cement resistor for heating the supplied aromatic substance into vapor directly, the invention achieves an excellent heating effect. Further, subject to the arrangement between the gear wheel and damping spring leaf, the adjustment of the angular position of the electric plug relative to the lamp socket is easy and accurate, avoiding damage. Further, subject to the use of the safety lampshade to enclose the light emitting device and the power wires, the invention assures a high level of safety.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of an aroma diffusing night lamp system in accordance with the present invention.
FIG. 2 is an exploded view of the aroma diffusing night lamp system in accordance with the present invention.
FIG. 3 is a schematic top view of the aroma diffusing night lamp system in accordance with the present invention.
FIG. 4 is a sectional view taken along line A-A of FIG. 3 .
FIG. 5 is a schematic bottom view of the aroma diffusing night lamp system in accordance with the present invention.
FIG. 6 is a sectional view taken along line B-B of FIG. 5 .
FIG. 7 is an enlarged view of part aa of FIG. 2 .
FIG. 8 is a sectional view taken along line C-C of FIG. 3 .
FIG. 9 is an exploded view of an alternate form of the aroma diffusing night lamp system in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , an aroma diffusing night lamp system with an angle-adjustable electric plug in accordance with the present invention is shown comprising a night lamp unit 10 and an aroma diffuser unit 20 .
Referring to FIGS. 2˜4 , the night lamp unit 10 comprises a lamp socket 11 , a light emitting device 12 , an electric plug 13 and a safety lampshade 14 . The light emitting device 12 is mounted in the lamp socket 11 and adapted to emit light through the safety lampshade 14 . The safety lampshade 14 surrounds the light emitting device 12 . The electric plug 13 is pivotally coupled to the lamp socket 11 and angularly adjustable relative to the lamp socket 11 .
Further, the electric plug 13 comprises an electric plug body 131 , a gear wheel 232 located on the cylindrical rear side of the electric plug body 131 , a first gear wheel cover 133 and a second gear wheel cover 134 . The first gear wheel cover 133 has two arched arms 1331 , defining an arched groove 1332 . The second gear wheel cover 134 has two arched arms 1341 , defining an arched groove 1342 . The arched arms 1331 of the first gear wheel cover 133 are respectively abutted against the arched arms 1341 of the second gear wheel cover 134 around the cylindrical rear side of the electric plug body 131 to keep the arched grooves 1332 and 1342 in friction engagement with the gear wheel 132 . Thus, the gear wheel 231 can be rotated with the electric plug body 131 relative to the first gear wheel cover 133 and the second gear wheel cover 134 . After rotation, the friction force between the gear wheel 231 and the first and second gear wheel covers 133 and 134 secures the gear wheel 132 and the electric plug body 131 to the first and second gear wheel covers 133 and 134 firmly in position.
The lamp socket 11 of the night lamp unit 10 comprises two symmetrical socket shells 111 and 112 and a power switch 113 . The safety lampshade 14 is fastened to the two symmetrical socket shells 111 and 112 at the top side. The two symmetrical socket shells 111 and 112 surround the light emitting device 12 , holding the light emitting device 12 firmly in position. The aroma diffusing night lamp keeps the light emitting device 12 and the power wires 19 and other connected electric components on the inside of the safety lampshade 14 , avoiding breaking of the outer lampshade and any possible accidental electric leakage due to accidental leakage of the applied aromatic substance or essential oil. The power switch 113 is installed in one socket shell 112 and exposed to the outside. After connection of the electric plug 13 to an external power source and pressing of the power switch 113 , the lamp socket 11 and light emitting device 12 of the night lamp unit 10 and the aroma diffuser unit 20 are electrically connected to emit light and to produce heat. On the contrary, when the user presses the power switch 113 again, the lamp socket 11 and light emitting device 12 of the night lamp unit 10 are electrically disconnected. The socket shell 111 has a round hole 115 for accommodating a part of the gear wheel 132 of the electric plug 13 .
Referring to FIGS. 5˜7 , the lamp socket 11 further comprises a damping spring leaf 119 having, for example, a W-shaped configuration. The damping spring leaf 119 has a protruding damping portion 1192 on the middle. The socket shell 111 has a locating groove 1151 in the round hole 115 configured to fit the W-shaped configuration of the damping spring leaf 119 . After mounting of the damping spring leaf 119 in the locating groove 1151 inside the round hole 115 , the protruding damping portion 1192 of the damping spring leaf 119 is kept suspending in the round hole 115 . When the gear wheel 132 of the electric plug 13 is partially inserted into the round hole 115 of the socket shell 111 , the protruding damping portion 1192 of the damping spring leaf 119 is stopped against the toothed periphery of the gear wheel 132 , holding the gear wheel 132 in place and allowing rotation of the gear wheel 132 with the electric plug body 131 relative to the lamp socket 11 to adjust the angle of the electric plug 13 . Thus, the user can adjust the angle of the electric plug 13 relative to the electric socket 11 accurately.
Referring to FIG. 8 and FIG. 2 again, the aroma diffuser unit 20 comprises an electrically insulative heater holder 21 , a heater 22 and an outer lampshade 23 . The heater 21 according to the present preferred embodiment is a cement resistor. Further, the electrically insulative heater holder 21 according to the present preferred embodiment is made from a phenol-formaldehyde plastic material (bakelite). The electrically insulative heater holder 21 is capped on the safety lampshade 14 of the night lamp unit 10 . The outer lampshade 23 has its bottom side kept in contact with the heater 22 . The heater 22 is carried in the electrically insulative heater holder 21 and electrically connected to the electric plug 13 by the power wires 19 for heating the outer lampshade 23 .
According to the present preferred embodiment, the outer lampshade 23 of the aroma diffuser unit 20 has a shadow fluid trough 232 defined in the top side thereof, a bottom edge 234 located on the bottom side thereof and a through hole 236 cut through the center of the bottom edge 234 . The outer lampshade 23 is prepared from a light transmissive material. The through hole 236 on the bottom edge 234 of the outer lampshade 23 is coupled to the lamp socket 11 of the night lamp unit 10 around the safety lampshade 14 . The bottom wall of the shadow fluid trough 232 is kept in contact with the top wall of the heater 22 . An aromatic substance (such as essential oil, fragrant wax or the like) is put in the shadow fluid trough 232 . Thus, by means of using cement resistors as heat source means to heat the applied aromatic fluid instead of an incandescent lamp bulb, the invention provides a stable heating effect. According to the present preferred embodiment, the light emitting device 12 of the night lamp unit 10 uses LEDs (light emitting diodes) to emit light, meeting modern green safety codes.
The aroma diffuser unit 10 further comprises a first top cover 16 , a second top cover 17 and at least one, for example, two elastic members 222 . The elastic members 222 can be compression springs or rubber blocks. According to this embodiment, the elastic members 222 are compression springs. The first top cover 16 has a plurality of vertically extending grooves 161 . The second top cover 17 has a plurality of vertically extending grooves 171 . The first top cover 16 and the second top cover 17 are abutted together. Thus, vertically extending grooves 161 of the first top cover 16 are respectively coupled to the vertically extending grooves 171 of the second top cover 17 , forming vertical through holes 18 . The first top cover 16 and the second top cover 17 are mounted in between the safety lampshade 14 of the night lamp unit 10 and the electrically insulative heater holder 21 of the aroma diffuser 20 . The electrically insulative heater holder 21 has at least one, for example, two foot members 211 extended from the bottom side thereof. The spring members 222 are respectively inserted into the vertical through holes 18 . The foot members 211 of the electrically insulative heater holder 21 are respectively inserted into the vertical through holes 18 and supported on the spring members 222 . The spring members 222 impart an upward spring force to the electrically insulative heater holder 21 , thereby forcing the heater 22 against the bottom wall of the shadow fluid trough 232 of the outer lampshade 23 . Therefore, the heater 22 is constantly and stably kept in close contact with the bottom wall of the shadow fluid trough 232 of the outer lampshade 23 .
The night lamp unit 10 further comprises a retainer 15 . The retainer 15 has a bottom ring 151 and a plurality of retaining pawls 153 . The retainer 15 is mounted on the top side of the lamp socket 11 to secure the outer lampshade 23 . Each retaining pawl 153 has a hooked portion 1531 and a recessed portion 1533 . The hooked portion 1531 has a top slope 1535 . The bottom ring 151 defines therein an inner thread 1512 . Each of the socket shells 111 and 112 has an externally threaded top flange 116 . The inner thread 1512 of the retainer 15 is threaded onto the externally threaded top flanges 116 of the socket shells 111 and 112 of the lamp socket 11 such that an annular space 117 is defined between the externally threaded top flanges 116 of the socket shells 111 and 112 of the lamp socket 11 and the retaining pawls 153 .
When coupling the through hole 236 on the bottom edge 234 of the outer lampshade 23 to the lamp socket 11 of the night lamp unit 10 around the safety lampshade 14 , the periphery of the through hole 236 will be moved downwardly over the top slopes 1535 of the retaining pawls 153 of the retainer 15 to force retaining pawls 153 into the annular space 117 toward the externally threaded top flanges 116 of the socket shells 111 and 112 of the lamp socket 11 so that the through hole 236 on the bottom edge 234 of the outer lampshade 23 an be forced into engagement with the recessed portions 1533 of the retaining pawls 153 . The retaining pawls 153 are equiangularly arranged on the top side of the bottom ring 151 for evenly distributing the contact pressure when the bottom edge 234 of the ceramic or glass outer lampshade 23 is attached to the retainer 15 at the top side of the lamp socket 11 , avoiding concentration of shear stress or flexural shear stress on contact points between the outer lampshade 23 and the retainer 15 .
The aroma diffusing night lamp system with an angle-adjustable electric plug uses the safety lampshade 14 to shield the light emitting device 12 , the power wires 19 and other connected electric components, avoiding breaking of the outer lampshade 23 and any possible accidental electric leakage due to accidental leakage of the applied aromatic substance or essential oil.
FIG. 9 shows an alternate form of the present invention. According to this alternate form, the cylindrical rear side of the electric plug body 131 of the electric plug 13 has a plurality of triangular retaining blocks 135 equiangularly spaced around the cylindrical rear side thereof. The gear wheel 135 is a gear ring, having a plurality of triangular retaining grooves 1321 equiangularly arranged on the inner diameter thereof and respectively forced into engagement with the triangular retaining blocks 135 of the electric plug body 131 of the electric plug 13 . After installation of the gear wheel 135 in the cylindrical rear side of the electric plug body 131 of the electric plug 13 , the electric plug 13 can then be fastened with the gear wheel covers 133 and 134 to the lamp socket 11 and then rotated relative to the lamp socket 11 to the desired angle.
Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims. | An aroma diffusing night lamp system having the characteristics of high heating performance, high level of safety and angle adjustability is disclosed to include a night lamp unit formed of a lamp socket holding a light emitting device, an electric plug rotatably coupled to the lamp socket and a safety lampshade surrounding the light emitting device, and an aroma diffuser unit formed of an electrically insulative heater holder, a heater carried in the electrically insulative heater holder and an outer lampshade that is mounted on the lamp socket around the safety lampshade and defines a top trough that holds an aromatic substance and has the bottom wall thereof kept in contact with the heater for enabling the aromatic substance to be heated into vapor safely. | 5 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a towable sub-aqua device of the type suitable for being steered by an individual being dragged by the towing device.
BACKGROUND OF THE INVENTION
Towable sub-aqua devices are known for both leisure and professional purposes. Such devices generally have various disadvantages associated therewith. For example such devices are either complex and/or expensive to manufacture, difficult and/or cumbersome to transport and store, or complicated to use. Examples of such known devices are described below.
U.S. Pat. No. 3,931,777 discloses an aqua sled for carrying people on and under water comprises a frame of aluminum tubing having a rigid planar section of transparent material to enable users to see beneath the sled and buoyant material affixed thereto to float the sled. A pair of sheets of rigid transparent material are affixed to the front of the frame and form a dihedral of approximately 90° with each other. Each of the sheets extends at an angle of approximately 45° with a corresponding side of the planar section of transparent material. A control device is affixed to the frame and is manually controllable to control the movement of the sled.
U.S. Pat. No. 4,149,483 discloses a device to be towed through the water by a boat and which in turn is adapted to tow a person through the water, the body of the device having a constant buoyancy and being equipped with steering means whereby it can be maintained on the surface of the water while being towed, can be submerged while towing a person with scuba gear, and which can be maneuvered under water to partially or completely roll the device and its user.
U.S. Pat. No. 4,207,829 discloses a towable, swimmer-controlled, aquatic plane device that includes an elongated wing element having sections symmetrical about a transverse center line and a fin element also having sections symmetrical about a transverse center line, the fin element being removably attached at its transverse center line to the wing element at its transverse center line with the fin element sections extending vertically above and below the wing element. Openings are provided in each fin element section adjacent its leading edge and adjacent the wing element for attaching a tow rope. Openings are provided in each fin element adjacent its trailing edge which form hand grip portions by which a swimmer can steer the device in any one or more of four directions, i.e., down for diving, up to plane on the surface of the water, or banking for turning left or right.
U.S. Pat. No. 5,178,090 discloses an underwater diving plane that has a main frame forming an isosceles triangle, having a base part, two side legs of equal length and an apex; a detachable transverse axle which is pivotally connected to the main frame, having two ends and two main planes each fixedly attached to the axle; a fore plane attached to the frame proximal to the apex; and a tow force transition cable to allow the planes stable planning action.
U.S. Pat. No. 5,655,939 discloses a rudder comprised of a planar body wherein a large front notch and a rear notch form two lobes or side wings which are perfectly symmetric with respect to the front-to-rear axis. On the axis and at the vicinity of the front notch is provided the unique point of towing, variable through a movable part, to which is fixed the corresponding towing rope. On each side wing, there are arranged, symmetrically and forward of the towing point, two windows that the user can grip with his or her hands and, behind the windows, in the lower part of the device and also in a symmetrical arrangement there are provided two rudder-like fins. The apparatus can be gripped manually with the arms extended forward allowing a swimmer-diver to move on the water or in the water.
All of these known devices have various ones or all of the known disadvantages stated hereinabove.
It is an aim of the present invention to provide an improved sub-aqua device, suitable for towing a person through the water. In particular it is an aim of the present invention to provide a sub-aqua device in which manoeuvrability is improved over known prior art devices.
SUMMARY OF THE INVENTION
The invention provides a device that is simple and inexpensive to manufactured. In particular the device is easy to use. The device is of a relatively small size, and easily transportable and readily stored. As such the relatively inexpensive cost of the device and its ease of use results in an increased activity of sub-aqua exploration, particularly in relation to leisure activity.
The structure of the plane mechanism of the device, provides significantly improved stability and manoeuvrability over previously known devices. The independent nature of the two parts of the plane mechanism, provides increased manoeuvrability of the device without any increase in the complexity of the device.
In accordance with a first aspect of the present invention there is provided a sub-aqua device including: a means for towing the device; a pair of planes for manoeuvring the device, each defining a depth plane; and a means for controlling each plane means including a handle, with each handle extending in a plane coincident with the respective manoeuvring plane.
In accordance with a second aspect of the present invention there is provided a sub aqua device including: a bar for towing the device; a pair of plane members for manoeuvring the device, each defining a manoeuvring plane; and a manoeuvring plane rod for controlling each plane member including a handle, each handle extending in a plane coincident with the respective manoeuvring plane.
In accordance with a third aspect of the present invention there is provided a sub-aqua device including: a means for towing the device; a pair of manoeuvring plane means for manoeuvring the device; and a means for controlling each manoeuvring plane means, wherein the means for towing the device comprises a bar extending between the respective manoeuvring plane means.
In accordance with a fourth aspect of the present invention there is provided a sub-aqua device including: a bar for towing the device; a pair of manoeuvring plane members for manoeuvring the device; and a rod for controlling each manoeuvring plane member, wherein the bar for towing the device extends between the respective manoeuvring plane means.
BRIEF DESCRIPTION OF THE FIGURES
The present invention will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 illustrates a preferred embodiment of the present invention;
FIG. 2 illustrates a first illustrative cross-section through A—A of FIG. 1;
FIG. 3 illustrates a second illustrative cross-section through A—A of FIG. 1;
FIG. 4 illustrates a first modification to the embodiment of FIG. 1; and
FIG. 5 illustrates a second modification to the embodiment of FIG. 1 .
FIG. 6 illustrates a third modification to the embodiment of FIG. 1 .
DETAILED DESCRIPTION
Referring to FIG. 1, there is shown a preferred embodiment of a sub-aqua device in accordance with the present invention. The main components of the device are: a device support member 2 , a pair of manoeuvring planes 4 and 6 which are used for manoeuvring the device, and handles 8 and 10 for controlling the manoeuvring plane.
The support member 2 includes a tow hook 24 . The tow hook 24 is used for attaching a towrope to the sub-aqua device. The other end of the towrope or towing device is, in use, connected to a boat or other aquatic towing means or vehicle for towing the sub-aqua device of the present invention through or under the water.
Each of the planes 4 and 6 , or plane, comprises a handle for manoeuvring the sub-aqua device. The planes 4 and 6 each comprise a water foil having a wing or fin type shape. The structures in the preferred embodiment of the invention are made of hard rubber, plastic, wood or metal. In general, the shape of the planes 4 and 6 is that of a water foil having a pair of opposing surfaces for offering resistance to the water through which the sub-aqua device is towed. A description of the operation of the planes 4 and 6 means utilising the opposing surfaces is given in further detail herein below.
Each of the planes 4 and 6 has affixed thereto a respective means for positioning each plane, or manoeuvring handles 8 and 10 . The manoeuvring handles 8 and 10 includes a port griping handle 16 , and a starboard gripping handle 18 having a retention portion, respectively identified as 20 and 22 .
The respective retention portions 20 and 22 are attached to the respective manoeuvring planes 4 and 6 . The support member 2 is provided at distal ends thereof with rings 12 and 14 for connecting to the respective retention portion of each handle. Thus a ring 12 is provided for connecting the distal end 26 of the support member 2 to the retention portion 20 , and a ring 14 is provided for connecting the distal end 28 of the support member 2 to the retention portion 22 .
The rings 12 and 14 are such that the retention portions 20 and 22 are rotatably mounted within the rings 12 and 14 . The rings 12 and 14 are fixably connected to the distal ends 26 and 28 of the support member 2 .
As the retention portions 20 and 22 are fixably connected to the manoeuvring planes 4 and 6 , as the retention portions 20 and 22 rotate about the rings 12 and 14 the manoeuvring planes 4 and 6 similarly rotate.
The rotation of the retention portions 20 and 22 is controlled, in use, by the gripping handles 16 and 18 of the gripping handles 8 and 10 . As the handles are turned, the retention portions turn and consequently the manoeuvring planes 4 and 6 rotate. As can be understood by reference to FIG. 1, if the handle 16 is rotated such that it moves upwards relative to the page, the manoeuvring plane rotates such that the front edge 30 of such rises and the rear edge 32 falls. This is exemplified by the cross-section, through A—A, shown in FIG. 2 .
As can be further understood by reference to FIG. 1, if the handle 16 is rotated such that it moves downwards relative to the page, the manoeuvring plane means rotates such that the front edge 30 of such falls and the rear edge 32 rises. This is exemplified by the cross-section, through A—A, shown in FIG. 3 .
It will be understood that the same manoeuvring plane control applies to the manoeuvring plane 6 .
Referring to FIGS. 2 and 3, the dashed lines 40 represent the depth plane of the manoeuvring plane 4 . That is to say, the dashed line 40 represents the direction in respect of which the user of the sub-aqua device is manoeuvring the device.
It is significant to note, referring to FIG. 3, that the rod 8 remains in a plane coincident with the depth plane at all times. As such, the handle is positioned at all times to minimise water resistance, since it always points in the direction in which the user is manoeuvring the device.
It should be also noted that the arrangement of the invention as shown in FIG. 1 enables the two manoeuvring plane 4 and 6 to be manipulated independently. As will be described further hereinafter this provides a significant degree of improved manoeuvrability Referring again to FIGS. 2 and 3, it can be seen that as the manoeuvring plane is rotated either a top surface 42 (FIG. 3) or a bottom surface 44 (FIG. 2) of the manoeuvring plane provides a resistance surface to the water. The arrow X represents the direction of the movement of the sub-aqua device 100 through the water, and the arrows Y represent the flow of water against the resistance surface. It is obvious that the speed of the device through the water is dependent on the strength of the user's arms. However, for the average adult user, being towed at 5 mph will provide a unique and enjoyable experience and should be well within the strength requirements,
As one skilled in the art will understand, the flow of water against a surface of the manoeuvring plane, assisted by the hydrodynamic design of the manoeuvring plane, will cause the manoeuvring plane to move in a particular direction, either up or down. In the position shown in FIG. 2, the sub-aqua device will move in an upwards direction, whilst in the position shown in FIG. 3 the sub-aqua device will move in a downwards direction.
As a consequence of the independent manoeuvring plane mechanism provided by the sub-aqua device of the present invention, one manoeuvring plane device may be steered upwards whilst the other is steered downwards. This enables more complex manoeuvring to be performed other than simple, up or down manoeuvres but also banking manoeuvres.
Once again it is worth emphasising that a significant advantage of the present invention is provided by the fact that the gripping portions or handles 16 and 18 extend in a direction perpendicular to the flexing portion 20 and 22 and parallel to the manoeuvring planes 4 and 6 . As such, in use, the handles 16 and 18 offer minimum resistance to the water flow and minimum interference with manoeuvring. FIGS. 2 and 3 particularly demonstrate this. As such the handles 16 and 18 offer minimum resistance to the water flow by always pointing in the direction in which the manoeuvring plane mechanism is positioned. Even in use, with the user's hands gripping the gripping handles 16 and 18 , resistance to the water flow, and hence interference with the manoeuvring plane mechanism is minimised.
It is important that the manoeuvring is controlled by the manoeuvring planes 4 and 6 , and the effects of any other aspects of the design of the sub-aqua device on the manoeuvring be minimised. The arrangement of the handles 16 and 18 in accordance with the present invention provides this.
The attachment of the support member 2 to gripping handles 8 and 10 is provided by various techniques know in the art and will be apparent to one skilled in the art. Nevertheless, two techniques for achieving the attachment are discussed below.
FIGS. 4 and 5 illustrate a close-up perspective of two embodiments of the arrangement for connecting the support member 2 , the manoeuvring planes 4 and 6 , and the gripping handles 8 and 10 .
Referring to FIG. 4, in a first embodiment the ring 12 connects the support member 2 to the handle 8 is located between two blocks 50 which are rigidly connected to the handle 8 . The blocks 50 operate to fix the location of the rings 12 relative to the handle 8 , thereby creating a stable structure, whilst still enabling the handle 8 to rotate relative to the ring 12 .
Referring to FIG. 5, in a second embodiment the means 12 is adapted to form a cylindrical device 54 that extends along the axis of the retention portion 20 of the handle 8 to connect with the side surface of the manoeuvring plane 4 at points 52 . In this embodiment the cylindrical device 54 is fixed at points 52 in a rotatable manner, such that the manoeuvring plane 4 still rotates relative to the cylindrical means responsive to rotation of the handle.
It should be appreciated that the examples shown in FIG. 4 and 5 are only illustrative examples, and the present invention is in no way limited thereby.
Referring to FIG. 6, the miunting of the plane 4 to the handle 16 is shown. Mating flange 80 is welded to end of handle 16 and connected to a matching flange on the plane 4 by fastner 88 . If the plane is made of metal or wood then the mating flange may be directly attached to the plane 4 , If however, the plane is made of a molded plastic or other synthetic material then gripping rods 82 , 84 , & 86 will have threaded ends and be positioned to mate with the flange 80 . In this embodiment the fastner 88 will connect to both flange 81 and the plane 4 . A similar connection is provided for plane 6 . | There is disclosed an improved sub-aqua device suitable for towing a person through the water. Specifically there is disclosed a sub-aqua device including: a support member; a pair of manoeuvring planes for manoeuvring the device, each defining an elevation plane; and a means for controlling each manoeuvring plane including a handle, each handle extending in a plane coincident with the respective elevation plane. | 1 |
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/005,971, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is generally related to a method for providing services to customers using controlled access to the customers' vehicles to facilitate the provision thereof. More particularly, the present invention is related to a method for providing scheduled services to customers relying on granting of controlled access to the customers' vehicles to facilitate exchanges between the customers and service providers. More specifically, the present invention is related to a method of scheduling a date and location for the provision of services, and performing the scheduled services to customers by relying on the customers' vehicles and controlled access granted thereto as a platform to facilitate exchanges between the customers and service providers.
[0004] 2. Description of the Prior Art
[0005] Typically, customers requiring services depend on service providers to have fixed locations or service vehicles to facilitate the provision of such services. As such, the customers must visit the fixed locations and/or the service vehicles must visit the customers to initiate and complete the service. Either way, the customers (or their agents) oftentimes must at some time meet with the service providers to facilitate the provision of such services. Given the conflicting schedules thereof, arranging such a meeting may never be convenient for the customers and service providers.
[0006] For example, difficulties may arise in arranging service for vehicles. Rather than servicing vehicles themselves, vehicle owners oftentimes rely on service garages to service their vehicles. In doing so, vehicle owners either remain onsite or leave their vehicles at the service garages for servicing. As such, the vehicle owners must either wait until servicing of their vehicles is complete, or, if their vehicles are left at the service garages, arrange for transportation from and back to the service garages. Either way, the vehicle owners are exposed to the inconvenience of waiting or arranging transportation. In certain circumstances, when the wait for service is excessive, or the service garages are located far from the vehicle owners' place of business or home, the vehicle owners can be extremely inconvenienced.
[0007] Furthermore, even if the service garages employed service vehicles, the vehicle owners must still meet the employees operating the service vehicles at their place of business or home to facilitate performance of the service. Unless the vehicles are left unlocked or the service garages are previously provided with access, the employees operating the service vehicles would not have access to the vehicles without meeting the vehicle owners.
[0008] Accordingly, for the convenience of customers, there is a need for a method for providing services to customers using controlled access to the customers' vehicles to facilitate the provision thereof. Such a method can employ the convenience of email and/or the Internet for account setup and scheduling, and rely on granting of controlled access to the customers' vehicles to facilitate exchanges between the customers and service providers, and thus enable the service providers to provide the scheduled services.
SUMMARY OF THE INVENTION
[0009] The present invention in one preferred embodiment contemplates method of granting a service provider access to a vehicle of a customer to facilitate provision of services therefor including the acts of scheduling a service appointment with the service provider for servicing at least one of the vehicle and articles placed within the interior or trunk of the vehicle, if the service appointment is scheduled for the articles, then locking the interior or trunk of the vehicle with the articles placed therein, attaching a security storage box to the vehicle or in proximity to the vehicle, and locking a means for accessing the interior or trunk of the vehicle in the security storage box, granting access to the service provider to the means for accessing locked in the security storage box, and permitting access the interior or trunk of the vehicle using the means for accessing to afford service to the vehicle or the articles.
[0010] The present invention in a further preferred embodiment contemplates a method of accessing a vehicle of a customer by a service provider to facilitate provision of services therefor including the acts of confirming an appointment with the customer for servicing at least one of the vehicle and articles placed within the interior or trunk of the vehicle, locating the vehicle on a date and at a location selected by the customer, unlocking a security storage box attached to the vehicle or in proximity to the vehicle to obtain a means for accessing the interior or trunk of the vehicle, accessing the interior or trunk of the vehicle using the means for accessing, if the service appointment is for the vehicle, servicing the vehicle, if the service appointment is for the articles, removing the articles, servicing the articles, and returning the articles to the interior or trunk of the vehicle, and, after the service is complete, locking the vehicle.
[0011] The present invention in another preferred embodiment contemplates a method of accessing a vehicle of a customer by a service provider to facilitate provision of services therefor including establishing an account with the service provider, scheduling a specified date and a specified location for a service appointment, scheduling services to be performed by the service provider during the service appointment, attaching a security storage box to the vehicle or in proximity to the vehicle, and locking a means for accessing the interior or trunk of the vehicle in the security storage box, granting access to the service provider to the means for accessing locked in the security storage box, locating the vehicle on the specified date in the specified location, unlocking the security storage box to obtain the means for accessing, accessing the interior or trunk of the vehicle using the means for accessing, and performing the service, and after the service is complete, locking the vehicle.
[0012] It is understood that both the foregoing general description and the following detailed description are exemplary and exemplary only, and are not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention. Together with the description, they serve to explain the objects, advantages and principles of the invention. In the drawings:
[0014] FIG. 1 is a flow chart depicting one embodiment of the method according to the present invention;
[0015] FIG. 2 depicts a security storage box attached to a window of a vehicle;
[0016] FIG. 2A depicts a perspective view of the security storage box; and
[0017] FIG. 3 depicts a mobile service station used as part of the present invention for servicing a vehicle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] The following description is intended to be representative only and not limiting, and many variations can be anticipated according to these teachings. Reference will now be made in detail to the preferred embodiments of this invention, examples of which are illustrated in the accompanying drawings.
[0019] FIG. 1 shows a method according to one embodiment of the present invention which is generally indicated by the numeral 10 . Method 10 includes steps numbered 20 - 42 . Using method 10 , a service appointment for a vehicle can be scheduled by customers with service providers. In doing so, the customers can schedule a date and a location for the service appointment, and request the type of services to be performed. The method 10 , as discussed below, relies on controlled access to vehicles 12 of the customers to facilitate exchanges between the customers and service providers, and thus enable the service providers to provide the scheduled services. In doing so, customers' vehicles 12 serve as a platform facilitating exchanges between the customers and service providers.
[0020] As discussed below, a security storage box (or lock box) 14 (shown in FIGS. 2 and 2A ), and a key, a keyless entry device, or a note with a security code provided thereon are used in granting controlled access to a vehicle 12 of the customer. Using security storage box 14 , the customer's vehicle 12 can be locked, but access to the interiors or trucks thereof can be still granted to the service providers.
[0021] Using method 10 , the customer can schedule services for articles requiring pick up and drop off from their vehicles, and/or schedule services for the vehicles themselves. For example, on a specified date while the customers' vehicles can be parked at, for example, a specified location such as at or adjacent the customer's place of business or home. On the specified date, the service providers drive to the specified location to pick up or drop off articles from the interiors or trunks of the customers' vehicles or perform the scheduled services thereon.
[0022] Services provided by the service providers can include, but are not limited to, laundry service and dry-cleaning services. Other services where customers can leave articles in the vehicles 12 for pick up are also contemplated using method 10 . With access thereto, the service providers can pick up the clothing (or other articles) from the customers' vehicles 12 , perform the laundry and dry-cleaning (or other) services, and drop off the clothing (or other articles) once those services are completed. Furthermore, the services provided on the vehicles themselves can include, but are not limited to, changing fluids of the vehicle, replacing parts on the vehicle, checking tire pressure and battery charge, and detailing the vehicle.
[0023] The service providers can employ service vehicles 16 adapted to facilitate the services provided. For example, if the service providers are providing service on the customers' vehicles, service vehicles such as a mobile service station 18 ( FIG. 3 ) can be used.
[0024] As shown in FIG. 3 , mobile service station 18 can be a pickup truck, and equipment and materials generally indicated by the numeral 19 mounted thereon for performing the scheduled services. Depending on the type of scheduled services to be provided, mobile service station 18 can be equipped with different equipment and materials for a particular service appointment. Furthermore, although, as shown in FIG. 3 , mobile service station 18 is a pickup truck, mobile service station 18 is not limited thereto. For example, mobile service vehicle 18 can also be a trailer with equipment and materials mounted thereon.
[0025] For example, to change the fluids of the vehicle, the mobile service station 18 can be equipped with a jack stand for access to the undercarriage of the vehicle and/or vacuum system (e.g., Sage OIL VAC® vacuum system) to drain and withdraw, respectively, fluids from the vehicle. The vacuum system can be used to reduce the possibility of spillage of fluids. Furthermore, the mobile service station 18 can be equipped with storage tanks, drums, and/or cans containing various fluids, as well as fluid dispensers for replenishing the fluids from the vehicle. The fluids can include any fluids useful in the maintenance, repair, and/or care of a vehicle in particular including, but not limited to various grades of motor oil, antifreeze, transmission/transaxle fluid, differential fluid, power steering fluid, gasoline, water, and/or windshield-wiper fluid. Therefore, if the scheduled services include changing and/or filling any of the above-mentioned fluids, mobile service station 18 can be equipped to facilitate such services. For example, the scheduled services can include changing the oil of the vehicle and filling the vehicle with gasoline.
[0026] Additionally, mobile service station 18 can include storage for replacement parts for the vehicle. Such replacement parts can include, for example, air filters, oil filters, windshield-wiper blades, and bulbs for exterior lights. Therefore, depending on the scheduled services, mobile service station 18 , in addition to the above-discussed equipment and materials, can include replacement parts necessary to complete the services. Furthermore, if the scheduled services include checking and adjusting the vehicle's tire pressure and/or battery charge, mobile service station 18 can include an air compressor and a battery charger, respectively. Moreover, if the scheduled services include detailing the vehicle, the mobile station can include car-washing tools and/or a vacuum cleaner. Accordingly, equipping mobile service station 18 with the above-discussed equipment and materials affords the service provider flexibility to provide the scheduled services.
[0027] Using method 10 , a customer at step 20 , before setting up a service appointment for articles requiring service or the customer's vehicle 12 , sets up an account with the service provider. In doing so, the customer can set up the account via telephone or the Internet using a website associated with the service provider. For example when setting up an account, the customer submits contact, billing, and vehicle information to the website of the service provider. The contact and billing information, for example, can include name, address, phone number, and payment details. Furthermore, to facilitate use of the customer's vehicle 12 as a platform facilitating exchanges between the customer and service provider, information regarding vehicle 12 is provided to the service provider. Such vehicle information can include the vehicle's license number, year, make, model, and possibly a picture of the vehicle, and, if the customer's vehicle is to be serviced, the vehicle's mileage and service history.
[0028] Once the account is set up, at step 22 the customer can schedule a service appointment also via telephone or the Internet. When using the Internet to schedule the service appointment, information can be exchanged between the customer and service provider using the website or by email-based communication. For example, the website of the service provider can be adapted with input and output fields to afford scheduling of a service appointment by the customer, or the customer and service provider can communicate regarding scheduling via email.
[0029] When scheduling the service appointment, the customer at step 24 can ascertain available dates and locations provided (via telephone and/or the Internet) by the service provider, and can schedule a date and a location for the service appointment accordingly. Furthermore, at step 26 the customer can request and/or select (via telephone and/or the Internet) the type of services to be performed. The availability of service appointments may depend on whether the service provider will be servicing a particular locale. Alternatively, the service provider can email the customer with dates that a particular locale will be served, and ask whether a service appointment is needed. By return email, the customer can schedule a date and a location for the services accordingly, and request the types of services to be performed on the vehicle.
[0030] Prior to the service appointment for the vehicle, the service provider can provide mobile service station 18 at step 28 with equipment and materials 19 necessary to facilitate transport of the articles and/or provide the scheduled services.
[0031] Also prior to the service appointment, the customer at step 30 can arrange for the service provider to have access to the vehicle. As discussed above, the customer can utilize security storage box 14 such as that shown in FIG. 3 to grant access to the customer's vehicle even when locked.
[0032] To grant access to the service provider, security storage box 14 can be attached, for example, to a window 50 of the customer's vehicle 12 , or in close proximity thereto. To secure security storage box 14 to the customer's vehicle 12 , a portion thereof can be trapped between the window and door jam/frame of the vehicle 12 . Furthermore, besides being attached to the customer's vehicle, security storage box 14 could be fixedly attached to a structure adjacent the location where the vehicle is ultimately parked.
[0033] Security storage box 14 includes a lip 52 to facilitate attachment of the customer's vehicle 12 . During attachment, window 50 is inserted between lip 52 and the remainder of security storage box 14 . Thereafter, the closing of window 50 secures security storage box 14 to the customer's vehicle 12 by trapping security storage box 14 . As shown in FIG. 2 , security storage box 14 is trapped between window 50 and a door jam 54 of the customer's vehicle 12 . For other vehicles (not shown), storage box 14 could be trapped between the window and a door frame (not shown) thereof.
[0034] Security storage box 14 can be purchased by the customer, or loaned to or rented by the service provider to the customer. Security storage box 14 (besides lip 52 ) also includes body 56 , a lid 58 , and a lock 60 . Lid 58 is hingedly connected to body 56 , and a compartment (not shown) formed in body 56 can be covered by lid 58 . Lock 60 (such as a combination or keyed lock) is used to secure lid 58 to body 56 , and restrict access to the compartment. As such, the key, the keyless entry device, and/or the note with the security code provided thereon for the customer's vehicle 12 can be placed in the compartment to be locked inside security storage box 14 .
[0035] An exemplary security storage box 14 is sold by HPC, Inc. under the brand-name Auto Key Keeper™. Whether purchased, loaned or rented, access to the security storage box 14 must be arranged. If purchased, the combination or a copy of an individualized key can be provided to the service provider by the customer to gain access to the interior of security storage box 14 . If loaned or rented, a combination or copy of an individualized key can be provided to the customer, and the service provider can rely on the combination and the individualized key, or a master key applicable to some or all of the boxes loaned or rented thereby to gain access to security storage box 14 .
[0036] When loaned to the customer, the service provider can retrieve security storage box 14 from the customer at the time the scheduled services have been performed. As such, the services can be performed on a single occasion without the need for the service provider to retrieve security storage box 14 at a later time.
[0037] Use of security storage box 14 grants access to the key, the keyless entry device, and/or or the note with the security code provided thereon for customer's vehicle 12 by the service provider, and hence, grants access to the customer's locked vehicle. With such access, the service provider can pick up and drop off articles requiring service, and perform services on the customer's vehicle 12 . Furthermore, with the access to the customer's vehicle 12 afforded by security storage box 14 , the services can be provided without need of a meeting between the customer and service provider.
[0038] Once the customer has scheduled a date and location for the service appointment and provided access for the service provider to the vehicle, customer at step 32 leaves the vehicle on the specified date in the specified location. If necessary, the precise location of the vehicle can be provided by the customer (via telephone and/or the Internet) on the date of service appointment to the service provider. For example, if the customer, while at work, parks the vehicle in a parking garage or lot, the precise location (e.g., parking space, row, and/or deck number within the parking garage or lot) of the vehicle can be provided to the service provider.
[0039] Thereafter, the service provider at step 34 locates the vehicle. Security storage box 14 can itself service as an identifier of which vehicle is the customer's vehicle 12 . For example, security storage box 14 can be colored and/or include markings identifying the customer. Furthermore, security storage box 14 can be equipped with a GPS (global positioning system) locator and/or a RFID (radio frequency identification) locator. Using these locators, the service provider can pinpoint the location of the customer's vehicle 12 .
[0040] However, to locate the vehicle, the service provider must also have access to the location where the vehicle is located. If the vehicle is parked at the home of the customer, then the customer can provide access to the vehicle. However, if the vehicle is parked in a parking garage or lot, the service provider must have access to the parking garage or lot. Accordingly, the service provider may arrange by agreement with the owner or operator of the parking garage or lot for access thereto. Such an agreement can be mutually beneficial to the service provider and the owner or operator. For example, in exchange for access to the parking garage or lot, the service provider can provide exclusivity by agreeing to only service that particular parking garage or lot. The owner or operator of the parking garage or lot can then market their parking services to patrons thereof as having the exclusive benefits afforded by the service provider. Furthermore, such an agreement could afford the service provider permission to market services to the patrons of the parking garage or lot.
[0041] At step 36 , the service provider accesses security storage box 14 to obtain the key, the keyless entry device, and/or the note with the security code provided thereon to gain access to the customer's locked vehicle.
[0042] Thereafter, at step 38 , the specified services are performed by the service provider for articles requiring service or on the customers' vehicles. To facilitate service of the articles, the service provider (with access to the customer's vehicle) can pick up and remove the articles from the customer's vehicle 12 and then service the articles. If necessary, the service provider can remove the articles to a remote location to perform the services.
[0043] Furthermore, when servicing the customer's vehicle 12 , the key, the keyless entry device, and/or the security code provided by the customer will afford the service provider access to the vehicle, and, if necessary, allow the vehicle to be temporarily moved. In doing so, spill/safety mats can be placed under the vehicle. The spill/safety mats cover and protect the surroundings, for example, in the parking garage or lot where the vehicle is parked. Furthermore, if the vehicle is moved from a parking space in a parking garage or lot, a space holder such as a sign, parking cone, or other physical barrier can be positioned in that parking space. If using a sign, the sign can, for example, indicate that any vehicle parked in that parking space will be towed.
[0044] After the scheduled services have been performed, at step 40 the service provider can drop off and return the articles to the customer's vehicle 12 , and lock vehicle 12 with the articles placed therein. If necessary, the vehicle can be returned to its previous location.
[0045] At step 40 , the key, the keyless entry device, and the note with the security code provided thereon can be returned to the customer using security storage box 14 , and an indicator can be left on the vehicle noting that scheduled services have been completed. Furthermore, if security storage box 14 has been loaned to the customer, the service provider, rather than returning them in security storage box 14 , can leave the key, the keyless entry device, or the note with the security code provided thereon in the customer's locked vehicle 12 . In doing, the service provider can retrieve security storage box 14 from the customer at the time the scheduled services have been performed. By retrieving security storage box 14 at the time the scheduled services have been performed, the service provide can remove the necessity for retrieving security storage box 14 from the customer at a later time.
[0046] Thereafter, at step 42 , the customer can be billed, and a detailed receipt and any additional information regarding the scheduled services can be left in the compartment of security storage box 14 or in the interior or trunk of the customer's vehicle 12 . Furthermore, the detailed receipt and the additional information can be communicated to the customer via the Internet. In doing so, the detailed receipt and the additional information can be reviewed by the customer, for example, through the website of the service provider or emailed to the customer.
[0047] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims. | A method of granting a service provider access to a vehicle of a customer to facilitate provision of services therefor is disclosed. The method includes the acts of scheduling a service appointment with the service provider for servicing at least one of the vehicle and articles placed within the interior or trunk of the vehicle, and, if the service appointment is scheduled for the articles, then locking the interior or trunk of the vehicle with the articles placed therein. The method further includes the acts of attaching a security storage box to the vehicle or in proximity to the vehicle, and locking a means for accessing the interior or trunk of the vehicle in the security storage box, granting access to the service provider to the means for accessing locked in the security storage box, and permitting access to the interior or trunk of the vehicle using the means for accessing to afford service to the vehicle or the articles. | 6 |
DUAL APPLICATIONS
This application is related to Application Ser. No. 768,330, filed Aug. 22, 1985.
FIELD OF THE INVENTION
This invention relates to a method for separating isopropyl acetate from isopropanol using certain higher boiling liquids as the extractive agent in extractive distillation.
DESCRIPTION OF PRIOR ART
Extractive distillation is the method of separating close boiling compounds or azeotropes by carrying out the distillation in a multiplate rectification column in the presence of an added liquid or liquid mixture, said liquid(s) having a boiling point higher than the compounds being separated. The extractive agent is introduced near the top of the column and flows downward until it reaches the stillpot or reboiler. Its presence on each plate of the rectification column alters the relative volatility of the close boiling compounds in a direction to make the separation on each plate greater and thus require either fewer plates to effect the same separation or make possible a greater degree of separation with the same number of plates. When the compounds to be separated normally form an azeotrope, the proper agents will cause them to boil separately during extractive distillation and thus make possible a separation in a rectification column that cannot be done at all when no agent is present. The extractive agent should boil higher than any of the close boiling liquids being separated and not form minimum azeotropes with them. Usually the extractive agent is introduced a few plates from the top of the column to insure that none of the extractive agent is carried over with the most volatile component. This usually requires that the extractive agent boil twenty Centigrade degrees or more higher than the lowest boiling component.
At the bottom of a continuous column, the less volatile components of the close boiling mixtures and the extractive agent are continuously removed from the column. The usual methods of separation of these two components are the use of another rectification column, cooling and phase separation or solvent extraction.
One of the commercially important ways to manufacture isopropyl acetate is by the catalytic esterification of isopropanol with acetic acid. Isopropyl acetate (b.p.=88.7° C.), isopropanol (b.p.=82.3° C.) and water (b.p.=100° C.) form a ternary azeotrope boiling at 75.5° C. containing 76 wt.% isopropyl acetate, 13 wt.% isopropanol and 11 wt.% water. Isopropyl acetate also forms a binary azeotrope with isopropanol which boils at 80.1° C. and contains 47.4 wt.% isopropyl acetate and a binary azeotrope with water boiling at 75.9° C. containing 88.9 wt.% isopropyl acetate. Isopropanol also forms a binary minimum azeotrope with water which boils at 80.4° C. and contains 87.8 wt.% isopropanol. Thus in the esterification of isopropanol with acetic acid to form isopropyl acetate and water, the rectification of this mixture has three binary and one ternary azeotrope to contend with, and yields the lowest boiling constituent, namely the isopropyl acetate-isopropanol-water ternary azeotrope. It is therefore impossible to produce isopropyl acetate from isopropanol and water mixtures by rectification because the lower boiling ternary azeotrope will always come off overhead as the initial product. Any mixture of isopropyl acetate, isopropanol and water subjected to rectification at one atmosphere pressure will produce an overhead product boiling at 75.5° C. and containing 76 wt.% isopropyl acetate, 13 wt.% isopropanol and 11 wt.% water. Extractive distillation would be an attractive method of effecting the separation of isopropyl acetate from isopropanol if agents can be found that (1) will break the isopropyl acetate-isopropanol-water azeotrope and (2) are easy to recover from the isopropanol, that is, form no azeotrope with isopropanol and boil sufficiently above isopropanol to make the separation by rectification possible with only a few theoretical plates.
Extractive distillation typically requires the addition of an equal amount to twice as much extractive agent as the isopropyl acetate-isopropanol-water on each plate of the rectification column. The extractive agent should be heated to about the same temperature as the plate into which it is introduced. Thus extractive distillation imposes an additional heat requirement on the column as well as somewhat larger plates. However this is less than the increase occasioned by the additional agents required if the separation is to be done by azeotropic distillation.
Another consideration in the selection of the extractive distillation agent is its recovery from the bottoms product. The usual method is by rectification in another column. In order to keep the cost of this operation to a minimum, an appreciable boiling point difference between the compound being separated and the extractive agent is desirable. It is also desirable that the extractive agent be miscible with isopropanol otherwise it will form a two-phase azeotrope with isopropanol in the recovery column and some other method of separation will have to be employed.
The breaking of this azeotrope by extractive distillation is a new concept. The closest application of the concept might be the breaking of the methyl acetate-methanol azeotrope reported by Yoshida & Oka in Japanese Pat. No. 54/119-411, Sept. 17, 1979, the breaking of the acetone-methanol azeotrope reported by Berg & Yeh, U.S. Pat. No. 4,501,645, Feb. 26, 1985 or the breaking of the n-butyl acetate-n-butanol-water azeotrope reported by Berg & Yeh, U.S. Pat. No. 4,525,245, June 26, 1985.
OBJECTIVE OF THE INVENTION
The object of this invention is to provide a process or method of extractive distillation that will enhance the relative volatility of isopropyl acetate from isopropanol in their separation in a rectification column. It is a further object of this invention to identify suitable extractive distillation agents which will eliminate the isopropyl acetate-isopropanol-water ternary azeotrope and make possible the production of pure isopropyl acetate and isopropanol by rectification. It is a further object of this invention to identify organic compounds which, in addition to the above constraints, are stable, can be separated from isopropanol by rectification with relatively few theoretical plates and can be recycled to the extractive distillation column and reused with little decomposition.
SUMMARY OF THE INVENTION
The object of the invention is provided by a process for separating isopropyl acetate from isopropanol which entails the use of certain amino alcohols as the agents in extractive distillation.
DETAILED DESCRIPTION OF THE INVENTION
We have discovered that certain amino alcohols, both individually and as mixtures, will effectively negate the isopropyl acetate-isopropanol-water ternary azeotrope and permit the separation of pure isopropyl acetate from isopropanol by rectification when employed as the agent in extractive distillation. Table 1 lists several amino alcohols and their mixtures and approximate proportions that we have found to be effective. The data in Table 1 was obtained in a vapor-liquid equilibrium still. In each case, the starting material was the isopropyl acetate-isopropanol-water azeotrope. The ratios are the parts by weight of extractive agent used per part of isopropyl acetate-isopropanol-water azeotrope. The relative volatilities are listed for each when two ratios were employed. The compounds that are effective when used alone are ethanolamine, diethanolamine, triethanolamine, N-methyl ethanol-amine, methyl diethanolamine and isopropanolamine. The compound which is effective when used in mixtures with amino alcohols is N-methyl-pyrrolidone. The two relative volatilities shown in Table 1 correspond to the two different ratios employed. For example, in Table 1, one half
TABLE 1______________________________________Effective Agents For Separating Isopropyl AcetateFrom Isopropanol Which Contain Amino Alcohols RelativeCompound Ratios Volatilities______________________________________Ethanolamine 1 3.54Diethanolamine " 2.72Triethanolamine " 2.03N--Methyl ethanolamine " 2.31Methyl diethanolamine " 6/5 1.46 1.88Isopropanolamine " 2.48Ethanolamine, N--Methylpyrrolidone (1/2).sup.2 3.22Triethanolamine, N--Methyl " (3/5).sup.2 1.98 1.99pyrrolidone______________________________________
part of N-methylpyrrolidone mixed with one half part of triethanolamine with one part of the isopropyl acetate-isopropanol-water azeotrope gives a relative volatility of 1.98, 3/5 parts of N-methylpyrrolidone plus 3/5 parts of triethanolamine gives 1.99. In every example in Table 1 the starting material is the isopropyl acetate-isopropanol-water azeotrope which possesses a relative volatility of 1.0.
TABLE 2______________________________________Data From Run Made In Rectification Column Wt. % Isopropyl Acetate RelativeAgent Overhead Bottoms Volatility______________________________________Blank 84.6 82.6 1.03Ethanolamine 98 83.8 3.4______________________________________ Initial Mixture: 304 gm. Isopropyl acetate + 52 gm. Isopropanol + 44 gm. Water Blank: No agent used Agent Added at 20 ml/min. and 65° C.
The data in Table 2 was obtained in the following manner. The charge was 76 wt.% isopropyl acetate, 13 wt.% isopropanol and 11 wt.% water and after a half hour of operation in the 4.5 theoretical plate column to establish equilibrium, ethanolamine at 65° C. and 20 ml/min. was pumped in. The rectification was continued for two hours with sampling of overhead and bottoms after one hour, 1.5 hours and two hours. The average of the three analyses was 98 wt.% isopropyl acetate in the overhead and 83.8 wt.% in the bottoms, both on a water-free basis which gives a relative volatility of 3.4 of isopropyl acetate to isopropanol. This indicates that the ternary azeotrope has been negated and separation accomplished. The isopropyl acetate comes off in the form of its binary azeotrope with water which on condensation, immediately forms two liquid layers. The solubility of isopropyl acetate in water is only 3%.
THE USEFULNESS OF THE INVENTION
The usefulness or utility of this invention can be demonstrated by referring to the data presented in Tables 1 & 2. All of the successful extractive distillation agents show that isopropyl acetate, isopropanol and water can be separated from their ternary azeotrope by means of distillation in a rectification column and that the ease of separation as measured by relative volatility is considerable. Without these extractive distillation agents, no improvement above the azeotrope composition will occur in a rectification column. The data also show that the most attractive agents will operate at a boilup rate low enough to make this a useful and efficient method of recovering high purity isopropyl acetate from any mixture of these three including the ternary minimum azeotrope. The stability of the compounds used and the boiling point difference is such that complete recovery is obtainable by a simple distillation and the amount required for make-up is small.
WORKING EXAMPLES
Example 1
The isopropyl acetate-isopropanol-water azeotrope is 76 wt.% isopropyl acetate, 13 wt.% isopropanol, 11 wt.% water. Fifty grams of the isopropyl acetate-isopropanol-water azeotrope and fifty grams of methyl diethanolamine were charged to an Othmer type glass vapor-liquid equilibrium still and refluxed for eleven hours. Analyses of the vapor and liquid by gas chromatography gave vapor composition of 83.4% isopropyl acetate, 16.6% isopropanol; liquid composition of 77.5% isopropyl acetate, 22.5% isopropanol. This indicates a relative volatility of 1.46. Ten grams of methyl diethanolamine were added and refluxing continued for another twelve hours. Analyses gave vapor composition of 83.2% isopropyl acetate, 16.8% isopropanol; liquid composition of 72.6% isopropyl acetate, 27.4% isopropanol which is a relative volatility of 1.88.
Example 2
Fifty grams of the isopropyl acetate-isopropanol-water azeotrope, 25 grams of N-methyl pyrrolidone and 25 grams of triethanolamine were charged to the vapor liquid equilibrium still and refluxed for nine hours. Analyses indicated a vapor composition of 90.7% isopropyl acetate, 9.3% isopropanol; a liquid composition of 83.2% isopropyl acetate, 16.8% isopropanol which is a relative volatility of 1.98. Five grams of N-methyl pyrrolidone and five grams of triethanolamine were added and refluxing continued for another twelve hours. Analyses indicated a vapor composition of 90.2% isopropyl acetate, 9.8% isopropanol; a liquid composition of 82.2% isopropyl acetate, 17.8% isopropanol which is a relative volatility of 1.99.
Example 3
A glass perforated plate rectification column was calibrated with ethylbenzene and p-xylene which possesses a relative volatility of 1.06 and found to have 4.5 theoretical plates. A solution of 304 grams of isopropyl acetate, 52 grams of isopropanol and 44 grams of water was placed in the stillpot and heated. When refluxing began, an extractive agent comprising ethanolamine was pumped into the column at a rate of 20 ml/min. The temperature of the extractive agent as it entered the column was 65° C. After establishing the feed rate of the extractive agent, the heat input to the isopropyl acetate, isopropanol and water in the stillpot was adjusted to give a total reflux of 10-20 ml./min. After one hour of operation, the overhead and bottoms samples of approximately two ml. were collected and analysed by gas chromatography. The overhead analyses were 98% isopropyl acetate, 2% isopropanol. The bottoms analyses were 83.8% isopropyl acetate, 16.2% isopropanol. Using these compositions in the Fenske equation, with the number of theoretical plates in the column being 4.5, gave an average relative volatility of 3.4 for each theoretical plate. | Isopropyl acetate cannot be completely removed from isopropyl acetate - isopropanol - water mixtures by distillation because of the presence of the minimum ternary azeotrope. Isopropyl acetate can be readily removed from mixtures containing it, isopropanol and water by using extractive distillation in which the extractive agent is a higher boiling oxygenated or nitrogenous organic compound or a mixture of these. Typical examples of effective agents are diethanolamine; ethanolamine and N-methyl pyrrolidone; triethanolamine and N-methyl pyrrolidone. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to suspended ceiling systems for supporting a plurality of ceiling panels, and more particularly, but not by way of limitation, to suspended ceiling systems employing a plurality of interconnected main and cross runners assembled to form a grid structure for supporting a plurality of ceiling panels or the like.
2. Description of the Prior Art
The prior art includes a number of schemes for the construction of grid systems for supporting ceiling panels. However, many of the prior systems are unsatisfactory due to the insufficient strength of the connections between abutting aligned main runners. Other of the prior art systems fail to provide secure connection of the cross runners to the medial portion of the main runners, thereby permitting the inadvertent disconnection of the cross runners from the main runners when the ceiling panels are being installed on the grid system.
Summary of the Invention
The present invention relates to a grid system for supporting ceiling panels or the like of the type which includes a plurality of longitudinal beams in a spaced parallel relation with each longitudinal beam including a plurality of main runners in aligned connection with each other, and a plurality of cross runners in parallel spaced relation normal to and interconnecting adjacent parallel longitudinal beams. Each main runner includes an intermediate elongated web portion having a longitudinally extending reinforcing bead portion along one longitudinal edge thereof and a longitudinally extending flange portion along the opposite edge portion thereof for supporting ceiling panels or the like. Each cross runner includes an intermediate elongated web portion having a reinforcing bead portion extending along one edge portion thereof and a flange portion extending along the opposite edge portion thereof for supporting ceiling panels or the like.
Improvement in this grid system includes a tongue portion integrally joined with and extending longitudinally from each end of the web portion of each main runner. Each tongue portion is laterally offset with respect to the respective web portion a distance approximately equal to the thickness of the web portion and is disposed wholly on the same side of the plane of the web portion. Each tongue portion has substantially parallel upper and lower edge portions in substantial alignment with the longitudinal axis of the respective main runner.
First detent means form in each tongue portion a distance from the respective end of the web portion for connecting the respective main runner to a like main runner is also included. Each first detent means is struck out from the respective tongue portion in the same direction as the offset of the respective tongue portion to the respective web portion.
First guide loop means formed in each end portion of the web portion and spaced a distance from the respective end thereof for receiving the tongue portion of a like main runner therethrough is also included. Each first guide loop means is struck out from the respective web portion in the opposite direction from the offset of said respective tongue portion relative to the respective web portion and a distance approximately equal to at least twice the thickness of the respective web portion.
The improvement further includes first detent engaging surface means formed on each first guide loop means distal from the respective end of the web portion of the respective main runner for engaging said first detent means of a like main runner and connecting the respective main runner and a like main runner in longitudinally aligned relation.
The improved grid system also includes first web cam surface means struck out from each end portion of each web portion adjacent to the respective first detent engaging surface means and in the same direction as the offset of said respective tongue portion of the respective main runner for camming a tongue portion of a like main runner into alignment with the respective web portion of the respective main runner when said first web cam surface means is engaged by the tongue portion of the like main runner as the main runners are connected.
The improvement further includes first loop cam surface means struck out from each first guide loop means proximate to the respective end of the web portion of the respective main runner and in the opposite direction from the offset of said respective tongue portion of the respective main runner for camming the tongue portion of a like main runner toward the web portion of the respective main runner as the main runners are connected.
It is, therefore, an object of the present invention to provide an improved ceiling grid system for supporting ceiling panels or the like which may be easily erected in a minimum amount of time.
Another object of the invention is to provide a ceiling grid system which may be easily assembled to provide a relatively rigid structure which will not become inadvertently disassembled during the installation of ceiling panels or the like.
A further object of the invention is to provide a novel joint for interconnecting longitudinal main runners in aligned relation which may be simply and easily connected, resist inadvertent disconnection, and provide great structural strength for supporting ceiling panels or the like.
Still another object of the invention is to provide an improved connection joint for cross runners which may be quickly and easily connected to the medial portion of a main runner, resists inadvertent disconnection during the installation of ceiling panels or the like, and provides sufficient structural strength to support ceiling panels or the like.
A still further object of the invention is to provide an improved ceiling grid structure which is economical to manufacture, simple and easy to erect, and structurally sound.
Other objects and advantages of the invention will be evident from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a portion of the ceiling grid system of the present invention.
FIG. 2 is a fragmentary perspective view of two main runners in aligned relation prior to the interconnection thereof.
FIG. 3 is a fragmentary perspective view of the two main runners of FIG. 2 interconnected to form a rigid structure.
FIG. 4 is a fragmentary side elevation view of two main runners in aligned relation prior to the interconnections thereof.
FIG. 5 is a fragmentary cross-sectional view of the two main runners of FIG. 4 taken along line 5--5 of FIG. 4.
FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 4.
FIG. 7 is a cross-sectional view taken along line 7--7 of FIG. 4.
FIG. 8 is a fragmentary perspective view of two cross runners in aligned relation and a main runner positioned therebetween and normal thereto prior to the interconnection of the cross runners and the main runner.
FIG. 9 is a fragmentary perspective view of the two cross runners and the main runner of FIG. 8 interconnected to form a rigid structure.
FIG. 10 is a fragmentary side elevation view of two cross runners in aligned relation and a main runner positioned therebetween and normal thereto prior to the interconnection of the cross runners and the main runner.
FIG. 11 is a fragmentary cross-sectional view of the two cross runners and the main runner of FIG. 10 taken along line 11--11 of FIG. 10.
FIG. 12 is a fragmentary side elevation of the two cross runners and the main runner of FIG. 10 interconnected to form a rigid structure.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and to FIG. 1 in particular, the suspended ceiling system of the present invention includes a grid system for supporting ceiling panels or the like which is generally designated by the reference character 10. The grid system 10 includes a plurality of longitudinal beams 12 aligned in spaced parallel relation, with each longitudinal beam 12 comprising one or more main runners 14 in aligned connection with each other. The grid system 10 further includes a plurality of cross runners 16 positioned in parallel spaced relation normal to and interconnecting adjacent parallel longitudinal beams 12.
Each main runner 14 includes an intermediate elongated web portion 18 having a longitudinally extending reinforcing bead portion 20 formed along the upper edge portion 22 thereof, and a longitudinally extending flange portion 24 formed along the lower edge portion 26 thereof for supporting ceiling panels or the like.
Each cross runner 16 includes an intermediate elongated web portion 28 having a reinforcing bead portion 30 formed along the upper edge portion 32 thereof, and a flange portion 34 formed along the lower edge portion 36 thereof for supporting ceiling panels or the like.
Apertures 38 are formed in the web portion 18 of each main runner 14 and in the web portion 28 of each cross runner 16 to facilitate the installation of the grid system 10 beneath a conventional ceiling or overhead structure. The grid system 10 may be suspended from such conventional ceiling or overhead structure by a plurality of hangers 40 the lower ends of which are secured to the grid system 10 preferably through an aperture 38 adjacent to the interconnection of two cross runners 16 and a main runner 14. Many apertures 38 are provided in a typical grid system 10, however, it will be readily apparent that all the apertures 38 need not be utilized to satisfactorily suspend the grid system 10 beneath a conventional ceiling or overhead structure.
Description of the Apparatus of FIGS. 2-7
Referring now to FIGS. 2-7, there is illustrated therein novel means for rigidly interconnecting two longitudinally aligned main runners 14 to form a rigid longitudinal beam 12. It will be noted that the end portions of the main runners 14 illustrated in FIGS. 2-5 are identical in construction. Each main runner 14 includes a tongue portion 42 joined with and extending longitudinally from the end of the web portion 18 thereof. Each tongue portion 42 is laterally offset with respect to the respective web portion 18 a distance substantially equal to the thickness of the web portion 18, as most clearly shown in FIG. 5. Each tongue portion 42 is disposed wholly on the same side of the plane of the respective web portion 18, with each tongue portion 42 having substantially parallel upper and lower edge portions 44 and 46 in substantial alignment with the longitudinal axis of the respective main runner 14.
Each tongue portion 42 includes first detent means formed thereon a distance from the respective end of the web portion 18 for connecting the respective main runner 14 to a like main runner. The first detent means comprises a first detent tab 48 struck out from the tongue portion 42 in the same direction as the offset of the tongue portion 42 to the respective web portion 18.
A first guide loop 50 is formed in the end portion of the web portion 18 and is spaced a distance from the respective end thereof. The first guide loop 50 is struck out from the respective web portion 18 in the opposite direction from the offset of the respective tongue portion 42 relative to the web portion 18. The first guide loop 50 is struck out a distance substantially equal to at least twice the thickness of the respective web portion 18. The first guide loop 50 is sized and shaped to slidingly receive therethrough the tongue portion 42 of a like main runner 14 to which the respective main runner 14 is to be connected. Each first guide loop 50 includes a first detent engaging surface 52 formed thereon distal from the respective end of the web portion 18 of the respective main runner 14 for engaging the first detent tab 48 of a like main runner 14 and thereby connecting the respective main runner 14 and the like main runner 14 in longitudinally aligned relation. See FIG. 3. The first guide loop 50 also includes a first loop cam surface 54 struck out from the respective first guide loop 50 proximate to the respective end of the web portion 18 of the respective main runner 14 and in the opposite direction from the offset of the respective tongue portion 42 of the respective main runner 14 for camming the tongue portion 42 of a like main runner 14 toward the web portion 18 of the respective main runner 14 as the two main runners are connected.
A first web cam surface 56 is struck out from the end portion of the respective web portion 18 adjacent to the respective first detent engaging surface 52 and in the same direction as the offset of the respective tongue portion 42 of the respective main runner 14 for camming the tongue portion 42 of a like main runner 14 into alignment with the respective web portion 18 of the respective main runner 14 when the first web cam surface 56 is engaged by the tongue portion 42 of the like main runner 14 as the two main runners are connected.
Each tongue portion 42 includes second detent means formed thereon intermediate the first detent tab 48 and the respective end of the web portion 18 for connecting the respective main runner 14 to a like main runner. The second detent means comprises a second detent tab 58 struck out from the respective tongue portion 42 in the same direction as the first detent tab 48. The first and second detent tabs 48 and 58 are preferably positioned in alignment with the longitudinal axis of the respective main runner 14 and equidistant from the upper and lower edge portions 44 and 46 of the respective tongue portion 42. A second guide loop 60 is formed in the end portion of the respective web portion 18 intermediate the respective first guide loop 50 and the respective end of the web portion 18. The second guide loop 60 is struck out from the respective web portion 18 in the same direction as the first guide loop 50. The second guide loop 60 is struck out a distance substantially equal to at least twice the thickness of the respective web portion 18, and is sized and shaped substantially identical to the first guide loop 50 described above. The second guide loop 60 includes a second detent engaging surface 62 formed thereon distal from the respective end of the web portion 18 of the respective main runner 14 for engaging the second detent tab 58 of a like main runner 14 and connecting the respective main runner 14 and a like main runner in longitudinally aligned relation. See FIG. 3. The second guide loop 60 also includes a second loop cam surface 64 struck out therefrom proximate to the respective end of the web portion 18 of the respective main runner 14 and in the same direction as the first loop cam surface 54 for camming the tongue portion 42 of the like main runner 14 toward the web portion 18 of the respective main runner 14 as the two main runners are connected.
A second web cam surface 66 is struck out from the respective end portion of the respective web portion 18 adjacent to the respective second detent engaging surface 62. The second web cam surface 66 is struck out from the web portion 18 in the same direction as the first web cam surface 56 of camming the tongue portion 42 of a like main runner 14 into alignment with the respective web portion 18 of the respective main runner 14 when the second web cam surface 66 is engaged by the tongue portion 42 of a like main runner 14 as the two main runners are connected.
Each tongue portion 42 includes a pair of parallel reinforcing ribs 58 and 70 formed therein and extending longitudinally therefrom into the respective web portion 18 for reinforcing the tongue portion 42 relative to the web portion 18. The preferred configuration of the reinforcing ribs 68 and 70 is clearly illustrated in FIGS. 4, 5 and 7.
An aperture 72 is formed in the web portion 18 of the respective main runner 14 proximate to the first web cam surface 56. The aperture 72 affords means for connecting a hanger 40 or the like to the main runner 14 to provide support therefor.
Operation of the Apparatus of FIGS. 2-7
In order to rigidly connect two main runners 14 in longitudinal alignment, the two main runners 14 are held in longitudinal alignment and the tongue portion 42 of one main runner 14 is inserted into the second guide loop 60 of the other main runner 14, while simultaneously the tongue portion 42 of the other main runner 14 is inserted into the second guide loop 60 of the first main runner 14. The two main runners 14 are then forced together in longitudinal alignment until the tongue portion 42 of each main runner 14 is fully received through the first and second guide loops 50 and 60 of the other main runner 14, at which time the respective web portions 18 of the main runners 14 will abut one another and the first and second detent tabs 48 and 58 of each main runner 14 will engage the corresponding first and second detent engaging surfaces 52 and 62 of the other main runner 14 thereby securely interconnecting the two main runners 14 as clearly illustrated in FIG. 3.
It will be readily apparent that the previously described interconnection of the two main runners 14 forms a longitudinal beam 12. Such a longitudinal beam 12 is not susceptible to inadvertent disconnection after the two main runners 14 are once assembled.
Description of the Apparatus of FIGS. 8-12
Referring now to FIGS. 8-12, there is illustrated therein novel means for rigidly interconnecting two aligned cross runners 16 to a respective longitudinal main runner 14 disposed therebetween and in normal relation thereto. It will be noted that the end portions of the cross runners 16 illustrated in FIGS. 8-12 are identical in construction. Each cross runner 16 includes a tongue portion 74 jointed with and extending from the end of the web portion 28 thereof. Each tongue portion 74 is laterally offset with respect to the respective web portion 28 a distance substantially equal to the thickness of the web portion 28, as most clearly shown in FIG. 11. Each tongue portion 74 is disposed wholly on the same side of the plane of the respective web portion 28, with each tongue portion 74 having a lower edge portion 76 in substantial parallel alignment with the flange portion 34 of the respective cross runner 16. The upper edge portion 78 of the tongue portion 74 includes a straight surface portion 80 extending from the respective end of the web portion 28 of the cross runner 16 adjacent to and in substantial parallel alignment with the upper edge portion 32 thereof and the lower edge of the respective reinforcing bead portion 30 thereof. A vertical portion 82 extends downwardly from the straight surface portion 80 and intersects a slightly downwardly inclined portion 84 to complete the upper edge portion 78 of the tongue portion 74.
The tongue portion 74 further includes tab means formed on the lower edge portion 76 thereof which includes a vertical portion 86 extending downwardly from the lower edge portion 76 and a substantially straight portion 88 intersecting the vertical portion 86 and extending away from the web portion 28 and in substantial parallel alignment with the lower edge portion 76 of the tongue portion 74.
Detent means in the form of a detent tab 90 is formed in each tongue portion 74 for engaging the web portion 18 of a respective main runner 14. Each detent tab 90 is struck out from the respective tongue portion 74 in the same direction as the offset of tongue portion 74 relative to the web portion 28 of the respective cross runner 16.
Each tongue portion 74 includes a reinforcing rib 92 extending therefrom and formed in the adjacent end of the respective web portion 28 of the respective cross runner 16.
As shown in FIGS. 8-12, the main runner 14 to which the cross runners 16 are to be connected includes a vertically oriented slot 94 formed in the web portion 18 of the main runner 14. The slot 94 is disposed intermediate the two apertures 38. It should be noted that in the manufacture of the main runners 14, the cluster comprising the slot 94 and the two apertures 38, as most clearly shown in FIG. 8, is preferably located on 6 inch centers over the entire length of the main runner 14. Each slot 94 includes an upper end 96, a lower end 98, and opposite sides 100 and 102. The width of the slot 94 between the sides 100 and 102 is of such size as to receive therethrough the respective tongue portions 74 of abutting cross runner 16 for assembly of the cross runner 16 and the main runner 14 as will be described thereinafter.
Operation of the Apparatus of FIGS. 8-12
In order to rigidly interconnect the two cross runners 16 and the main runner 14, as best illustrated in FIGS. 9 and 12, the two cross runners 16 are held in longitudinal alignment and the respective tongue portions 74 are inserted through the slot 94 in the main runner 14 from opposite sides of the main runner 14, one at a time.
Each cross runner 16 is in proper position relative to the main runner 14 when the lower edge portion 76 of the respective tongue portion 74 is positioned over and in contact with the lower end 98 of the slot 94. The straight surface portion 80 of the respective tongue portion 74 is positioned beneath and is in contact with the lower edge of the reinforcing bead portion 20 of the main runner 14 thereby retaining the lower edge portion 76 in contact with the lower end 90 of the slot 94. The detent tab 90 of the respective tongue portion 74 engages the web portion 18 of the main runner 14, and the vertical portion 86 of the tongue portion 74 also engages the web portion 18 of the main runner 14 below the lower end 98 of the slot 94, thereby preventing the disengagement and withdrawal of the respective cross runner 16 from the main runner 14, as clearly illustrated in FIGS. 9 and 12. It will be readily apparent that the engagement of the straight surface portion 80, the detent tab 90, the lower edge portion 76 and the vertical portion 86 of the tongue portion 74 of each of the two cross runners 16 with the main runner 14 as described above provides a rigid interconnection of the two cross runners 16 and the main runner 14 which restricts linear and angular movement of each cross runner 16 relative to the main runner 14 thereby preventing the disengagement thereof. The previously described apertures 38 afford means for connecting a hanger 40 or the like to the main runner 14 to provide support for the grid system 10 at the juncture of the two cross runners 16 and the main runner 14.
It will be readily apparent to those skilled in the art that the previously described cluster comprising the slot 94 and the two accompanying apertures 38 may also be formed in the web portion 28 of the cross runners 16, such as on 6 inch centers as mentioned above for the main runner 14. By selection of various lengths of main runners 14 and cross runners 16, virtually any grid system pattern may be fabricated to form ceiling structures in the desired configuration.
The main runners 14 and cross runners 16 described above may be suitably constructed of rolled and stamped thin sheet metal such as aluminum or steel. While the construction of the main and cross runners 14 and 16 is shown to be of the two piece variety, it will be readily apparent that the novel grid structure and interconnection features disclosed herein are readily applicable to main and cross runners formed of a single piece of relatively thin sheet metal.
It is believed apparent that the apparatus disclosed in the present invention readily obtains the objectives set forth herein. Changes may be made in the arrangement or combination of parts or elements shown in the drawings and described in the specification without departing from the spirit and scope of the invention as defined in the following claims. | A suspended ceiling system employing a plurality of main and cross runners for supporting a plurality of ceiling panels, with both the main and cross runners being provided with means for supporting the ceiling panels. Also disclosed are interlocking joint means formed on each end of a respective main runner for interconnection with a like main runner, and interlocking joint means formed on each end of a respective cross runner for interconnection with a like cross runner and the medial portion of a respective main runner disposed therebetween. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to certain 6-(bicyclic heterocyclic)-2-(lower alkyl)-3-(substituted)quinazolinone compounds which have demonstrated activity as angiotensin II (AII) antagonists and are therefore useful in alleviating angiotensin induced hypertension and for treating congestive heart failure.
SUMMARY OF THE INVENTION
According to the present invention, there are provided novel 6-(bicyclic heterocyclic)-2-(lower alkyl)-3-(substituted) quinazolinone compounds of Formula I which have angiotensin II antagonizing properties and are useful as anti-hypertensives: ##STR2## wherein:
R 6 is ##STR3##
R 5 is lower alkyl of 3 to 5 carbon atoms;
R is: ##STR4##
R 1 , R 2 , and R 3 are independently selected from H and lower alkyl of 1 to 4 carbon atoms; n is one or two; or the pharmaceutically acceptable salts thereof.
The present invention also provides novel intermediate compounds, methods for making the novel 2,3,6 substituted quinazolinone angiotensin II antagonizing compounds, a novel pharmaceutical composition containing the novel 2,3,6-substituted quinazolinone compounds, methods of using the novel quinazolinone angiotensin II antagonizing compounds to treat hypertension, congestive heart failure and to antagonize the effects of angiotensin II.
DETAILED DESCRIPTION OF THE INVENTION
The novel compounds of the present invention are prepared according to the following reaction scheme: ##STR5##
Referring to Scheme I, aldehyde 1, reported in EPO0497150, where R 5 is hereinbefore defined is reacted with Grignard reagent 2 where R 1 , R 2 , and R 3 are hereinbefore defined and X is Br, I or Cl to give alcohol 3.
As described in EPO0497150, biphenyl 4 is attached to quinazolinone intermediate 3 by initially alkylating the quinazolinone with a para-substituted benzyl bromide and subsequently attaching a second phenyl moiety containing a trityl protected tetrazole or a cyano via a transition metal catalyzed coupling at the para position at the first phenyl ring. Alternatively, the coupling of quinazolinone intermediate 3 where R 1 , R 2 , R 3 and R 5 are hereinbefore defined with biphenyl 4 where R 7 is a trityl protected tetrazole prepared by the methods of N. B. Mantlo, J. Med. Chem, 34, 2919-2922 (1991) or cyano prepared by the methods outlined in D. J. Carini, J. Med. Chem. 34, 2525-2547 (1991) and gives coupled product 5 by dissolving 3 and 4 in acetone or another suitable solvent such as N,N-dimethylformamide, N,N-dimethyl-acetamide, N-methylpyrrolidinone, methanol, ethanol, t-butanol, tetrahydrofuran, dioxane or dimethylsulfoxide, in the presence of excess potassium carbonate or another suitable base such as sodium carbonate, cesium carbonate, sodium hydride, potassium hydride, sodium methoxide, sodium ethoxide, lithium methoxide, sodium t-butoxide, potassium t-butoxide, lithium diisopropylamide (LDA) or lithium hexamethyldisilazide for 2-48 hours, at 20°-60° C. The obtained alkylated quinazolinone intermediate 5 may be purified by chromatography or used as is in further transformations and/or deprotection. Quinazolinone intermediate 5 is then oxidized with pyridinium dichromate, manganese dioxide or other suitable oxidant to give ketone 6. Ketone 6 is reacted with commercially available cyclic trimethylsilyl enol ether reagent 7 in the presence of titanium tetrachloride to afford diketone quinazolinone intermediate 8. Reduction of 8 with sodium borohydride gives diol 9. Reaction of 9 with methanesulfonyl chloride and a base facilitates ring closure to afford 10.
Deprotection of the trityl group is accomplished by refluxing an aqueous acetone solution of the alkylated quinazolinone 10 with a catalytic amount of hydrochloric acid or other suitable acid such as sulfuric, trifluoroacetic or hydrogen chloride for 2-24 hours. Additionally, heating 10 in tetrahydrofuranmethanol removes the trityl protecting group and affords 11. Reaction of 10 where R 7 is cyano with sodium azide in the presence of tri-n-butyltin chloride in refluxing xylene affords the desired tetrazole 11 after acid work-up. Contemplated equivalents to tri-n-butyltin chloride include tri-(lower alkyl C 1 -C 4 )tin chlorides and bromides. Contemplated equivalents to sodium azide include potassium azide and lithium azide.
Reactions are performed in a solvent appropriate to the reagents and materials employed and suitable for the transformation being effected. It is understood by those skilled in the art of organic synthesis that the various functionalities present on the molecule must be consistent with the chemical transformations proposed. This may necessitate judgement as to the order of synthetic steps, protecting groups, if required, and deprotection conditions. Substituents on the starting materials may be incompatible with some of the reaction conditions. Such restrictions to the substituents which are compatible with the reaction conditions will be apparent to one skilled in the art.
Pharmaceutically suitable salts include both the metallic (inorganic) salts and organic salts; a list of which is given in Remington's Pharmaceutical Sciences, 17th Edition, pg. 1418 (1985). It is well known to one skilled in the art that an appropriate salt form is chosen based on physical and chemical stability, flowability, hydroscopicity and solubility. Preferred salts of this invention for the reasons cited above include potassium, sodium, calcium, magnesium and ammonium salts.
Some of the compounds of the hereinbefore described schemes have centers of asymmetry. The compounds may, therefore, exist in at least two and often more stereo-isomeric forms. The present invention encompasses all stereoisomers of the compounds whether free from other stereoisomers or admixed with other stereoisomers in any proportion and thus includes, for instance, racemic mixture of enantiomers as well as the diastereomeric mixture of isomers. The absolute configuration of any compound may be determined by conventional X-ray crystallography.
While the invention has been illustrated using the trityl protecting group on the tetrazole, it will be apparent to those skilled in the art that other nitrogen protecting groups may be utilized. Contemplated equivalent protecting groups include, benzyl, p-nitrobenzyl, propionitrile or any other protecting group suitable for protecting the tetrazole nitrogen. Additionally, it will be apparent to those skilled in the art that removal of the various nitrogen protecting groups, other than trityl, may require methods other than dilute acid.
The compounds of this invention and their preparation are illustrated by the following nonlimiting examples.
EXAMPLE 1
2-Butyl-6-(1-hydroxy-2-propenyl)-4(1H)-quinazolinone
To a solution of 10.00 g of 2-butyl-1,4-dihydro-4-oxo-6-quinazolinecarboxaldehyde in 350 ml of tetrahydrofuran, cooled to 0° C. is added 130.43 ml of 1.0M vinylmagnesium bromide in tetrahydrofuran over 15 minutes. The reaction mixture is stirred at 0° C. for 30 minutes. The reaction mixture is quenched at 0° C. with 50 ml of saturated ammonium chloride solution and extracted with ethyl acetate. The organic layer is dried (Na 2 SO 4 ) and concentrated in vacuo to afford a residue which is purified by column chromatography on silica gel using 1:1 ethyl acetate-hexane to give 4.81 g of the desired product, as a white solid, MP 141° C.
EXAMPLE 2
2-Butyl-6-(1-hydroxy-2-propenyl)-3-[[2'-[1-triphenylmethyl)-1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl]-4 (3H) -quinazolinone
A mixture of 4.81 g of the product of Example 1, 20.77 g of 5-[4'-(bromomethyl)[1,1'-biphenyl]-2-yl]-(triphenylmethyl)-1H-tetrazole, 0.850 g of lithium methoxide in 75 ml of tetrahydrofuran is refluxed for 48 hours and diluted with ethyl acetate. The mixture is washed with water and the organic layer dried (MgSO 4 ), and concentrated to a residue which is purified by column chromatography using ethyl acetate-hexane (1:4 to 1:1) to give 11.72 g of the desired product as a white solid. 1 H NMR(300MHz, CDCl 3 )δ 8.3(1H, s), 7.9(1H,dd), 7.8(1H,dd), 7.65(1H,dd) , 7.5-6.8(22H,n), 6.15(1H,m), 5.3(3H,m), 5.25(2H, br s), 2.65(2H, t), 1.7(2H,m), 1.4(2H,m), 0.9(3H, t).
EXAMPLE 3
2-Butyl-6-(1-oxo- 2-propenyl)-3-[[2'-[1-(triphenylmethyl) -1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl]-4(3H)-quinazolinone
A mixture of 1.00 g of the product of Example and 10.0 g of manganese dioxide in 25 ml of methylene chloride is stirred at room temperature for 2 hours then filtered through diatomaceous earth. The cake is washed with methylene chloride and the filtrate concentrated in vacuo to a residue which is purified by column chromatography on silica gel using 1:3 ethyl acetate-hexane to give 0.389 g of the desired product as a white solid.
1 H NMR(300 MHz, CDCl 3 )δ 8.9(1H, s), 8.4(1H,dd), 7.95(1H,dd), 7.75(1H, d), 7.5-6.9(22H,m), 6.55(1H,dd), 6.0(1H, dd), 5.3(1H,br s), 2.7(2H,t), 1.7(2H,m), 1.35(2H,m), 0.9(3H, t).
EXAMPLE 4
2-Butyl-6-[1-oxo-3-(2-oxocyclopentyl)propyl]-3-[[2'-[1-(triphenylmethyl) -1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl]-4(3H)-quinazolinone
To a solution of 0.201 g of the product of Example 3 in 4.5 ml of methylene chloride, cooled to -78° C., is added dropwise 0.549 ml of 1.0M TiCl 4 in methylene chloride. The reaction mixture is stirred at -78° C. for 30 minutes and 0.098 ml of 1-(trimethylsilyloxy)-cyclopentene added dropwise. The reaction mixture is stirred at -78° C., for 0.5 hours and quenched with saturated potassium carbonate, diluted with chloroform, filtered through magnesium sulfate and concentrated in vacuo to give a residue which is purified by chromatography on silica gel by elution with 1:3 ethyl acetatehexane to give 0.079 g of the desired product as a white solid.
MS (FAB): m/z 839(M+Na).
EXAMPLE 5
2-Butyl-6-[1-oxo-3-(2-oxocyclohexyl)propyl]-3-[[2'-[1-(triphenylmethyl) -1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl-4(3H)-quinazolinone
To a solution of 2.50 g of the product of Example 3 in 10.0 ml of methylene chloride, cooled to -78° C., is added dropwise 6.831 ml of 1.0M TICl 4 in methylene chloride. The reaction mixture is stirred at -78° C. for 30 minutes and 1.33 ml of 1-cyclohexenyloxytrimethylsilane added dropwise. The reaction mixture is stirred at -78° C., for 0.5 hours and quenched with saturated potassium carbonate diluted with chloroform, filtered through magnesium sulfate and concentrated in vacuo to give a residue which is purified by chromatography on silica gel by elution with 1:2 ethyl acetatehexane to give 0.979 g of the desired product as a white solid.
MS (FAB): m/z 853(M+Na).
EXAMPLE 6
2-Butyl-6-[1-hydroxy-3-(2-hydroxycyclopentyl)propyl]-3-[[2'-[1-(triphenylmethyl)-1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl-4(3H)-quinazolinone
To a solution of 0.950 g of the product of Example 4 in 25 ml of ethyl alcohol and 50 ml of tetrahydrofuran is added in one portion at room temperature 0.111 g of sodium borohydride. The reaction mixture is stirred at room temperature for one hour then poured into water and extracted with chloroform. The organic layer is dried with magnesium sulfate and concentrated in vacuo to give a residue which is purified by chromatography on silica gel by elution with 3:2 ethyl acetate-hexane to give 0.507 g of the desired product as a white solid.
MS (FAB): m/z 843(M+Na).
EXAMPLE 7
2-Butyl-6-[1-hydroxy-3-(2-hydroxycyclohexyl)propyl]-3-[[2'-[1-(triphenylmethyl)-1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl]-4(3H)-quinazolinone
To a solution of 0.950 g of the product of Example 5 in 25 ml of ethyl alcohol and 50 ml of tetrahydrofuran is added in one portion at room temperature 0.109 g of sodium borohydride. The reaction mixture is stirred at room temperature for one hour then poured into water and extracted with chloroform. The organic layer is dried with magnesium sulfate and concentrated in vacuo to give a residue which is purified by chromatography on silica gel by elution with 2:1 ethyl acetate-hexane to give 0.147 g of the desired product as a white solid.
MS(FAB): m/z 857(M+Na).
EXAMPLE 8
2-Butyl-6-(octahydro-2H-1-benzopyran-2-yl)-3-[[2'-[1-triphenylmethyl) -1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl]-4(3H)-quinazolinone
To a solution of 0.498 g of the product of Example 7 in 5.0 ml of pyridine is added 0.051 ml of methanesulfonylchloride followed by stirring at room temperature for 48 hours and heating at reflux for 5 hours. The reaction mixture is cooled and concentrated in vacuo to a residue which is purified by column chromatography on silica gel by elution with 1:3 ethyl acetate-hexane to give 0.080 g of the desired product as a white solid.
MS(FAB): m/z 839(M+Na).
EXAMPLE 9
2-Butyl-6-(octahydrocyclopenta[b]pyran-2-yl) -3-[[2'-[1-(triphenylmethyl)-1H-tetrazol-5-yl][[1,1'-biphenyl]-4-yl]methyl]-4(3H)-quinazolinone
To a solution of 0.491 g of the product of Example 6 in 5.0 ml of pyridine is added 0.051 ml of methanesulfonylchloride followed by stirring at room temperature for 48 hours and heating at reflux for 5 hours. The reaction mixture is cooled and concentrated in vacuo to a residue which is purified by column chromatography on silica gel by elution with 1:3 ethyl acetate-hexane to give 0.044 g of the desired product as a white solid.
MS(FAB): m/z 825(M+Na).
EXAMPLE 10
2-Butyl-6-(octahydrocyclopenta[b]pyran-2-yl)-3-[[2'-(1H) -tetrazol-5-yl)[1,1'-biphenyl]-4-yl]methyl]-4(4H)-quinazolinone
A solution of 0.040 g of the product of Example 9 in 0.5 ml of tetrahydrofuran and 2.5 ml of methyl alcohol is heated at reflux for 18 hours. The volatiles are evaporated in vacuo to a residue which is purified by column chromatography on silica gel by elution with 9:1 chloroform-methyl alcohol to give 0.017 g of the desired product as a white solid.
MS (FAB): m/z 561(M+H).
EXAMPLE 11
2-Butyl-6-(octahydro-2H-1-benzopyran-2-yl) -3-[[2'-(1H)-tetrazol-5-yl)[1,1'-biphenyl]-4yl]methyl]-4-(3H)-quinazolinone
A solution of 0.071 g of the product of Example 8 in 0.5 ml of tetrahydrofuran and 2.5 ml of methyl alcohol is heated at reflux for 18 hours. The volatiles are evaporated in vacuo to a residue which is purified by column chromatography on silica gel by elution with 9:1 chloroform-methyl alcohol to give 0.035 g of the desired product as a white solid.
MS(FAB): m/z 575 (M+H)
Angiotensin II Antagonists In Vitro Tests
Materials and Methods
Beef adrenals are obtained from a local slaughter house (Maxwell-Cohen). [ 125 I](Sar 1 , Ile 8 )AngII, S.A. 2200 Ci/mmole, is purchased from Dupont (NEN®, Boston, Mass.). All unlabeled AngII analogs, Dimethylsulfoxide (DMSO), nucleotides, bovine serum albumin (BSA) are purchased from Sigma Chemical Co., St. Louis, Mo. U.S.A.
Preparation of Membranes
Approximately sixteen (16) to twenty (20) beef adrenal glands are processed as follows: fresh adrenal glands received on crushed ice are cleaned of fatty tissues and the tough membranes encapsulating the glands are removed and discarded. The brownish tissue forming the adrenal cortex is scraped off and finely minced with scissors before homogenization. Care is taken to avoid contamination with medullary tissue during dissection. The scraped cortices are suspended in twenty volumes of an ice-cold buffer medium consisting of 10 mM Tris.HCl (pH 7.4 at 22° C.) and containing 1.0 mM EDTA and 0.2M sucrose. Unless otherwise indicated, all subsequent operations are done at 4° C. The tissue is homogenized in a glass homogenizer with a motor-driven teflon pestle with a clearance of 1.0 mm. The homogenate is centrifuged first at low speed (3,000× g) for 10 min. The resulting pellet is discarded and the supernatant fluid recentrifuged at 10,000× g for 15 minutes to give a P 2 pellet. This P 2 pellet is discarded and the liquid phase is carefully decanted off in clean centrifuge tubes and recentrifuged at high speed (1000,000× g) for 60 min. The translucent final pellet is harvested and combined in a small volume (20-50.0 ml) of 50.0 mM Tris.HCl buffer, pH 7.2. A 100 μl aliquot is withdrawn and the protein content of the preparation is determined by the Lowry's method (Lowry, O. H., Rosebrough, N. F., Farr, A. L. and Randall, R. J., Protein measurement with Folin phenol reagent. J. Biol. Chem., 48, 265-275, 1951). The pelleted membrane is reconstituted in 50.0 mM Tris.HCl buffer containing 0.1 mM of phenylmethylsulfonyl fluoride (PMSF) to give approximately a protein concentration of 2.5 mg per ml of tissue suspension. The membrane preparation is finally aliquoted in 1.0 ml volumes and stored at -70° C. until use in the binding assays.
Receptor Binding Assay
Binding of [ 125 I](Sar 1 , Ile 8 )AngII
The binding of [ 125 I](Sar 1 , Ile 8 )AngII to microsomal membranes is initiated by the addition of reconstituted membranes (1:10 vols.) in freshly made 50.0 mM Tris.HCl buffer, pH 7.4 containing 0.25% heat inactivated bovine serum albumin (BSA): 80 μl membrane protein (10 to 20 μg/assay) to wells already containing 100 μl of incubation buffer (as described above) and 20 μl [ 125 I](Sar 1 , Ile 8 )AngII (Specific Activity, 2200 Ci/mmole). Non-specific binding is measured in the presence of 1.0 μM unlabeled (Sar 1 , Ile 8 )AngII, added in 20 μl volume. Specific binding for [ 125 I](Sar 1 , Ile 8 )AngII is greater than 90%. In competition studies, experimental compounds are diluted in dimethylsulfoxide (DMSO) and added in 20 μl to wells before the introduction of tissue membranes. This concentration of DMSO is found to have no negative effects on the binding of [ 125 I](Sar 1 , Ile 8 )AngII to the membranes. Assays are performed in triplicate. The wells are left undisturbed for 60 min. at room temperature. Following incubation, all wells are harvested at once with a Brandel® Biomedical Research & Development Labs. Inc., Gaithersburg, Md., U.S.A.). The filter discs are washed with 10×1.0 ml of cold 0.9% NaCl to remove unbound ligand. Presoaking the filter sheet in 0.1% polyethyleneimine in normal saline (PEI/Saline) greatly reduces the radioactivity retained by the filter blanks. This method is routinely used. The filters are removed from the filter grid and counted in a Parkard® Cobra Gamma Counter for 1 min. (Packard Instrument Co., Downers Grove, Ill., U.S.A.). The binding data are analyzed by the non-linear interactive "LUNDON-1" program (LUNDON SOFTWARE Inc., Cleveland, Ohio, U.S.A.). Compounds that displace 50% of the labelled angiotensin II at the screening dose of 50 μM are considered active compounds and are then evaluated in concentration-response experiments to determine their IC 50 values. The results are shown in Table I.
TABLE I______________________________________ ##STR6## Angiotensin II ReceptorEx. No. R R.sup.5 Binding IC.sub.50 (M)______________________________________10 ##STR7## (CH.sub.2).sub.3 CH.sub.3 105 × 10.sup.-911 ##STR8## (CH.sub.2).sub.3 CH.sub.3 132 × 10.sup.-9______________________________________
The enzyme renin acts on a blood plasma alpha 2 -globulin, angiotensinogen, to produce angiotensin I, which is then converted by angiotensin converting enzyme to AII. The substance AII is a powerful vasopressor agent which is implicated as causative agent for producing high blood pressure in mammals. Therefore, compounds which inhibit the action of the hormone angiotensin II (AII) are useful in alleviating angiotensin induced hypertension.
As can be seen from Table I, the compounds demonstrate excellent Angiotensin II Receptor Binding activity.
The compounds of this invention inhibit the action of AII. By administering a compound of this invention to a rat, and then challenging with angiotensin II, a blockage of the vasopressor response is realized. The results of this test on representative compounds of this invention are shown in Table II.
AII CHALLENGE
Conscious Male Okamoto-Aoki SHR, 16-20 weeks old, weighing approximately 330 g are purchased from Charles River Labs (Wilmington, Mass.). Conscious rats are restrained in a supine position with elastic tape. The area at the base of the tail is locally anesthetized by subcutaneous infiltration with 2% procaine. The ventral caudal artery and vein are isolated, and a cannula made of polyethylene (PE) 10-20 tubing (fused together by heat) is passed into the lower abdominal aorta and vena cava, respectively. The cannula is secured, heparinized (1,000 I.U./ml), sealed and the wound is closed. The animals are placed in plastic restraining cages in an upright position. The cannula is attached to a Statham P23Db pressure transducer, and pulsatile blood pressure is recorded to 10-15 minutes with a Gould Brush recorder. (Chan et al., (Drug Development Res., 18:75-94, 1989).
Angiotensin II (human sequence, Sigma Chem. Co., St. Louis, Mo.) of 0.05 and 0.1 μg/kg i.v. is injected into all rats (predosing response). Then a test compound, vehicle or a known angiotensin II antagonist is administered i.v., i.p. or orally to each set of rats. The two doses of angiotensin II are given to each rat again at 30. 60. 90. 120. 180. 240 and 300 minutes post dosing the compound or vehicle. The vasopressor response of angiotensin II is measured for the increase in systolic blood pressure in mmHg. The percentage of antagonism or blockade of the vasopressor response of angiotensin II by a compound is calculated using the vasopressor response (increase in systolic blood pressure) of angiotensin II of each rat predosing the compound as 100%. A compound is considered active if at 30 mg/kg i.v. it antagonized at least 50% of the response.
TABLE II__________________________________________________________________________ANGIOTENSIN II (AII) VASOPRESSOR RESPONSE AII Dose Min Post Control Response AverageDose (mg/Kg) mcg/Kg Dose Before AII After AII Change Change % Inhibition__________________________________________________________________________Control 0.05 0 255 295 40 42.5 250 295 45 0.1 250 310 60 57.5 260 315 55Ex. No 11 3 iv 0.05 30 245 260 15 17.5 59 245 265 20 0.1 250 260 10 20 65 250 280 30 0.05 60 230 260 30 22.5 47 240 255 15 0.1 240 260 20 15 74 245 255 10 0.05 90 235 265 30 20 53 235 245 10 0.1 255 285 30 27.5 52 235 260 25 0.05 120 245 255 10 10 76 230 240 10 0.1 240 255 15 20 65 225 250 25 0.05 180 235 265 30 32.5 24 225 260 35 0.1 235 270 35 27.5 52 235 255 20 0.05 240 230 250 20 13.5 68 233 240 7 0.1 250 285 35 32.5 43 225 255 30 0.05 300 245 275 30 22.5 47 240 255 15 0.1 240 275 35 32.5 43 245 275 30__________________________________________________________________________ SPONTANEOUSLY HYPERTENSIVE RATS n = 2 Body weights(s): 400, 400 grams
When the compounds are employed for the above utility, they may be combined with one or more pharmaceutically acceptable carriers, for example, solvents, diluents and the like, and may be administered orally in such forms as tablets, capsules, dispersible powders, granules, or suspensions containing, for example, from about 0.05 to 5% of suspending agent, syrups containing, for example, from about 10 to 50% of sugar, and elixirs containing, for example, from about 20 to 50% ethanol, and the like, or parenterally in the form of sterile injectable solutions or suspension containing from about 0.05 to 5% suspending agent in an isotonic medium. Such pharmaceutical preparations may contain, for example, from about 0.05 up to about 90% of the active ingredient in combination with the carrier, more usually between about 5% and 60% by weight.
The effective dosage of active ingredient employed may vary depending on the particular compound employed, the mode of administration and the severity of the condition being treated. However, in general, satisfactory results are obtained when the compounds of the invention are administered at a daily dosage of from about 0.5 to about 500 mg/kg of animal body weight, preferably given in divided doses two to four times a day, or in sustained release form. For most large mammals the total daily dosage is from about 1 to 100 mg, preferably from about 2 to 80 mg. Dosage forms suitable for internal use comprise from about 0.5 to 500 mg of the active compound in intimate admixture with a solid or liquid pharmaceutically acceptable carrier. This dosage regimen may be adjusted to provide the optimal therapeutic response. For example, several divided doses may be administered daily or the dose may be proportionally reduced as indicated by the exigencies of the therapeutic situation.
These active compounds may be administered orally as well as by intravenous, intramuscular, or subcutaneous routes. Solid carriers include starch, lactose, dicalcium phosphate, microcrystalline cellulose, sucrose and kaolin, while liquid carriers include sterile water, polyethylene glycols, non-ionic surfactants and edible oils such as corn, peanut and sesame oils, as are appropriate to the nature of the active ingredient and the particular form of administration desired. Adjuvants customarily employed in the preparation of pharmaceutical compositions may be advantageously included, such as flavoring agents, coloring agents, preserving agents, and antioxidants, for example, vitamin 1E, ascorbic acid, BHT and BHA.
The preferred pharmaceutical compositions from the standpoint of ease of preparation and administration are solid compositions, particularly tablets and hard-filled or liquid-filled capsules. Oral administration of the compounds is preferred.
These active compounds may also be administered parenterally or intraperitoneally. Solutions or suspensions of these active compounds as a free base or pharmacologically acceptable salt can be prepared in water suitably mixed with a surfactant such as hydroxypropylcellulose. Dispersions can also be prepared in glycerol, liquid polyethylene glycols and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syringability exists. It must be stable under the conditions of manufacture and storage and must be preserved against the contaminating action of micro-organisms such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (e.g., glycerol, propylene glycol and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oils. | This disclosure describes novel 2,3,6-substituted quinazolinones of the formula: ##STR1## where R 6 , R 5 and R are described in the specification which have activity as angiotensin II (AII) antagonists. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present invention claims priority to U.S. Provisional Application No. 61/437,886 entitled “Electrospinning Process for Fiber Manufacture,” filed Jan. 31, 2011; and to U.S. application Ser. No. 13/362,467 entitled “Electrospinning Process for Manufacture of Multi-Layered Structures,” filed Jan. 31, 2012 now U.S. Pat. No. 8,968,626.
FIELD OF THE INVENTION
The present invention relates to systems and methods for the manufacturing of microscale or nanoscale concentrically-layered fibers by electrospinning.
BACKGROUND
Macro-scale structures formed from concentrically-layered nanoscale or microscale fibers (“core-sheath fibers”) are useful in a wide range of applications including drug delivery, tissue engineering, nanoscale sensors, self-healing coatings, and filters. On a commercial scale, the most commonly used techniques for manufacturing core-sheath fibers are extrusion, fiber spinning, melt blowing, and thermal drawing. None of these methods, however, are ideally suited to producing drug-loaded core-sheath fibers, as they all utilize high temperatures which may be incompatible with thermally labile materials such as drugs or polypeptides. Additionally, fiber spinning, extrusion and melt-blowing are most useful in the production of fibers with diameters greater than ten microns.
Core-sheath fibers can be produced by electrospinning in which an electrostatic force is applied to a polymer solution to form very fine fibers. Conventional electrospinning methods utilize a charged needle to supply a polymer solution, which is then ejected in a continuous stream toward a grounded collector. After removal of solvents by evaporation, a single long polymer fiber is produced. Core-sheath fibers have been produced using emulsion-based electrospinning methods, which exploit surface energy to produce core-sheath fibers, but which are limited by the relatively small number of polymer mixtures that will emulsify, stratify, and electrospin. Core-sheath fibers have also been produced using coaxial electrospinning, in which concentric needles are used to eject different polymer solutions: the innermost needle ejects a solution of the core polymer, while the outer needle ejects a solution of the sheath polymer. This method is particularly useful for fabrication of core-sheath fibers for drug delivery in which the drug-containing layer is confined to the center of the fiber and is surrounded by a drug-free layer. However, both emulsion and coaxial electrospinning methods can have relatively low throughput, and are not ideally suited to large-scale production of core-sheath fibers. To increase throughput, coaxial nozzle arrays have been utilized, but such arrays pose their own challenges, as separate nozzles may require separate pumps, the multiple nozzles may clog, and interactions between nozzles may lead to heterogeneity among the fibers collected. Another means of increasing throughput, which utilizes a spinning drum immersed in a bath of polymer solution, has been developed by the University of Liberec and commercialized by Elmarco, S.R.O. under the mark Nanospider®. The Nanospider® improves throughput relative to other electrospinning methods, but it is not currently possible to manufacture core-sheath fibers using the Nanospider®. There is, accordingly, a need for a mechanically simple, high-throughput means of manufacturing core-sheath fibers.
SUMMARY OF THE INVENTION
The present invention addresses the need described above by providing a system and method for high-throughput production of core-sheath fibers.
In one aspect, the present invention relates to a device for high-throughput production of core-sheath fibers by electrospinning The device comprises a hollow tube having a lengthwise slit therethrough, which can be filled with a solution of the core polymer, and optionally includes a bath in which the hollow tube is immersed, which can be filled with a solution of the sheath polymer. The tube also optionally includes structural features such as channels or regions of texture or smoothness through which the sheath polymer solution can run. In an alternate embodiment, the device comprises three adjacent troughs arranged so that two external troughs sandwich a central trough. The central trough is filled with a solution of the core polymer, while the external troughs are filled with solutions of the sheath polymer.
In another aspect, the present invention relates to a device for collection of electrospun fibers in yarn form. The device comprises a grounded collector for electrospun yarns, the collector being configured to rotate so that fibers are twisted into yarns as they are collected from an electrospinning apparatus.
In yet another aspect, the present invention relates to methods of making core-sheath fibers and electrospun yarns using the devices of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, like reference characters generally refer to the same parts throughout the different views. Drawings are not necessarily to scale, as emphasis is placed on illustration of the principles of the invention
FIG. 1A-1D show schematic illustrations of a fiber generated by the present invention.
FIG. 2 is a schematic illustration of a portion of an electrospinning apparatus according to an embodiment of the invention.
FIG. 3A-3B show schematic illustrations of a portion of an electrospinning apparatus according to an embodiment of the invention.
FIG. 4A-4B show schematic illustrations of a portion of an electrospinning apparatus according to another embodiment of the invention.
FIG. 5A-5B show schematic illustrations of a portion of an electrospinning apparatus according to yet another embodiment of the invention.
FIG. 6 is a schematic illustration of a yarn-making apparatus according to an embodiment of the invention.
FIG. 7A-7B comprise photographs of an example of the present invention.
FIG. 8A-8B show photographs of another example of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to electrospun fibers, including drug-containing electrospun fibers and yarns described in co-pending U.S. patent application Ser. No. 12/620,334 (United States Publication No. 20100291182), the entire disclosure of which is incorporated herein by reference.
An example of a fiber produced by the devices and methods of the present invention is shown schematically in FIGS. 1 a and 1 b. Fiber 100 is generally tubular in shape, and is characterized by a length 110 and a diameter 111 . Fibers generated by the devices and methods of the present invention are generally small enough to be useful for implantation to address a wide range of medical applications. As such, the fiber 100 has a diameter that is preferably up to about 20 microns. The length 110 of fiber 100 will vary depending on its intended use, and may range widely from micrometers to centimeters or greater. In a preferred embodiment, fiber 100 includes an inner radial portion 120 and an outer radial portion 130 , as shown in FIGS. 1 c and 1 d. In this preferred embodiment, the total diameter 111 of the fiber is no more than about 20 microns, and the diameter of the outer radial portion is about 1-7 microns larger than the inner radial portion.
FIG. 2 illustrates one embodiment of the present invention. Apparatus 200 comprises a hollow cylindrical tube 210 having a longitudinal slit 220 along its entire length. A core polymer solution 230 can be introduced into the lumen of tube 210 in a volume sufficient for the surface of the solution to emerge through slit 220 . In one example, tube 210 is 0.5-20 cm in diameter with a wall thickness of 50-5,000 microns. The cylindrical tube 210 is made of a conducting material such as stainless steel, copper, bronze, brass, gold, silver, platinum, and other metals and alloys. Slit 220 preferably has a width sufficient to permit formation of Taylor cones 240 from the surface of the core polymer solution 230 , the width of slit 220 being generally between 0.01 and 20 millimeters, and preferably between 0.1 to 5 millimeters. The length of tube 210 is preferably between 5 centimeters and 50 meters, and more preferably between 10 centimeters and 2 meters.
In certain alternate embodiments, multiple apparatuses 200 may be placed in rows comprising up to 50 units, either in parallel or end-to-end, with a preference for 10 or fewer units per row. An advantage of using multiple units versus one long unit is better control over the flow of the polymer solutions.
The core polymer solution 230 preferably has a viscosity of between 10 and 10,000 centipoise, and is more preferably between 500 and 5,000 centipoise. Core polymer solution 230 is preferably pumped through the lumen of tube 210 and slit 220 at rates of between 0.01 and 10 milliliters per hour, more preferably between 0.1 and 2 milliliters per hour per centimeter. A voltage, preferably between 1 and 150 kV, more preferably between 20-70 kV, is applied. The positive electrode of the power supply is preferably connected to the conducting slit-cylinder directly or via a wire, such that a potential difference exists between the slit cylinder and a grounded collector 250 . Grounded collector 250 is preferably placed at a distance between 1 and 100 centimeters from slit 220 and parallel to the axial dimension of tube 210 . Grounded collector 250 is a planar plate of various geometries (e.g. rectangular, circular, triangular, etc.), rotating drum/rod, wire mesh, or other 3D collectors including spheres, pyramids, etc. Upon application of a sufficient voltage, Taylor cones 240 and electrospinning jets 241 will form in the exposed surface of polymer solution 230 , and the jets will flow toward collector 250 , forming homogeneous fibers.
In certain embodiments of the present invention, the apparatus will include means for co-localizing a sheath polymer solution to the site of Taylor cone initiation, so that core-sheath fibers can be produced. In certain embodiments, such as that illustrated in FIG. 3 , hollow cylindrical tube 210 will be arranged so that slit 220 points downward, and a sheath polymer solution 260 will be applied to the upward-facing external surface of tube 210 so that sheath polymer solution 260 runs down the sides of tube 210 and co-localizes with the core-sheath polymer at sites of Taylor cone and jet initiation 240 , 241 . Once the sheath polymer solution 260 is co-localized with the Taylor cone, it will be incorporated into the jet. The sheath polymer solution 260 is drawn toward and over the core fibers by varying the flow rate and viscosity of the sheath polymer solution 260 , or by incorporating structural features 211 such as grooves, channels, coatings, and textured or smooth surfaces on the outer surface of hollow tube 210 .
In certain alternate embodiments, as illustrated in FIG. 4 , hollow tube 210 will be partially submerged in a bath 270 containing the sheath polymer solution 260 . The volume of the sheath polymer solution 260 within bath 270 will be set at a level so that the top surface of the sheath polymer solution is at or near the sites of Taylor cone and jet initiation 240 , 241 . As described above, the rate at which sheath polymer solution 260 is drawn into fibers can be controlled by varying the viscosity of sheath polymer solution 260 , or by incorporating structural features 211 on the outer surface of hollow tube 210 such as grooves, channels, coatings and textured or smooth surfaces.
In still other alternate embodiments, such as the one described in Example 2, infra, the sheath polymer solution 260 can be introduced directly to the sites of Taylor cone and jet initiation 240 , 241 , by using a syringe pump and needle. This method is preferred over previously used coaxial nozzle arrays, as single bore needles are used, reducing the likelihood of clogging.
In an alternate embodiment of the present invention, three parallel troughs are utilized, as illustrated in FIG. 5 . Apparatus 300 comprises an inner trough 310 and two outer troughs 320 , 330 . The walls 311 , 312 of inner trough 310 are optionally tapered, so that their thickness decreases to zero at the top of inner trough 310 . Inner trough 310 is filled with a solution of core polymer solution 220 , which is pumped through inner trough 310 from the bottom up at rates suitable for electrospinning, generally between 0.1 to 2 milliliters per hour per centimeter, but up to 10 milliliters per hour per centimeter. Alternatively, the solution can be fed in from the sides or a combination of the bottom and sides. Inner trough 310 has a height ranging preferably from 5-10 centimeters and a width sufficient to permit formation of Taylor cones and jets 240 , 241 , which emerge from the surface of core polymer solution 220 , the width of inner trough 310 being generally between 0.01 and 20 millimeters, and preferably between 0.1 to 5 millimeters. Outer troughs 320 , 330 are filled with sheath polymer solutions 260 to heights sufficient for the sheath polymer solution to be drawn into the sites of Taylor cone and jet initiation 240 , 241 . As shown in FIG. 5 b , walls 311 , 312 of inner trough 310 may incorporate a reciprocal periodic wave structure, forming regions of higher and lower width within inner trough 310 , which structure biases the formation of Taylor cones and jets 240 , 241 to regions in which the width of inner trough is locally maximized. The voltage is applied by attaching the positive electrode of the power supply to the inner walls of the trough, which is composed of a metallic conducting material such as stainless steel, copper, bronze, gold, silver, platinum and other alloys.
In an alternate embodiment, the invention comprises a collector plate configured as a drum 400 , which can be placed into a yarn-spinning apparatus as shown in FIG. 6 . At any point during collection of fibers (prior to initiation, during collection, or after collection initiation), the drum is engaged with a belt that is in turn engaged with a mandrel that can spin in one direction, and free ends of the collected fibers are attached to another drum engaged with another belt that is engaged with a different mandrel which spins in a direction opposite from that of the first mandrel. The resulting yarns can be post-processed into higher-order structures such as ropes by attaching opposite ends of multiple yarns to opposing drums, and spinning them in opposite directions as described above.
In some embodiments of the invention, the polymers used in the present invention include additives such as metallic or ceramic particles to yield fibers having a composite structure.
The devices and methods of the present invention may be further understood according to the following non-limiting examples:
Example 1
Formation of Homogeneous Fibers
Homogeneous fibers made of poly(lactic co-glycolic acid) (L-PLGA) were manufactured in accordance with the present invention. A solution containing 4.5 wt % of 85/15 L-PLGA in hexafluoroisopropanol was pumped into one end of a 10 cm long hollow tube (1 cm diameter) having a 0.4 cm slit of the present invention at a rate of 8 milliliters per hour. A grounded, flat, rectangular collecting plate was placed approximately 15 centimeters from the slit of the cylinder, and a voltage of 25-35 kV was applied, and the resultant fibers were collected on the collecting plate and examined under scanning electron microscopy as illustrated in FIG. 7 b.
Example 2
Formation of Core-Sheath Fibers
Core-sheath fibers were manufactured in accordance with the present invention, as shown in FIG. 8 a . A rhodamine-containing core solution containing 15 wt % polycaprolactone in a 3:1 (by volume) chloroform:acetone solution was pumped through a hollow cylindrical tube having a slit therethrough at a rate of 10 ml/hour. Jets were formed by applying a voltage of 25 kV. Once the Taylor cones were stable, a syringe pump and needle filled with a fluorescein-containing sheath solution containing 15 wt % polycaprolactone in a 6:1 (by volume) chloroform:methanol solution was placed so that the needle was adjacent to one of the Taylor cones, and the sheath solution was pumped at a rate of 6 ml/hour. To verify the core-sheath structure of the resulting fibers, fluorescence micrographs were obtained which demonstrated that the rhodamine-containing core component was indeed surrounded by the fluorescein-containing sheath component, as shown in FIG. 8 b.
The present invention provides devices and methods for producing homogeneous and core-sheath fibers. While aspects of the invention have been described with reference to example 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 scope of the invention. | Devices and methods for high-throughput manufacture of concentrically layered nanoscale and microscale fibers by electrospinning are disclosed. The devices include a hollow tube having a lengthwise slit through which a core material can flow, and can be configured to permit introduction of sheath material at multiple sites of Taylor cone formation formation. | 3 |
FIELD OF THE INVENTION
The present invention relates to a method and to a device for producing hydrocarbons by pumping in a substantially horizontal drain hole. The drain hole is drilled in a hydrocarbon reservoir along a trajectory comprising at least one portion that is greatly inclined with respect to the vertical.
The present invention applies to cases where the hydrocarbons drained by the horizontal drain hole contain a proportion of gas that can be significant in relation to the liquid phase, more or less viscous. In this case, pumping of a two-phase effluent can have a low efficiency.
BACKGROUND OF THE INVENTION
It is well-known to set a static separator in a part of the inclined drain hole, but the pumping efficiency is not really improved because the level difference between the inlet and the outlet of the separator is low and the separator can generate pressure drops prejudicial to the pumping efficiency and to the separating action. Furthermore, when the dynamic level of the effluent is low in relation to the inclined well portion, setting the pump and the separator is practically impossible in too inclined a zone.
The present invention can preferably relate to all the drain holes in which the effluent is a multiphase effluent and flows through the drain hole in a stratified flow, i.e., in case of gas and liquid, the gas fills the upper part of the drain hole whereas the oil flows at the bottom of the substantially horizontal drain hole.
SUMMARY OF THE INVENTION
The present invention thus relates to a pumping method in a well comprising a portion greatly inclined with respect to the vertical, in which pumping means secured to a string of tubes are lowered into said well, the string is held at the ground surface by suspension means, suction means are placed at the lower end of the pumping means. In the method, the following stages are performed:
at least one suction port is placed laterally with respect to said suction means and in a single direction,
said suction means are substantially placed in said greatly inclined portion,
the direction of said port is so oriented that it is substantially opposite a lower generating line of said well.
According to the method, said port can be oriented by rotation of the string of tubes from the ground surface, said string driving the pumping means and the suction means into the same rotating motion.
The orientation of the ports can be controlled by performing surface measurements on the effluent delivered by said pumping means.
A product can be injected from the ground surface substantially at the level of the suction port.
The invention further relates to a pumping device in a well comprising a portion that is greatly inclined with respect to the vertical, said device includes pumping means secured to a string of tubes, suspension means for suspending the string to the ground surface, suction means placed at the lower end of the pumping means. The suction means comprise at least one suction port oriented laterally with respect to said suction means and in a specific direction.
The port can be situated on a body and said body can comprise at least one rotating link so that it can rotate in relation to said pumping means.
The body can comprise orienting means suited to place substantially said port opposite a lower generating line of the inclined well portion.
The orienting means can comprise magnets placed laterally with respect to said port.
The suction means can comprise means for injecting a fluid substantially in the neighbourhood of the port.
The injection means can comprise a swivel linked to said body by means of a rotating link.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will be clear from reading the description hereafter, given by way of non limitative examples, with reference to the accompanying drawings in which:
FIG. 1 diagrammatically shows the device set in a production well,
FIG. 2A is a lengthwise section of a particular embodiment of the invention,
FIGS. 2B and 2C are cross-sections along lines I--I and II--II, respectively of the embodiment according to FIG. 2A,
FIG. 3A is a lengthwise section of another embodiment of the invention; and
FIGS. 3B and 3C are cross-sections along lines III--III and IV--IV, respectively of the embodiment according to FIG. 3A.
FIG. 4 shows a of the embodiment illustrated by FIG. 3A
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a sectional view of a well 1 drilled from the ground surface with a substantially vertical part then an inclined part that substantially reaches a horizontal position in the reservoir bed containing the hydrocarbons. A casing 3 is set in the well generally in order to cover the formation from the surface to the inlet of the pay zone. Pumping means 4, for example a Moineau type positive-displacement pump, are lowered into the well through a string of tubes 5 held at the well head by suspension means 6. Pump 4 is generally positioned below the dynamic level 7 of the effluent filling well 1. In the example shown here, the pump includes a rotor 8 driven in rotation by a string 9 of pipes or tubes, said string being driven in rotation by mechanical surface means 10.
Casing 3 comprises a lateral line 13 controlled by a valve 14. The gas that is collected in the inner space of this string 3 can be discharged through lateral line 13.
The string of tubes 5 also comprises at the surface a flowline 11 for delivering the production drawn off by pump 4. A valve 12 controls the flow.
The suction line of the pump is extended by a tail pipe 15 so as to be able to position the suction point or points in the optimum place in the horizontal drain hole in order to obtain the best production efficiency. Tail pipe 15 can comprise, at the end thereof, a head 16 whose port or ports are arranged in a preferred direction in relation to the axis of the drain hole.
In FIG. 1, the effluent is shown in a stratified flow: the gas 17 is in the upper part of drain hole 2, above the liquid phase of the hydrocarbons. In the well part that is less inclined with respect to the vertical, the stratified flow is generally disturbed, for example, by the sucking action of the pump, by the presence of the pump or of tubes that reduce the annular space and of course by the action of gravity. The gas can re-form as bubbles or plugs 19.
Suction head 16 can comprise at least one opening situated along a generating line of the tube so that the orientation of said generating line around the axis thereof allows to direct and to place the suction opening as close as possible to the lower generating line of the horizontal drain hole. The suction point will thus be at the furthest distance from the gas possibly accumulated in the upper part of the drain hole. The suction opening can be made up of one or several cylindrical holes lined up on the same generating line, or of an oblong opening lined up on a generating line.
In a first embodiment of the invention, tail pipe 15 and possibly the suction head are secured to the stator of the pump, which is secured to the string of tubes 5. Furthermore, the suspension means 6 intended to hold string 5 at the well head comprise rotation means equivalent to a rotary table, so as to be able to rotate the whole of string 5 about its axis, while driving in the same motion the stator of the pump, tail pipe 15 and suction head 16 into rotation. It is thus possible, from the surface, to shift in rotation the suction openings so as to position them as low as possible in the horizontal drain hole. Measuring devices of the pendulum type can be used to locate the position of said openings. These devices are not described here since they are well-known and already used by technicians to orient an instrument in a well, for example a bent sub.
Another method for checking the optimum lower position of the suction openings consists in controlling the proportion of gas carried along by the effluent delivered by the pump (GOR or gas/oil ratio) for several orientations of the openings, these orientations being obtained with the aid of means 6. The orientation providing the lowest proportion of gas will be selected if this is the desired result.
In certain well configurations, it is difficult or at least dangerous to turn the whole of string 5 round on itself It will generally be the case in deflected wells with a small bending radius where frictions can exceed the torsional strength of the tubes. It is then advantageous to use a suction head 16 according to FIGS. 2A, 2B and 2C.
FIG. 2A is a sectional view of the end of tail pipe 15 screwed, by means of a conventional sub 21, onto suction head 22. Suction head 22 is mainly made up of a fastening sub 24 suited to be screwed onto sub 21 and of a body 25 linked to fastening sub 24 by a rotating link 23. Body 22 can thus freely rotate about axis 27. Body 25 comprises a line 28 that extends the inner space 29 of tail pipe 15. Line 28 ends with a lateral opening 26 of elongate shape in the direction of a generating line. The width of the opening is illustrated in FIG. 2C.
Body 25 also comprises a series of magnets 30 and 31 respectively placed before and behind opening 26 and along substantially the same generating line as the opening.
FIG. 2B is a sectional view of the circumferential position of the magnets.
FIG. 2C is a sectional view of the shape that lateral opening 26 may exhibit, and of its position in relation to tube 32 that covers the horizontal drain hole. Of course, this tube (generally referred to as liner) is perforated over the total length of the drain hole so that the effluent contained in the reservoir rock can flow into the drain hole.
The working principle of suction head 22 consists in taking up a specific orientation by itself so that opening 26 is turned towards the bottom of liner 32, i.e. at a greater distance from the gas accumulated in the upper part of the liner. The suction means are placed in the greatly inclined portion of the well and they therefore rest on the bottom of the drain hole, i.e. substantially in contact with the lower generating line of the drain hole. Orientation of the opening is notably obtained through the action of gravity and by means of rotating link 23. Body 25 is so machined that its center of gravity is below axis 27, and the machining of body 25 providing masses on either side of the opening can be clearly seen in FIGS. 2B and 2C. To complete the action of gravity, magnets 30 and 31 tend to bring body 25 into rotation about its axis in order to decrease the dimension of the air gap consisting of the magnets and of the inner wall of liner 32. Of course, liner 32 will be made of a magnetic material.
A means 33 facilitating the longitudinal and transverse sliding of the body on the wall of the liner can be placed at the end of body 25.
FIGS. 3A, 3B and 3C illustrate a variant of the embodiment of FIG. 2 where means for injecting a product, for example a product for thinning the liquid hydrocarbon, have been added. This injection is performed substantially in the neighbourhood of the suction port, at the level of the suction head. Suction head 22 comprises a body 34 that is fastened to tail pipe 15 in the same way as shown in FIG. 2A. The inner line 28 and the lateral opening 26 can be similar to the previous embodiment. Magnets 30 and 31 can also be arranged in the same way and they fulfil the same function.
At the end of body 34, an injection nozzle is assembled by means of a rotating link 36 that can be similar to link 23. Injection nozzle 35 is fastened in rotation to tail pipe 15 by a tube 37. Tube 37 will preferably be made from a nonmagnetic material in order not to disturb the action of the magnets intended to orient opening 26 by rotating body 34. The inner line 38 of tube 37 communicates with a series of channels 39 drilled in nozzle 35. Channels 39 end in injection ports 40, 41, 42 and 43. The layout of the injection ports can notably be defined by the nature of the viscous hydrocarbons, the presence, more or less considerable, of gas or the nature of the flow.
FIGS. 3B and 3C are sectional views of the position of tube 37.
It is thus possible to have an automatic-orientation suction head and a fluid injection system before the suction head.
Tube 37 is connected to the surface by a tube 44 (FIG. 1) placed in the annulus defined by strings 3 and 5. As the pumping device is lowered into the well, tube 44 is unwound or assembled in order to follow the lowering of the suction head. Tube 44 can be a metal tube of the coiled tubing type or a flexible tube made of composite.
FIG. 4 is a variant that is very close to that of FIG. 3A. The outside diameter of body 25 is so machined that suction head 22 overhangs in relation to tail pipe 15 and sub 21. In this variant, the diameter of sub 21 is widened so that body 25 is practically not in contact with the wall of the horizontal drain hole. The orienting means can be similar to those of the other variants. Furthermore, an injection tube 50 for injecting a thinning fluid flows from the annular space into the suction head by means of a tube joint 51. The tube is extended up to the end of the suction head by a tube portion 52 substantially placed longitudinally in line with body 25. Tube 52 runs through the nozzle of the suction head through an axial port 53. Tube 52 is ended by a spray tip 54 allowing a fluid to be injected at the front of the suction head. Other ports 55 are provided on the length of tube 52 so as to inject part of the thinning fluid at the level of opening 26. With such a layout, tube 52 is fixed with respect to tail pipe 15 while allowing body 25 to rotate freely about its axis. | The present invention relates to a pumping method and device in a well comprising a portion that is greatly inclined with respect to the vertical. A pump is secured to a strong of tubes that are lowered into the well. Suction devices are set into the greatly inclined well portion at the lower end of the pumping means. At least one suction port is placed laterally with respect to the suction devices and in a single direction. The direction of the port is oriented so that it is substantially opposite a lower generating line of the well. In a variant, the suction devices comprise an articulated body that can place the port opposite the lower generating line of the well. | 4 |
This is a continuation of application Ser. No. 866,715 filed July 14, 1986, now U.S. Pat. No. 4,786,20 which in turn is a Continuation under 37 C.F.R. 1.60 of prior application Ser. No. 730,257, filed May 6, 1985, now U.S. Pat. No. 4,636,112, which is a Continuation under 37 C.F.R. 1.62 of prior application Ser. No. 367,886, filed Apr. 13, 1982, now abandoned.
FIELD OF THE INVENTION
This invention relates to a method of and apparatus for controlling fluid leakage through soil, and is particularly useful for sealing the bottom of an artificial pond such as a solar pond during its construction.
DESCRIPTION OF PRIOR ART
Construction of large-scale artificial solar ponds whose area measures in the millions of square meters, requires sealing large land areas against fluid leakage. Such ponds usually have a three-layer regime: at the surface, a convective, wind-mixed layer of brackish water of from 3-5 percent salinity some 30-50 cm deep; an intermediate non-convective layer about 1 meter in depth in the form of a halocline whose salinity increases from about 5 percent at the top to about 30 percent near the bottom; and a lower heat storage layer from 3-5 m. deep with a uniform salinity of about 30 percent. Solar radiation incident on the surface of the pond is absorbed in the various layers creating a temperature profile in the pond that matches the salinity profile, the halocline serving to insulate the heat storage layer from conductive heat loss to the atmosphere. By known techniques, heat in the heat storage layer can be extracted and used for producing electricity.
With millions of cubic meters of. high-salinity water at from 80°-90° C. in the pond, economic and ecological considerations require the bottom of the pond to be sealed against fluid leakage. One conventional technique for controlling leakage through soil involves constructing a liner by overlapping strips of rubberized sheet material and bonding the seams in situ. This is a technique that is very expensive in materials and labor. Another technique suggested in the prior art is to lay overlapping plastic sheets, of polyethylene, for example, on the surface to be protected, and to cover the strips with a shallow layer of soil. By laying another layer of overlapping strips of sheet material on top of the layer of soil in such a way that the seams in the second layer are staggered with respect to the seams of the first layer, and then covering the second layer with a shallow layer of soil, an effective seal is created. A reliable seal against leakage is provided, because any holes in the plastic layers are likely to be horizontally displaced, and the soil trapped between the two plastic layers acts as a flow resistor that effectively severely limits leakage.
The problem with this last-mentioned technique lies in the time and expense in applying it to a large area, primarily because it is a labor-intensive technique by reason of the problems in driving largescale earth-moving equipment directly on the sheet material. Other conventional techniques might be faster, but the quality of the seal obtained over large areas remains to be determined. For example, U.S. Pat. Nos. 4,098,089 and 4,154,549 disclose an arrangement in which a hollow cutting blade containing a supply of sheet material is dragged through the soil at a predetermined depth as sheet material is fed through an opening in the blade rearwardly of its cutting edge so that the soil effectively, is lifted over the blade and onto the sheet material that trails the blade. This approach has the advantage of mechanization, but control of the depth of the blade is extremely difficult, and the power required to move the blade as it traverses large expanses is difficult to control. Furthermore, this technique does not permit the edges of adjacent strips of sheet material to be overlapped, and the quality of the seal achieved even if it were possible to have overlying layers of sheet material remains to be proven.
A possible arrangement to avoid these problems is shown in U.S. Pat. No. 3,309,875 which discloses a tractor type of vehicle with a bucket elevator at its front for digging a shallow trench in the ground as the vehicle traverses a region. Soil dug by the bucket elevator is conveyed rearwardly on the vehicle and deposited near the rear thereof on top of a strip of sheet material unrolled from a carrier mounted in the vehicle behind the bucket elevator. This arrangement is simpler than the arrangement shown in the '089 patent, and is amenable to laying strips over a large land area; but it suffers from the same problem as the '089 patent in that the edges of the strips cannot be overlapped, and installation of overlying layers using this type of equipment does not appear to be practical.
Thus, the prior art does not disclose a technique adapted to mechanization which will control fluid leakage over large land areas by the installation of overlapping strips of sheet material in multiple layers. It is therefore an object of the present invention to provide a new and improved method of and apparatus for controlling fluid leakage which does not suffer from the deficiencies of the prior art.
DESCRIPTION OF INVENTION
According to the present invention, fluid leakage through soil in a region is controlled by sequentially passing over the region and digging a plurality of parallel, laterally displaced grooves in the surface, removing and temporarily storing the soil dug from a groove as it is created laying over a groove during each pass a strip of sheet material wider than the groove, and depositing the temporarily stored soil onto the strip such that the latter is covered with earth except along one edge, the other edge of the strip overlying the uncovered edge of an adjacent strip laid down during a previous pass over the region whereby a first layer of overlapping strips of sheet material covered by soil is installed over the region.
The spacing between grooves is selected such that one edge of a subsequently-laid strip can directly engage the uncovered edge of a previously-laid strip to form a seam. The seal at the seam is enhanced by using compressed air to clear any soil form the overlap region just ahead of the newly-laid strip.
The present invention can be carried out conveniently by conventional earth-moving equipment in the form of a scraper mechanism having a bowl with a trailing wheel support, and a leading scraper blade selectively engagable with the surface of the ground for scraping a groove therein when the mechanism traverses the ground, the scraped soil being deposited in the bowl. Scraper mechanisms of this type are well known in the art, and can contain an elevator for raising the scraped soil into the rear portion of the bowl. An example of such a conventional mechanism is the No. 633D elevating scraper manufactured by Caterpillar Tractor Company. This conventional mechanism can be modified in accordance with the present invention by attaching a roll of plastic sheet material to the mechanism, the sheet material being wider than the width of the scraper blade, and the axis of rotation of the roll being parallel to the axis of rotation of the trailing wheel support. As the mechanism scrapes a groove, a strip of sheet material is unrolled from the roll over the groove. By mounting a spreader on the mechanism, soil lifted by the elevator of the mechanism can be distributed non-uniformly across the width of the strip, so that one edge thereof remains uncovered.
The advantage of this arrangement lies in the simplicity of modification required of a conventional elevating scraper; namely, attaching a roll of sheet material to the rear of the scraper, and providing a spreader that carries the soil scraped by the scraper blade up, over, and behind the axle of the trailing wheel mount. Alternatively, the roll of sheet material can be located between the trailing wheel support and the scraper blade; in this case, a spreader is provided that guides the soil scraped by the scraper blade over the roll of sheet material in order to deposit the soil behind the roll and in front of the trailing wheel support. Thus, the trailing wheel support rides on soil deposited on top of the strip by the spreader thus protecting the sheet material from direct contact with the wheel support.
In one form of the invention, the soil is spread substantially uniformly deep on the strip; and in order to provide an overlying layer of sheet material, extra soil is mounded on the overlapped regions of the strips. Thereafter, the process described above is repeated in that the mounds are sequentially passed over in a direction along the length thereof to dig soil therefrom and to lay a strip of sheet material over the scraped mound. The soil scraped from a mound is deposited on the strip such that the scraped mound is covered with soil except along one edge of the strip, with the other edge of the strip overlying the uncovered edge of an adjacent strip laid down during a previous pass over an adjacent mound. Thus, a second layer of overlapping strips of sheet material is laid down over the first layer of overlapping strips, and the seams in the second layer are staggered with respect to the seams in the first layer.
Alternatively, the soil removed when the first groove is dug can be spread nonuniformly across the width of the strip in such a way that there is less soil in the center region of the strip as compared to the peripheral regions, whereby a mound of earth is created at the overlap of adjacent strips. This avoids the need to bring in extra soil after the first layer has been laid down, and before the second layer is laid down.
BRIEF DESCRIPTION OF DRAWINGS
Embodiments of the invention are described below by way of example, and with reference to the accompanying drawings, wherein:
FIG. 1 is a side view, with parts broken away, of a conventional elevating scraper into which the present invention is incorporated;
FIG. 2 is a cross-section of the ground taken along the line 2--2 in FIG. 1 during a first pass over a region;
FIGS. 3-5 are other cross-sections through the ground during subsequent passes showing the result of using the apparatus shown in FIG. 1 in accordance with the present invention;
FIG. 6 is similar to FIG. 2, but shows another embodiment of the invention;
FIG. 7 is the cross-section of FIG. 6, showing the result of using the apparatus of FIG. 1 in accordance with another aspect of the present invention;
FIG. 8 is a side view of apparatus similar to that of FIG. 1;
FIG. 9 is a top view of the apparatus shown in FIG. 8 in operation, showing the manner in which overlapping of the strips is carried out in sequential passes over the region to be treated;
FIG. 10 is a side view of a second embodiment of the present invention;
FIG. 11 is a sectional view of a groove showing its relationship to a strip and the distribution pattern of soil for one form of the invention; and
FIG. 12 is a view similar to FIG. 11 for another form of the invention.
DETAILED DESCRIPTION
Referring now to FIG. 1, reference numeral 10 designates one embodiment of apparatus according to the present invention for controlling fluid leakage through soil. Apparatus 10 comprises a conventional elevating scraper 12 such as a 633D elevating scraper manufactured by Caterpillar Tractor Company to which sheet-feeding mechanism 14 and spreader mechanism 16 are attached Elevating scraper 12 comprises tractor 18 containing operator housing 13, an engine (not shown) for powering drive wheels 20, and controls (not shown) for controlling the application of power to the drive wheels. Cushion hitch and goose neck 22 connects the tractor to bowl 24 of the scraper, which is supported by trailing wheel support 26 through hitch connection 28.
By reason of the controls of the scraper, the bowl 24 can be raised or lowered so that scraper blade 30 can be brought into selective engagement with the surface 32 of the ground. By lowering the scraper blade into the surface of the ground, soil is scooped into the bowl in the space just below the lower reach of elevator 34 which is mounted in the scraper mechanism.
The mechanism described above is entirely conventional in nature; and in its usual operation, the operator makes a pass of a region by powering wheels 20 after lowering the scraper blade 30 into the ground to a predetermined depth. Soil scraped into the bowl is loaded in the rear portion thereof with the assistance of elevator 34, whose speed is controlled by the operator.
In addition to elevating scraper 12, apparatus 10 according to the present invention includes roll mechanism 14 attached to the rear bumper 36 of the scraper. Mechanism 14 may be suspended from the bumper, or may include A-shaped frame 38, which carries ground-engaging wheels 40 supporting axle 42, on which a roll of sheet material, such as polyethylene, is mounted. The axis of rotation of roll 44 is parallel to the axle of trailing wheel support 26.
Finally, mechanism 10 includes spreader 16, which guides soil lifted by elevator 34 over the axles of the trailing wheel mount and deposits the soil to the rear of mechanism 14 for the purpose of distributing the soil onto the top of the strip of sheet material as it is unrolled from roll 44. As shown in FIG. 9, the width of the roll exceeds the width of scraper blade 30; and the function of spreader 16 is to distribute the soil removed from the groove scraped by the scraper mechanism across the width of the strip. In general, spreader 16 distributes the soil on strip 45 in such a way that an edge of the strip, namely, edge 47, is left uncovered. Edge 47 will thus provide the base for the next strip laid by mechanism 10.
The first manner in which the invention is used is illustrated in FIGS. 2-5, to which reference is now made. FIG. 2 shows the result of making a single pass across a region to be treated, whereby a single groove 50 is scraped in surface 32 by mechanism 10. Soil removed from the groove is temporarily stored in the mechanism as elevator 34 lifts the soil onto spreader 16, which carries the soil over trailing wheel mount 26. Sheet 45, which is unrolled from roll 44, trails out behind the mechanism, covering groove 50. Spreader 16 is designed to distribute soil 51 uniformly deep across the entire width of the strip, as shown in FIG. 9, so that edge 47 remains uncovered. The cross-section of soil 51 matches the cross-section of the groove 50.
After the mechanism has completed its first pass across the region to be treated, another groove 52 is scraped parallel to first groove 51 by making another pass across the region with mechanism 10. The spacing between the grooves is selected in relation to the width of the strip such that one edge of second strip 53 overlaps uncovered edge 47 of first strip 45. To ensure intimate contact of the overlapped seam between the strips, compressed air may be directed onto edge 47 of the first-laid strip just before second strip 53 contacts the first strip. As in the first pass, soil removed from groove 52 is distributed across the width of the second-laid strip to a uniform depth, as shown in FIG. 3, but one edge 54 remains uncovered. FIG. 9 illustrates successive passes by mechanism 10.
When the pass across the region is completed, mechanism 10 makes a further pass to create further groove 55, as indicated in FIG. 3; the process is repeated until the entire region is covered by overlapping strips of plastic sheet material. As can be seen in FIG. 3, the process described above lays a first layer of impermeable material in terms of individual strips of material that have overlapping edges, and the first layer is uniformly covered with soil. Heavy earth-moving machinery can immediately drive onto the treated region without damaging the sheet material. This permits earth-moving equipment to deposit mounds of earth 56 on top of the overlapping edges of the strips, as shown in FIG. 4. Soil for these mounds can be scraped by mechanism 10, operated in a conventional manner, from areas adjacent the treated area.
After the mounds have been deposited, as shown in FIG. 4, the process described in connection with FIGS. 2 and 3 can be repeated. That is to say, mechanism 10 can be driven along the mounds so that the scraper blade bites into and removes the upper portion of a mound as another plastic strip 62 is laid over the mound, as shown in FIG. 5. The soil removed from the mound by the elevator is then distributed across strip 62, except for one edge 65, as shown in FIG. 5, in preparation for making another pass by driving the scraper across an adjacent mound and repeating the process.
When the steps described above have been carried out, a region will have been covered by two layers of impermeable material with a layer of soil trapped between the two layers each layer comprising strips of impermeable material that overlap with the overlaps in one layer being staggered with respect to the overlaps in the other layer. This arrangement provides the maximum resistance to leakage of fluid.
A jet of compressed air may be applied to the clear edges of a strip by air line 66, as shown in FIG. 9. This will blow away any particles of soil that may have drifted onto the edge, and will provide a clean surface for the sheet material of the second strip to engage the edge of the first strip. If desired, or if necessary, a bonding agent may be applied behind the jet of air for the purpose of bonding the edges of the strips together.
The alternative arrangement shown in FIGS. 6 and 7 eliminates the need to create mounds 56 by carting soil from another region, and thus materially speeds up the process of laying down overlying layers. In this alternative arrangement, the depth of the scraper blade is increased over that previously described for the purpose of removing sufficient soil from the groove to provide the mounds. This arrangement is shown in FIGS. 6 and 7, and the function of spreader 16 in this case is to provide the desired widthwise distribution of the soil, as shown in FIG. 12. To achieve this end, spreader 1 may include rotating mechanical spreaders (not shown). After multiple passes over the region have been carried out, the arrangement shown in FIG. 7 will result, and mounds 68 will be similar to mounds 56. Mounds 68, however, are created by the scraping of the grooves without the necessity of the extra step of separately creating the mounds. This procedure thus eliminates one traverse of earth-moving equipment over the plastic sheets, and materially increases the rate at which the bottom of a pond can be constructed.
Alternative to embodiment 10 shown in. FIGS. 1 and 8, embodiment 10' shown in FIG. 10 can be used. In embodiment 10', roll 70 of sheet material is carried within the bowl of the scraper, and is located forwardly of rear wheel support 26' and rearwardly of elevator 34'. In this case, the spreader is in the form of baffle 72 built over roll 70 for the purpose of providing a path for the soil lifted by elevator 34'. In this case, the soil temporarily stored in the scraper is deposited onto the strip ahead of the rear wheel support, which rides over the deposited soil.
As shown in FIG. 9, roll 44 of plastic material is symmetrically located with respect to the center line of the vehicle; and spreader 16 has its trailing edge eccentrically located relative to the center line It is also possible, however, to eccentrically locate the roll, and to arrange for the trailing edge of the spreader to be symmetrical with respect to the center line.
It is believed that the advantages and improved results furnished by the method and apparatus of the present invention are apparent from the foregoing description of the preferred embodiment of the invention. Various changes and modifications may be made without departing from the spirit and scope of the invention as described in the claims that follow. | Fluid leakage through soil in a region thereof is controlled by sequentially passing over the region to dig a plurality of parallel, laterally displaced grooves in the surface. Soil dug from each groove is temporarily stored, and a strip of sheet material is laid over a groove as it is created during each pass, the width of the strip being greater than the width of the groove. Thereafter, the temporarily stored soil is deposited on the strip such that it is covered with soil except along one edge, the other edge of the strip overlying the uncovered edge of an adjacent strip laid down during a previous pass over the region. As a consequence, a first layer of overlapping strips of sheet material covered with soil is installed over the region. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application relates to co-pending U.S. patent application Ser. No. 10/447,290, entitled “SYSTEM AND METHODS UTILIZING NATURAL LANGUAGE PATIENT RECORDS,” filed on May 29, 2003; U.S. patent application Ser. No. 10/413,405, entitled “SYSTEMS AND METHODS FOR CODING INFORMATION,” filed Apr. 15, 2003, now U.S. Pat. No. 7,233,938; U.S. patent application Ser. No. 11/068,493, entitled “A SYSTEM AND METHOD FOR NORMALIZATION OF A STRING OF WORDS,” filed on Feb. 28, 2005, now U.S. Pat. No. 7,822,598; co-pending U.S. patent application Ser. No. 10/448,320, entitled “METHOD, SYSTEM, AND APPARATUS FOR DATA REUSE,” filed on May 30, 2003; co-pending U.S. patent application Ser. No. 10/448,317, entitled “METHOD, SYSTEM, AND APPARATUS FOR VALIDATION,” filed on May 30, 2003; U.S. patent application Ser. No. 10/448,325, entitled “METHOD, SYSTEM, AND APPARATUS FOR VIEWING DATA,” filed on May 30, 2003, now abandoned; U.S. patent application Ser. No. 10/953,448, entitled “SYSTEM AND METHOD FOR DOCUMENT SECTION SEGMENTATIONS,” filed on Sep. 30, 2004, now abandoned; U.S. patent application Ser. No. 10/953,471, entitled “SYSTEM AND METHOD FOR MODIFYING A LANGUAGE MODEL AND POST-PROCESSOR INFORMATION,” filed on Sep. 29, 2004, now U.S. Pat. No. 7,774,196; U.S. patent application Ser. No. 10/951,291, entitled “SYSTEM AND METHOD FOR CUSTOMIZING SPEECH RECOGNITION INPUT AND OUTPUT,” filed on Sep. 27, 2004, now U.S. Pat. No. 7,860,717; co-pending U.S. patent application Ser. No. 10/953,474, entitled “SYSTEM AND METHOD FOR POST PROCESSING SPEECH RECOGNITION OUTPUT,” filed on Sep. 29, 2004; U.S. patent application Ser. No. 10/951,281, entitled “METHOD, SYSTEM AND APPARATUS FOR REPAIRING AUDIO RECORDINGS,” filed on Sep. 27, 2004, now U.S. Pat. No. 7,542,909; U.S. patent application Ser. No. 11/069,203, entitled “SYSTEM AND METHOD FOR GENERATING A PHASE PRONUNCIATION,” filed on Feb. 28, 2005, now U.S. Pat. No. 7,783,474; U.S. patent application Ser. No. 11/007,626, entitled “SYSTEM AND METHOD FOR ACCENTED MODIFICATION OF A LANGUAGE MODEL,” filed on Dec. 7, 2004, now U.S. Pat. No. 7,315,811; co-pending U.S. patent application Ser. No. 10/948,625, entitled “METHOD, SYSTEM, AND APPARATUS FOR ASSEMBLY, TRANSPORT AND DISPLAY OF CLINICAL DATA,” filed on Sep. 23, 2004; and U.S. patent application Ser. No. 10/840,428, entitled “CATEGORIZATION OF INFORMATION USING NATURAL LANGUAGE PROCESSING AND PREDEFINED TEMPLATES,” filed on Sep. 23, 2004, now U.S. Pat. No. 7,379,946, all of which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus, system, and method for predicting and accurately reproducing linguistic properties of character and word sequences using techniques involving affix data preparation, generation, and prediction.
Automated document preparation systems have been available for some time. These systems allow a plurality of individuals to dictate information to a transcription center where the dictated information is stored, transcribed and processed for distribution in accordance with a predetermined arrangement. Such systems are commonly employed in the healthcare industry where physicians, nurses and other medical professionals are required to maintain detailed records relating to the status of the many patients they see during the course of their daily routine.
As with virtually all industries, the healthcare industry in particular is beset by a need for readily available information. From physicians to patients the ready availability of information is somewhat limited when one looks to the availability of information in other fields. While much of the known scientific information relating to medicine is available via public and/or private databases, the manner in which the data is gathered and analyzed is very similar to methods which have been utilized since the development of the printing press.
That is, physicians typically conduct research on an individual basis and publish reports telling of the information they have found through their research. The basis for their research is, however, usually information of which they have first hand knowledge or information which has been previously published by other physicians.
In addition to the limited availability of information for use by physicians, the available information regarding the practice of medicine is stored and prepared in an arcane manner not readily understandable by the conventional patient. As such, medical patients are often forced to rely entirely upon information given to them by their personal physicians, and consequently overlook alternate procedures which may be preferable to those suggested by their personal physician.
Automated document preparation systems for some time have incorporated natural language processing to enhance document processing and information retrieval. For example, a natural language processor linked with a text normalization processor may be configured to compile relevant information related to reports generated by an automated document preparation system. The relevant information may be information related to diagnosis of diseases, treatment protocols, billing codes and the like. The relevant information may be compiled and indexed for later retrieval and research.
In the conventional natural language processors, morphological analysis and stemming techniques have been implemented to enhance natural language processing and information retrieval. Morphological analysis may include inflectional and derivational of natural language text. More particularly, inflectional analysis may involve determining patterns in paradigms and derivational analysis may involve the process of word formation. Computational methods applied to morphological analysis and generation in natural language parsing; text generation; machine translation; dictionary tools; text-to-speech and speech recognition; word processing; spelling checking; text input; information retrieval, summarization, and classification; and information extraction.
However, drawbacks and disadvantages are associated with the text processing engines. For example, the conventional information extraction engine is typically constructed using databases or tables of terms. In the medical fields, these tables often encompass several million of terms (words and phrases). The size of these tables not only encumbers computer memory resources, but also encumbers the performance of the normalization engine. More specifically, as the tables grow larger, the time required to search the tables grows larger. It would also be desirable to apply the same generation and prediction methods for a number of information extraction processing steps such as uninflection, underivation, and part-of-speech prediction; and for these methods to work equally well over words and phrases. The problem of processing text is burdened by the fact that it is not possible to list all possible terms. Consequently, prediction technology should not only provide precise information about the terms of which it has direct knowledge, but also be able to accurately predict information for novel or out-of-vocabulary terms.
Several shortcomings of the prior art that are addressed by the patent are: (a) enforcing the requirement that the prediction method is capable of perfectly rendering information supplied by the data set used to generate the predictor; (b) providing a method of excluding data from the generation process; (c) providing a method of incorporating exceptional data into the generation process; and, thereby, (d) providing the ability either to replace completely the original data set or to combine perfect rendition of the information in a data set and highly accurate prediction for novel or out-of-vocabulary terms.
SUMMARY OF THE INVENTION
One embodiment generally pertains to a method of prediction. The method includes generating an ordered set of affixes from a selected input sequence and comparing the set of affixes with a stored set of affixes. The method also includes selecting an affix from the stored set of affixes used for prediction; and retrieving the prediction associated with that affix. In the following presentation, the term “affix” is used to refer to suffixes (trailing sequences), prefixes (leading sequences), and infixes (interior sequences) and their combinations.
Another embodiment generally relates to a method for generating a data set. The method includes receiving a corpus (organized set of texts) and generating a set of data triplets based on the corpus. Each triplet consists of an affix, an associated pattern, and a frequency of occurrence for the affix and associated pattern. The method also includes selecting a subset of triplets as the data set, where a selection criteria is based on length and frequency of occurrence.
Yet another embodiment generally relates to a system for predicting a pattern using affixes. The system includes an affix prediction module, an affix prediction data set, and an affix generation module. The affix prediction module is configured to retrieve terms based on matching affixes generated from an input sequence with entries in the affix prediction data set generated by the affix generation module.
Yet another embodiment generally pertains to an apparatus for generating a data set. The apparatus includes means for receiving a corpus comprising of a plurality of sequences and means for generating a set of triplets based on the corpus. Each triplet has an affix, an associated pattern, and a frequency of occurrence for the affix and associated pattern. The apparatus also includes means for selecting a subset of triplets as the data set, where a selection criteria is based on length and frequency of occurrence.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed the same will be better understood from the following description taken in conjunction with the accompanying drawings, which illustrate, in a non-limiting fashion, the best mode presently contemplated for carrying out the present invention, and in which like reference numerals designate like parts throughout the Figures, wherein:
FIG. 1 illustrates a block diagram of the affix prediction module in accordance with an embodiment of the invention;
FIG. 2 illustrates a diagram of a system utilizing the affix prediction module in accordance with another embodiment of the invention;
FIG. 3 shows a flow diagram of loading predictive data according one embodiment of the present invention;
FIG. 4 shows a flow diagram of matching input data according to one embodiment of the present invention;
FIG. 5 shows a flow diagram of constructing data sets according to one embodiment of the present invention;
FIG. 6 shows a flow diagram of processing data sets according to one embodiment of the present invention;
FIG. 7 shows a flow diagram of steps associated with element 80 of FIG. 4 according to one embodiment of the present invention; and
FIG. 8 illustrates a computer system implementing the affix prediction module in accordance with yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present disclosure will now be described more fully with reference the to the Figures in which an embodiment of the present disclosure is shown. The subject matter of this disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein.
FIG. 1 illustrates a block diagram of an affix prediction module 100 in accordance with an embodiment of the present invention. It should be readily apparent to those of ordinary skill in the art that the affix prediction module 100 depicted in FIG. 1 represents a generalized schematic illustration and that other components may be added or existing components may be removed or modified. Moreover, the affix prediction module 100 may be implemented using software components, hardware components, or a combination thereof.
As shown in FIG. 1 , the affix prediction module 100 includes a prediction module 110 , an affix generation module 120 , and a storage module 130 . The prediction module 110 may be configured to make predictions based on a sequence of letters, words, tokens, etc. This sequence, i.e., affix, may consist of a combination of prefix, infix, and suffix sequences drawn from the input sequence. The prediction module 110 may utilize an affix prediction data set, stored on the storage module 130 . More particularly, the prediction module 110 may process input sequences from an input file in one embodiment. In other embodiments, the input sequences may be provided over a network.
The prediction module 110 may generate all possible affixes for the selected input sequence. The prediction module 110 may compare the generated affixes with affixes stored in the affix prediction data set, which is may be stored on the storage module 130 . When the prediction module 110 determines a match between the longest affix of the input sequence with an affix in the affix prediction data set, the prediction module 110 retrieves the pattern and/or action associated with the matching affix. In one embodiment, the affix may represent an electronic mail address and the action may initiate the loading of an electronic mail client with the affix.
The affix generation module 120 may be configured to generate three data sets: a master data set, an excluded data set, and an add-in data set. Each data set comprises of entries of triplets. A triplet consists of an affix form, i.e., an ordered sequence of characters or words, a pattern, i.e., an attribute, property, or action associated with the associated affix form, and a frequency, which is derived or estimated frequency of occurrence of the form-pattern combination.
The master data set is configured to provide a basis for pattern generation, which is used to generate the affix prediction data set. The excluded data set is configured to provide a subset of triplets from the master data set that are not intended to undergo pattern generation. The excluded data set may be utilized under some circumstances to ensure that irrelevant affixes are not generated for non-productive data types. For example, a closed set of function words (prepositions, conjunctions, pronouns, article, and so forth) in a natural language may be excluded from the generation of part-of-speech prediction patterns for content words (nouns, verbs, adjectives, and adverbs). The add-in data set is configured to contain a set of triplets that are added “as-is” to the affix prediction data set. The add-in data set is used to incorporate exceptions into the affix prediction data set. In certain embodiments, the affix prediction data set may be generated based on the master data set alone or in combination with the excluded data set or add-in data set. The actual combination of data set may depend on the requirements of a particular application for the natural language processor.
The affix generation module 120 may be configured to receive the master data set, i.e., a corpus of organized set of texts, a vocabulary or lexicon, or other similar input, to generate the affix prediction data set. The affix generation module 120 may also be configured to receive a set of parameters, e.g., the length of the longest affix, lowest frequency affix-pattern combination, etc., associated with the predicted affix set. The affix generation module 120 may pre-process the master data set by pre-pending and/or post-pending each term in the master data set with a distinctive peripheral symbol (the symbol being different from any possible character or word) to identify the beginning and the end of a sequence.
The affix generation module 120 may be further configured to generate triplets for the characters and/or words of on the master data set and, optionally, the application of either the excluded data set or the add-in data set or both. More particularly, the affix generation module 120 may generate sequences of characters in a predefined order, i.e., an affix, from the characters and/or words of the master data set. For each sequence, the affix generation module 120 may determine an associated pattern of the affixes, and the frequency of the affix-pattern combination. In one embodiment, the affix generation process may incorporate a shortest pattern consisting of the distinctive peripheral symbol for each member of the corpus. The default prediction (i.e., when no non-empty affix matches) is provided by this special affix. In other embodiments, the affix generation module 120 may eliminate an affix-combination pattern if it is longer than the pre-determined longest affix.
The affix generation module may be further configured to maintain the frequency of each affix-pattern combination by keeping a count of the frequency of each affix-pattern combination and adding to the count for every new instance of that affix-pattern combination. In further embodiments, the affix generation module may eliminate affix-pattern combinations for those combinations, which fall below the predetermined lower frequency pattern combination.
The affix generation module 120 may yet be further configured to select a subset of the generated triplets. More particularly, the affix generation module 120 may sort all triplets based on length of affix, the frequency, i.e., from shortest to longest affix and from lowest to highest frequency. The affix generation module 120 may then start from the shortest affix to determine the highest frequency of an affix-pattern combination for a given affix. The shortest affix with the high frequency is entered into the affix prediction data set. The affix generation module 120 may also determine that a most frequent affix-pattern combination for a selected affix has the same prediction as an affix that is contained within another shorter affix, the selected affix is then eliminated.
FIG. 2 illustrates a natural language patient record (NLPR) system 200 utilizing the affix prediction module in accordance with yet another embodiment. It should be readily apparent to those of ordinary skill in the art that the system 200 depicted in FIG. 2 represents a generalized schematic illustration and that other components may be added or existing components may be removed or modified. Moreover, the system 200 may be implemented using software components, hardware components, or a combination thereof.
As shown in FIG. 2 , the NLPR system 200 includes a plurality of workstations 205 interconnected by a network 210 . The NLPR system 200 also includes a server 215 executing a computer readable version 220 of the NLPR system and data storage 225 . The NLPR system 200 is a system for maintaining electronic medical records of patients, which is described in greater detail in co-pending U.S. patent application Ser. No. 10/447,290, entitled, “SYSTEM AND METHOD FOR UTILIZING NATURAL LANGUAGE PATIENT RECORDS,” filed May 29, 2003, which has been incorporated by reference in its entirety.
The workstations 205 may be personal computers, laptops, or other similar computing element. The workstations 205 execute a physician workstation (PWS) client 230 from the NLPR system 200 . The PWS client 225 provides the capability for a physician to dictate, review, and/or edit medical records in the NLPR system 200 . While FIG. 2 is described in the realm of the medical field, it will be understood by those skilled in the art that the present invention can be applied to other fields of endeavor where users dictate, review and edit records in any domain.
The workstations 205 also execute a transcriptionist client 235 for a transcriptionist to access and convert audio files into electronic text. The NLPR system 200 may also use speech recognition engines to automatically convert dictations from dictators into electronic text.
The network 210 is configured to provide a communication channel between the workstations 205 and the server 215 . The network 210 may be a wide area network, local area network or combination thereof. The network 210 may implement wired protocols (e.g., TCP/IP, X.25, IEEE802.3, IEEE802.5, etc.), wireless protocols (e.g., IEEE802.11, CDPD, etc.) or combination thereof.
The server 215 may be a computing device capable of providing services to the workstations 205 . The server 215 may be implemented using any commonly known computing platform. The server 215 is configured to execute a computer readable version of the NLPR software 220 . The NLPR software provides functionality for the NLPR system 200 . The NLPR system 200 may receive audio files and/or documents by other network access means such as electronic mail, file transfer protocols, and other network transferring protocols.
The data storage 225 may be configured to interface with network 210 and provide storage services to the workstations 205 and the server 215 . The data storage 225 may also be configured to store a variety of files such as audio, documents, and/or templates. In some embodiments, the data storage 225 includes a file manager (not shown) that provides services to manage and access the files stored therein. The data storage 225 may be implemented as a network-attached storage or through an interface through the server 215 .
FIG. 3 illustrates a flow diagram of loading predictive data 300 executed by the prediction module 120 according to one embodiment of the present invention. It should be readily apparent to those of ordinary skill in the art that this flow diagram 300 represents a generalized illustration and that other steps may be added or existing steps may be removed or modified.
As shown in FIG. 3 , when invoked the prediction module 110 may retrieve a predictive data set of affixes 310 from the storage module 130 . In the NLPR system, the predictive data set of affixes is loaded during NLPR system initialization. In other embodiments, the prediction module 110 may access the predictive data set 310 from a remote database, server or other similar persistent memory device.
In yet other embodiments, the predictive data set of affixes 310 may be tailored to a specific application. More specifically, the affix prediction module 100 may utilize a predictive data set of affixes 310 generated based on a legal lexicon for legal applications. Similarly, the affix prediction module 100 may be specifically tailored for specialties within a field. For example, predictive data set of affixes may be generated for oncology applications, gynecology applications, internal medicine applications, infectious diseases, etc. Accordingly, the affix prediction module 100 may be programmed to a specialty based on selecting the appropriate predictive data set.
FIG. 4 illustrates a flow diagram of matching input data 400 implemented by the prediction module 110 according to one embodiment of the present invention. It should be readily apparent to those of ordinary skill in the art that this flow diagram 400 represents a generalized illustration and that other steps may be added or existing steps may be removed or modified.
As shown in FIG. 4 , the prediction module 110 may be configured to receive an input sequence from an input file, in step 405 . The prediction module 110 , in step 410 , may be configured to determine whether or not the last input sequence from the input file has been processed. For example, the prediction module may determine if an end-of-file character has been reached.
If the prediction module 110 determines that the end of input sequences has been reached, the prediction module 110 may terminate processing, in step 415 . Although not explicitly shown, the prediction module 110 may return control to a calling program.
Otherwise, if the prediction module 110 determines that an input sequence has been retrieved for processing, the prediction module 110 may be configured to generate all possible affixes for the received input sequence, in step 420 . The affix generation process done during prediction is identical to the process applied during the affix prediction data base generation phase. In an inflection prediction application, the affix generation (resp. recognition) process might consist of generating all possible suffixes of a given input term. For example, given the term “#diabetes#” (where ‘#’ is the peripheral symbol), the affix generation (resp. recognition) process might generate the set of suffixes, from right-to-left of the input term: {#, #s, #se, #set, #sete, #seteb, #seteba, #setebai, #setebaid, #setebaid#}. In another embodiment, the affix generation (resp. recognition) process might incorporate prefixes or suffixes of the input term.
In step 425 , the prediction module 110 may compare the generated affixes with the entries in the predictive data set 310 . More specifically, the prediction module 110 may match the longest affix of the received input sequence with the predictive data set 110 . A match is guaranteed since all sequences must contain peripheral symbols. In step 430 , the prediction module 110 may retrieve the associated pattern/action associated with the longest match. In step 435 , the retrieved pattern/action is returned to the calling program for further processing. Subsequently, the prediction module 110 retrieves the next input sequence from the input file in step 405 .
FIG. 5 illustrates a diagram of data sets 500 involved in generating the affix prediction data set 305 by the affix generation module 120 (shown in FIG. 1 ) according to one embodiment of the present invention. In certain embodiments, a master data set 510 , an excluded data set 520 , and an add-in data set may be used to generate the affix prediction data set 305 . Each of the data sets comprises of triplets. A triplet comprises an affix sequence, a pattern associated with the affix sequence, and a frequency associated the affix sequence-pattern combination.
The master data set 510 may be configured to provide a basis for pattern generation. The excluded data set 520 may comprises a subset of triplets that are excluded from the master data set 510 that are not intended to undergo affix pattern generation. The add-in data set 530 may be configured to provide a set of triplets that are added “as-is” to the affix prediction data set 305 .
The excluded data set 520 and the add-in data set 530 may be included at the option of the end-user or as a function of the application of the affix prediction module 100 . More particularly, a master data set of word inflections may contain a large number of irregular inflections (e.g., run, runs, running, ran). In natural languages, irregular inflections are not productive, i.e., their patterning is not used, for example, in creating inflections of new words, and thereby may qualify to be included in the excluded data set. However, the irregular inflections would be included in the add-in data set to ensure that irregular inflections are found in the affix prediction data set.
FIG. 6 illustrates a flow diagram for the generation of the affix prediction data set 305 implemented by the affix generation module 120 according to another embodiment of the invention. It should be readily apparent to those of ordinary skill in the art that this flow diagram 600 represents a generalized illustration and that other steps may be added or existing steps may be removed or modified.
As shown in FIG. 6 , the affix generation module 120 may be configured to receive the master data set 510 and the excluded data set 520 and remove the triplets of the excluded data set 520 from the master data set 510 , in step 605 . In other embodiments, the excluded data set 520 may not be processed to filter entries in the master data set 510 . The inclusion of the excluded data set may be an end-user's discretion.
In step 610 , the affix generation module 120 may be configured to generate the minimal affix patterns associated with each triplet in the excluded or filtered master data set to generate a temporary predictive data set 615 . FIG. 7 illustrates in greater detail the generation of the minimal affix patterns, as described herein below.
In step 620 , the affix generation module 120 may be configured to add the add-in data set 530 to the temporary predictive data set 615 to created the final predictive affix patterns as the prediction data set 310 . In yet other embodiments, the add-in data set 520 may not be processed. The processing of the add-in data set 520 may be an end-user option.
FIG. 7 illustrates a flow diagram 700 of the generation of the minimal affix patterns (shown in FIG. 6 ) as implemented by the affix generation module 120 according to yet another embodiment of the invention. It should be readily apparent to those of ordinary skill in the art that this flow diagram 700 represents a generalized illustration and that other steps may be added or existing steps may be removed or modified.
As shown in FIG. 7 , the affix generation module 120 may be configured to set parameters, in step 705 . More specifically, the affix generation module 120 may set threshold values for parameters such as length of the longest affix, lowest frequency affix-pattern combination allowed, and so forth. In certain embodiments, the affix generation module 120 may generate a graphical user interface for a user to set the threshold values.
In step 710 , the affix generation module 120 may be configured to implement a sequence preparation on the filtered master data set. More particularly, the affix generation module 120 may pre-pend and/or post pend each term with a distinctive peripheral character or word to identify the beginning or end of a sequence.
In step 715 , the affix generation module 120 may be configured to generate triplets for the characters and/or words of the corpus. More particularly, the affix generation module 120 may generate sequences of characters in a predefined order, i.e., an affix, from the characters and/or words of the corpus. For each sequence, the affix generation module 120 determines an associated pattern of the affixes, and the frequency of the affix-pattern combination. In other embodiments, the affix generation module 120 may eliminate an affix-combination pattern if it is longer than the pre-determined longest affix.
In step 720 , the affix generation module 120 may be configured to maintain the frequency of each affix-pattern combination by keeping a count of the frequency of each affix-pattern combination and adding to the count for every new instance of that affix-pattern combination. In further embodiments, the affix generation module 120 may eliminate affix-pattern combinations for those combinations, which fall below the predetermined lower frequency pattern combination.
In step 725 , the affix generation module 120 may select a subset of the generated triplets. More particularly, the affix generation module 120 may sort all triplets based on length of affix, the frequency, i.e., from shortest to longest affix and from lowest to highest frequency. The affix generation module 120 may then start from the shortest affix to determine the highest frequency of an affix-pattern combination for a given affix. The shortest affix with the high frequency is entered into the affix prediction data set. The affix generation module 120 may also determine that a most frequent affix-pattern combination for a selected affix has the same prediction as an affix that is contained within a shorter affix, but there are not affixes intervening between this shorter affix and the given affix with a different pattern, the selected affix is then eliminated.
FIG. 8 illustrates an exemplary block diagram of a computer system 1000 where an embodiment may be practiced. The functions of the affix prediction module 100 may be implemented in program code and executed by the computer system 800 . The affix prediction module 100 may be implemented in computer languages such as PASCAL, C, C++, JAVA, and so forth.
As shown in FIG. 8 , the computer system 800 includes one or more processors, such as processor 802 , that provide an execution platform for embodiments of the affix prediction module. Commands and data from the processor 802 are communicated over a communication bus 804 . The computer system 800 also includes a main memory 806 , such as a Random Access Memory (RAM), where the software for the affix prediction module 80 may be executed during runtime, and a secondary memory 808 . The secondary memory 808 includes, for example, a hard disk drive 820 and/or a removable storage drive 822 , representing a floppy diskette drive, a magnetic tape drive, a compact disk drive, or other removable and recordable media, where a copy of a computer program embodiment for the affix prediction module 100 may be stored. The removable storage drive 822 reads from and/or writes to a removable storage unit 824 in a well-known manner. A user interfaces with the affix prediction module 100 with a keyboard 826 , a mouse 828 , and a display 820 . The display adaptor 822 interfaces with the communication bus 804 and the display 820 and receives display data from the processor 802 and converts the display data into display commands for the display 820 .
Certain embodiments may be performed as a computer program. The computer program may exist in a variety of forms both active and inactive. For example, the computer program can exist as software program(s) comprised of program instructions in source code, object code, executable code or other formats; firmware program(s); or other known program. Any of the above can be embodied on a computer readable medium, which include storage devices and signals, in compressed or uncompressed form. Exemplary computer readable storage devices include conventional computer system RAM (random access memory), ROM (read-only memory), EPROM (erasable, programmable ROM), EEPROM (electrically erasable, programmable ROM), and magnetic or optical disks or tapes. Exemplary computer readable signals, whether modulated using a carrier or not, are signals that a computer system hosting or running the present invention can be configured to access, including signals arriving from the Internet or other networks. Concrete examples of the foregoing include distribution of executable software program(s) of the computer program on a CD-ROM or via Internet download. In a sense, the Internet itself, as an abstract entity, is a computer readable medium. The same is true of computer networks in general.
It will be apparent to one of skill in the art that described herein is a novel system and method for predicting and accurately reproducing linguistic properties of character and word sequences using techniques involving affix data preparation, generation, and prediction. While the invention has been described with reference to specific preferred embodiments, it is not limited to these embodiments. The invention may be modified or varied in many ways and such modifications and variations as would be obvious to one of skill in the art are within the scope and spirit of the invention and are included within the scope of the following claims. | One embodiment generally pertains to a method of prediction. The method includes generating a set of affixes from a selected input sequence and comparing the set of affixes with a predictive set of affixes. The method also includes selecting an affix from the predictive set of affixes. The invention uses various input data sets and allows the ability to perfectly render the original data set and the minimal size of the predictive set of affixes. | 6 |
BACKGROUND OF THE INVENTION
[0001] I. Field of the Invention
[0002] The present invention relates generally to vehicle-mounted concrete mixing and dispensing systems and, more particularly, to on-board auxiliary fluid supply systems employed to supply water for washout or adding water to a concrete mix. Specifically, the present invention relates to a pump-operated on-board auxiliary fluid supply system that eliminates the need for a pressurized tank and is self purging of residual fluid.
[0003] II. Related Art
[0004] Transit concrete mixing trucks, sometimes referred to as ready-mix trucks, have long been in use. They are equipped with large chassis-mounted rotatable mixing drums for mixing and dispensing a quantity of concrete. The drums typically are mounted on an incline and have an opening in the upper end for receiving ingredients to be mixed and discharging mixed concrete products. Loading is accomplished through a charge hopper which extends a distance into the opening of the drum. The drum is further provided with internal helical flights or fins extending around its internal surface which acts to mix the concrete when the drum is caused to rotate in one direction and cause the concrete to be discharged out of the opening when the rotation of the drum is reversed. The upper portion of the drum includes a ring and roller system for drum support and rotation that is carried by a heavy pedestal support assembly.
[0005] After mixing and discharge, such concrete mixing drums retain an amount of residual concrete on the mixing fins and inner drum surface and discharge chutes which needs to be periodically washed out to prevent it from curing and hardening inside the drum and on external chutes. Therefore, it has become part of the operating routine to wash the interior of the drum and the discharge chutes one or more times per day. In addition, it may be necessary to add additional makeup water to a mix in the drum prior to discharge.
[0006] In conjunction with the use of makeup or washout water on transit concrete mixing trucks, it has further become a common practice to provide a water supply on the vehicle. The supply has included a water tank that has been typically pressurized to 50 psi or higher by a supply of air from a compressor carried on the truck. This, in turn, supplies water under pressure for washout or other uses through hoses and a valving system in a well-known manner.
[0007] Such a prior system is illustrated in FIGS. 1 a and 1 b in which a concrete mixer truck, generally at 10 , having a mixing drum 12 and discharge chute 14 is provided with a pressurizable auxiliary water tank 16 mounted on the vehicle. As seen in FIG. 1 b , the auxiliary water tank 16 includes an air inlet valve 20 that controls the flow of air under pressure from a pressure source (not shown) through an air supply line (also not shown). An air pressure regulator with gauge 22 is provided, together with a pressure relief or pop-off valve at 24 , which prevents over-pressurization of the system. A discharge outlet pipe or hose is provided at 26 suitably valved at 28 . The system may be purged by using pressurized air to clear the hose or pipe 26 .
[0008] More recently, however, government regulations have curtailed the use of such pressurized tanks in many areas and so it would be desirable to eliminate the need for pressurization of the tank without diminishing the washout or easy purge capabilities of the system.
SUMMARY OF THE INVENTION
[0009] By means of the present invention, there is provided a self-purging auxiliary fluid supply system for supplying water for washout or adding to batches in a truck-mounted concrete mixing drum. The system includes a truck-mounted fluid reservoir for containing a quantity of water, the reservoir being connected to supply non-pressurized fluid to a pump assembly. The pump assembly includes an air-operated diaphragm pump apparatus for supplying auxiliary fluid from the fluid reservoir under pressure to a discharge assembly which connects to a conventional washout/supply system associated with the operation of the mixing drum. The fluid supply system is provided with valving which enables it to quickly integrally purge itself after use.
[0010] Several embodiments are shown with different locations for the mounting of the pump of the invention. The system is designed for ease of manufacture or as a convenient retrofit system on existing transit concrete mixing trucks. The pump and piping system eliminate the need for pressurizing the reservoir tank and facilitate the draining or purging of associated water lines to prevent freezing in cold weather. A typical diaphragm pump of the invention uses air at about 100 psig to operate the pump and can supply up to 25 gpm of water at a pressure of about 10 psig for water injection or about 8 gpm at about 75 psig for washout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the drawings, wherein like numerals depict like parts throughout the same:
[0012] FIG. 1 a is a side elevational view of a transit concrete mixing truck carrying an auxiliary water system in accordance with the prior art;
[0013] FIG. 1 b is an enlarged side elevational view of a prior art auxiliary water tank from the system of FIG. 1 a;
[0014] FIG. 2 is an enlarged partial perspective view of an embodiment of an auxiliary water system in accordance with the present invention which utilizes a side pump mounting;
[0015] FIG. 3 a is a view similar to FIG. 2 illustrating an alternate embodiment of the auxiliary water system of the present invention;
[0016] FIG. 3 b is an enlarged frontal view of the diaphragm pump of FIG. 3 a;
[0017] FIG. 4 is an enlarged perspective view of another embodiment of the present invention using a tank-mounted pump;
[0018] FIG. 5 is a perspective view of another embodiment which utilizes a side pump mounting; and
[0019] FIG. 6 is an alternate embodiment of a water supply tank equipped with an additive supply tank.
DETAILED DESCRIPTION
[0020] Certain embodiments of the present invention will be described with reference to drawing figures. They represent examples of an auxiliary water supply system for a transit concrete mixing truck which provides high pressure water for washout or additional water to be added to the drum. The embodiments described are meant as examples and are not intended to limit the inventive concepts.
[0021] It is an important aspect of the present invention that the need for an expensive pressurized water supply tank is eliminated. In addition, the invention further provides a rapid self-purging feature to purge the system of water after use.
[0022] FIG. 2 depicts an enlarged partial perspective view of an embodiment of the invention which includes a side or frame-mounted pump. The system includes an auxiliary water supply tank 30 which may be fabricated from metal or non-metal materials and is shown carried by support pedestals or saddles 32 , 33 fixed thereto by heavy straps 34 , 35 . Saddles 32 , 33 , in turn, are fixed to truck frame members 36 , 38 , respectively. An air-operated diaphragm pump 40 is mounted on a bracket 42 fixed to the truck frame member 36 . An air supply inlet connection is shown at 44 , which connects to an air pressure supply tank or accumulator which is pressurized by a conventional source of high pressure air such as a compressor (not shown) used to operate diaphragm pump 40 . The pump 40 has a suction inlet at 46 connected as by a tee 48 , one side of which is connected to a water feed line 50 which, in turn, is connected to the tank 30 at 52 .
[0023] The tank discharge is preferably a top discharge, bottom draw system using a conventional bottom draw standpipe tube (not shown) that is connected to outlet 52 at the top and extends to the bottom of the tank. This greatly facilitates hose system drainage after use. However, a bottom discharge arrangement can also be used. The tee 48 also leads to a manually operated ball valve 54 used to drain and purge the system. The pump discharge outlet manifold shown at 56 is connected to a pump discharge hose 58 usable for washout or adding water to the drum. The water tank 30 is further provided with a breather vent 60 and fill opening 62 . The pump discharge hose 58 is connected to conventional suitable control valves (not shown) in a well known manner.
[0024] FIGS. 3 a and 3 b depict an alternative trailer-mounted embodiment which uses a mounting bracket 70 mounted flush with trailer frame member 72 . In this embodiment, the water feed line 74 is shown as being connected to a tank discharge outlet on the bottom of the tank 30 and the upper outlet 52 is suitably capped at 76 . Of course, a top discharge, bottom-draw connection could also be used. A ball valve is provided in the intake line at 78 . As best seen in FIG. 3 b , the input/drain line between valves 78 and 54 is inclined slightly downward to valve 54 . This is to assure easy drainage when valve 54 is opened after the system is used.
[0025] Another embodiment is depicted in FIG. 4 in which the air-operated diaphragm pump is mounted on the fluid supply tank itself. The pump is fixed to a mounting plate 90 which is mounted to the upper surface of the tank 30 . This embodiment also includes a water feed line 50 which accesses the tank 30 from the top at 52 and which also preferably uses a bottom draw standpipe system.
[0026] FIG. 5 depicts yet another embodiment of an auxiliary fluid supply system in accordance with the invention in which the air-operated diaphragm pump 40 is mounted to the side of the fluid supply or water tank 30 . The pump is mounted on a bracket having a platform 90 and side members 92 . The bracket is attached to a stable mounting stand structure 94 which, in turn, is mounted on a truck alongside tank 30 in any convenient location in a well known manner. Connections between the tank and pump and the pump include top mounted water feed line 50 and discharge hose 58 . A drain valve 54 is also shown.
[0027] FIG. 6 depicts an alternative embodiment of a water supply tank at 100 which is carried by a pair of spaced pedestals 102 and 104 and heavy attaching straps 106 and 108 . A fill opening is shown at 110 and a breather vent at 112 . A top discharge, bottom draw connection is shown at 114 with outlet hose 116 . The tank 100 further carries a smaller reservoir 118 containing additive material to be blended into the water supplied from the main auxiliary water supply tank 100 using supply hose 120 suitably valved at 122 , which can be manifolded with supply hose 116 at the pump input or other conventional mixer system in a well known manner.
[0028] In operation, with a supply of water or other desirable fluid in the tank 30 , the conventional output control valves (not shown) are opened in accordance with the use of the system and the diaphragm pump 40 is supplied with high pressure air, generally about 100 psig. The diaphragm pump 40 is operated to provide intake suction and pressurized fluid in the discharge line. When the desired amount of water is supplied for the desired use, the control valves in the pump discharge hose 58 and the drain/input valve 54 is opened. This allows water in the line to drain from the pump and also allows the pump to pump air through the system thereby purging out all the lines. This is particularly advantageous to avoid freezing of the system in cold weather.
[0029] This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use embodiments of the example as required. However, it is to be understood that the invention can be carried out by specifically different devices and that various modifications can be accomplished without departing from the scope of the invention itself. | A self-purging auxiliary fluid supply system for supplying washout or makeup water or other fluids under pressure to a truck-mounted concrete mixing/dispensing drum is disclosed. The system includes a truck-mounted fluid reservoir for containing a quantity of fluid connected to supply fluid to an air-operated diaphragm pump connected to supply auxiliary fluid from the fluid reservoir under pressure to a discharge assembly. The pump further provides an integral purge system for displacing fluid in the fluid supply system after use. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to cages and utility cargo racks for the beds of pickup trucks and trailers. The present invention is particularly directed towards a multipurpose, hinged framed cage and utility rack designed for a variety of uses including a loading ramp, a protective cage for animals and a theft resistant enclosure for articles left in the bed of the vehicle.
2. Description of the Prior Art
A variety of livestock cages and utility racks for pickup trucks have been in use for some time. One principal problem arising with the use of these devices is the absence of security locking features and their limited range of use. Although utility and cargo racks for trucks are useful for hauling long items such as lumber or ladders, and stock racks are useful for transporting livestock, they are generally limited to their specific uses. This is quite obvious from an examination of past art patents.
To examine pertinent past art patents, GAU 312 was considered, and a search was conducted in the following classes and subclasses: 119/82, 7, 8, 9, 10, 11, 12, 15, 17; 296/100, 10, 106, 120A; and 180/289. In relationship to our invention, the following patents were noted as being most pertinent: 2,043,858; 2,909,387; 3,428,359; 3,456,977; 3,923,334; 3,930,680; 3,989,148; 4,284,303; and 4,668,002.
U.S. Pat. No. 2,043,858 teaches a cover far a truck that covers all open areas including the top. The top is shown to pivot open in the FIG. 3 illustration.
U.S. Pat. No. 3,930,680 teaches a truck with mesh panels that enclose the back area of the truck.
U.S. Pat. No. 3,989,148 teaches mesh sides for a pickup in which one side panel can be used as a ramp.
The other patents are cited to show what is representative in the art.
Most of the cage-like covers shown for use on the bed of a pickup truck or a trailer were either too low profile for animal use or if large enough, required considerable superstructure or solid backing limiting usefulness of the caging and detracting from structural appearance.
When using a cage and utility covering for a pickup truck bed, the shaping of the support members and the cage frame is a primary factor if multiple use of the cage sections is to be adequately accomplished. For example, using a unreinforced side panel as a drive up ramp as shown in U.S. Pat. No. 3,989,148 provides a ramping member ok but on a very unsubstantial support. To load a small tractor would require additional supports. A machine of any useful size and power would bend the supports and would probably be large enough so it wouldn't fit in the cage area as illustrated.
Although U.S. Pat. No. 2,043,858 illustrates a side cage structure which pivots open horizontally, the invention does not use cage frame shape for any other utility, and the cage sides hang freely down and must be hooked to prevent swinging.
A complete cage frame for the back of a large truck is disclosed in U.S. Pat. No. 3,930,680. For security, a solidly retained frame of this nature is criterion for the purpose. For versatility, a light weight, easily mounted and unmounted cage structure is far better for use on a pickup truck bed.
All of the cages shown for pickup truck bed or trailer use either had short horizontal panels or had an unnecessary vertical brace half way along the panel. To prevent possibly head injury to any animals being transported inside our cage, we have avoided vertical supports except at the very ends of the cage structure. None of the devices illustrated in past art patents seen used any kind of cage shaping to provide a multiple of uses for the side and top panels nor were any structural provisions made for easy assembling and mounting or for disassembly for transporting or storage.
As will be shown further in the specification which follows, our invention not only overcomes major disadvantages seen in all patent disclosures of pertinent truck bed caging devices but utilizes the cage structure in new and unique ways.
SUMMARY OF THE INVENTION
In practicing our invention we have developed an easily assembled and easily installed cage for vehicles, primarily for use on the bed of a pickup truck. The unique shape of the side cage panels allows them to be pivoted upwardly as a raised top closure for the cage, turned over and swung downwardly as horizontally aligned extended side carriage or work racks, and swung inside the truck bed as a raised second deck. A roof panel, specially framed and reinforced, can be used as a top cage covering for carrying ladders and materials to a job site, can be fastened as a raised bed to the truck bed inside frame, can be used as a rear extension to the truck bed with one end supported on a pedestal, or can be used as a loading ramp at the rear of the pickup of sufficient length to provide an easy-up incline. The roof panel is of sufficient strength to support considerable weight.
The half octagonal shape of the front and rear framing members produces a pleasing appearance in the cage structure. This frame shape is the primary unique factor of the invention. The particular shaping of the cage structure and the pin hinging allows pivotal panels to be interchanged, reversed, turned over, and used for a variety of purposes. The shape design also works well for the top hinging of a similarly configured back panel and for security fitting of extended material on the lower leading edge of a like front panel. Both side panels and the back panel are removably hinged to the frame, the side panels by self-locking removable pins. The back panel is hingedly attached upwardly by strap and tubular hinging to a horizontally aligned section of supporting frame members. The supporting frame members are sectional for easily dismantling, fit directly or have adjustable auxiliary structure to align with stake apertures in the horizontal truck bed shoulder of various pickup truck beds into which the lower ends or the auxiliary pins are inserted.
The side panels of our cage can be turned and pivoted upwardly to form a somewhat peaked roof frame. Over the roof frame and cage support members, a waterproof covering can be attached to provide a weather resistant shelter for the pickup truck bed.
Therefore, a principal object of our invention is to provide a utility cage with carrier provisions for use on the bed of a pickup truck.
Another object of the invention is to provide a cage suitable to accommodate one or a few untethered animals protected in the bed of a pickup truck.
A further object of the present invention is to provide a security and work covering for the bed of a pickup truck which is cage-like having pivotal and removable side and top panels with the panels being capable of being repositioned for a variety of uses.
Other objects and the many unique advantages of the invention will become obvious from a reading of the specification and considering numbered parts therein in the light of similarly numbered parts shown on the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an exploded view of the invention showing the front or cab frame member at A, the left or driver side panel at B, the rear left side support frame at C, the tale gate panel and upper hinge frame at D, the rear right side support frame at E, the right or passenger side panel at F, and a support rod for horizontal alignment of side panels at G.
FIG. 2 is a rear view of a pickup truck with the utility cage assembled and installed on the bed frame and illustrates the side panels angled out in opened positions and the tailgate panel fastened down.
FIG. 3 shows the rear of the pickup truck, the cage installed, the tailgate opened upwardly, and the side panels repositioned to open outwardly supported by a support rod as work or load shelves.
FIG. 4 shows cage in the pickup truck bed with the tailgate opened and the rear cage panel in the tailgate position. The side panels are shown in an inverted, top-attached positionforming a raised carrier bed well above the pickup truck bed.
FIG. 5 is a sectional perspective view of the right rear corner of the closed cage on the pickup bed illustrating padlocking the looped ends of the attachment pin structure for securely locking the cage.
FIG. 6 shows the pickup truck with the cage installed on the bed in a side view illustrating the top hinged rear panel opened and supported by the support rod.
FIG. 7 shows the top cage panel on the cage frame in a perspective view illustrating the reinforced structure and positioning of the top cage panel in relationship to the right side panel. One truck wall insert fitting is shown detached and aligned for attachment to the rear cage frame member.
FIG. 8 illustrates the top reinforced cage panel at the rear of the pickup truck bed positioned for use as loading ramp.
FIG. 9 shows the cage on the truck bed with side panels hinged at the shorter ends and positioned upwards to form an enclosure supporting a waterproof covering.
FIG. 10 is a side view of the truck and upwardly positioned side panels shown from the rear in FIG. 9.
FIG. 11 is a rear portion side view of the pickup truck illustrating the tailgate horizontally positioned and the top reinforced cage panel supported at the end by a special pedestal used table-like as a horizontal extension of the tailgate.
FIG. 12 is a perspective view of the pickup truck bed, the cage support frame installed with the side panels removed, and showing the top reinforced cage panel attached to the front and rear cage frame in use as a raised platform.
FIG. 13 shows the back of the pickup truck cab and the front cage panel attached to the cage frame with enlargements illustrating S-type bed frame support fittings and frame attachment fittings.
FIG. 14 illustrates a locking hinge pin in a side view at A and in an end view at B.
FIG. 15 shows a rear view of a wide bodied pickup truck wit the cage frame installed showing reverse positioning of the side cage panels to form concave equipment compartments and the cage fame attached to the wider bed walls by offset insert pins.
FIG. 16 shows the cage frame attached to a narrow pickup truck bed wall illustrating attachment of the cage frame to the narrow truck bed wall by reversing the offset insert pins.
DRAWING REFERENCE NUMERALS
10 cab end front cage panel
12 tailgate end rear cage panel
14 driver left side cage panel
16 passenger right side cage panel
18 front cage panel framing
20 rear cage panel framing
22 side cage panel framing
24 expanded metal caging material
26 right rear cage support member
28 left rear cage support member
30 angle-forming horizontal side panel brace
32 angled side panel pivotal hangers
34 rear cage panel hinge bar
36 female attachment ends
38 male attachments ends
40 pickup truck
42 pickup truck bed
44 truck side walls
46 truck tailgate
48 strap and tube hinge fittings
50 attachment tabs
52 locking hinge pin apertures
54 locking hinge pin
56 S-type hangers
58 side wall inserts
60 offset side wall inserts
62 support rod
64 pedestal
66 security front panel extension
68 waterproof covering
70 directional arrows
72 padlock
74 reinforced top cage panel
76 top panel frame
78 top panel longitudinal support members
80 top panel handle openings
82 cover attachments
84 frame attachment clip
86 illustrative ladder
88 ring
90 spring biased ball bearings
92 wide bed pickup truck
94 narrow bed pickup truck
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings at FIG. 1. The disassembled parts of the invention are shown placed for assembly and are described as positioned in the drawings. A first end cage panel member designated cab end front cage panel 10, illustrated at FIG. 1 A, is a half octagonal shaped member formed of front cage panel framing 18 and covered by expanded metal caging material 24. Expanded metal cage material 24, is angled outward below the lower horizontal section of front cage panel framing 18 and forms security front panel extension 66. Towards the corners on the upper horizontal section of front cage panel framing 18, locking hinge pin apertures 52 are opened and side wall inserts 58 are attached downwardly to extending ends at the lower corners of front cage panel framing 18. FIG. 1 B shows driver left side cage panel 14 which is formed as a single panel of expanded metal caging material 24 affixed to side cage panel framing 22. Both vertical ends of side cage panel framing 22 extend upwardly above the top horizontal frame and are formed into angled side panel pivotal hangers 32. Locking hinge pin apertures 52 pass through the ends of angled side panel pivotal hangers 32 positioned for pin-hinging by locking hinge pin 54 inserted and attached through locking hinge pin apertures 52 in front cage panel framing 18. It is noted that locking hinge pin 54 has a ring attached through an aperture at one end, see FIG. 14, to prevent pull-through and snap-in ball bearing stops towards both ends to retain the pin in locking hinge pin apertures 52 and acts as a pin hinge allowing pivotal movement of the attached members. Angle-forming horizontal side panel brace 30 is affixed in driver left side cage panel 14 approximately a third of the way upwardly from the lower horizontal member of side cage panel framing 22 shaping driver left side panel 14 to conform with the frame shape of cab end front cage panel 10.
Passenger right side cage panel 16 is shown in FIG. 1 at F and is essentially a reversed version of driver left side cage panel 14. The same framing and frame designation numbers, attachment features and feature designation numbers, and bracing and bracing designation numbers are used in both passenger right side cage panel 16 and driver left side cage panel 14 as the two sides turned end for end are actually interchangeable.
At C in FIG. 1, left rear cage support member 28 is illustrated. Along with right rear cage support member 26, shown at F in FIG. 1, when both are upwardly attached to rear cage panel hinge bar 34, FIG. 1 D, these two members support the full cage structure adjacent the tailgate end of a pickup. Both rear cage support members, 26 and 28, are fitted downwardly to side wall inserts 58 retained by locking hinge pins 54 through locking hinge pin apertures 52. In FIG. 1 at G, support rod 62 is illustrated. Support rod 62 has reversed right angled tip ends and is useful for holding opened panels of the cage in fixed positions, see FIG. 3 and FIG. 6.
A second end cage panel member is designated tailgate end rear cage panel 12 and is shown in FIG. 1 at D. Attached by strap and tube hinge fittings 48 to rear cage panel hinge bar 34, tailgate end rear cage panel 12 is shaped to conform with cab end front cage panel 10 and the angled structural shape produced when rear cage support members 26 and 28 are attached to rear cage panel hinge bar 34. Both ends of rear cage panel hinge bar 34 are shaped into female attachment ends 36. The upper ends of both right rear cage support member 26 and left rear cage support member 28 are formed into male attachment ends 38. These male and female fittings attached by locking hinge pin 54 through apertures 52 connect rear cage panel hinge bar 34 to the rear cage support members 26 and 28. The pin hinging and angled shape of the entire cage structure is extremely important for utility functions of which this device is capable and are described further on in the specification.
FIG. 2 is a rear view of a pickup truck 40. Rear support members 26 nd 28 are attached upwardly to rear cage panel hinge bar 34 and are fastened to the top of truck side walls 44 by side wall inserts 58. Side wall inserts 58 fit into the standard stake apertures in the top of truck side walls 44. Side cage panels 14 and 16, in this assemblage, are pivotal and can be raised or lowered as indicated by directional arrows 70. Tailgate end rear cage panel 12 is hingedly attached along the upper horizontal section of rear cage panel framing 20 to to rear cage panel hinge bar 34 by strap and tube hinge fittings 48. This allows tailgate end rear cage panel 12 to be swung upward as shown in FIG. 3 or swung downward and locked by attachment tabs 50 as shown in FIG. 2. In FIG. 3, a downwardly fastening of side cage panels 14 and 16 is illustrated with the side cage panels useful for work surfaces, tool containers, or external cargo carriers. The FIG. 3 illustration shows passenger right side cage panel 16 retained in a horizontal position by support rod 62.
Another useful positioning of side cage panels 14 and 16 is shown in FIG. 4. Truck tailgate 46 is opened and tailgate end rear cage panel 12 is unfastened and placed in the tailgate position blocking entrance and exit to pickup truck bed 42. The side cage panels 14 and 16 are swung inward, fastened together, and formed into a raised cargo support area well above pickup truck bed 42 which is also useful for tools or cargo with the side cage panels in this position. Repositioning the cage panels for a variety of different uses is easily accomplished by simply removing locking hinge pins 54, repositioning angled side panel pivotal hangers 32 to line up various locking hinge pin apertures 52 and inserting locking hinge pins 54. In all illustrations, directional arrows 70 indicate direction of movement either way.
In FIG. 5, a partial right hand corner view of the truck side wall 44 with the utility cage of the invention installed illustrates a locking method. The shackle of padlock 72 is attached through the rings of the locking hinge pins 54 at the corner of the cage and locking padlock 72 secures the cage structure.
FIG. 6 is a side elevation of pickup truck 40 with the utility cage installed. The vertical sections of front cage panel framing 18 and side cage panel framing 22 are adjacently aligned. The side view shows a substantially rectangular driver left side cage panel 14 covered by expanded metal caging material 24. Inside along a lower section, angle-forming horizontal side panel brace 30 longitudinally supports the cage frame. The forward extension of expanded metal caging material 24 below front cage panel framing 18 forming security front panel extension 66 is shown by dotted lines in FIG. 6. The vertical rear section of side cage panel framing 22 is adjacent vertical left rear cage support member 28. The cage structure is fastened to rest atop of truck side walls 44. Tailgate end rear panel 12 is in the opened position retained by support rod 62.
Reinforced cage top panel 74 is shown in a prospective illustration on top the cage frame structure in FIG. 7. Reinforced cage top panel 74, a substantially rectangular configuration, is framed by top panel frame 76 and strengthened by top panel longitudinal support members 78. Attachment tabs 50 locked on by locking hinge pins 54 releasably hold reinforced cage top panel 74 positioned. Two centrally aligned openings one towards each ends in reinforced cage top panel 74 form top panel handle openings 80 used for lifting and repositioning reinforced cage top panel 74. As illustrated in FIG. 8, reinforced cage top panel 74 can be positioned for use as a ramp at the rear of pickup truck 40. Reinforced cage top panel 74 is sufficiently strong to support considerable weight on a low-angled upgrade and attachment tabs 50 with locking hinge pins 54 installed can be used to retain the ramp in position against pickup truck bed 42.
FIG. 9 reveals another unique application of the present invention. Side cage panels 14 and 16 unfastened, inverted, and refastened are angled and attached upwardly to form a roof-like support over which waterproof covering 68 can be fitted. Cover attachments 82 hold waterproof covering 68 in place. The side view of pickup truck 40 in FIG. 10 further illustrates the upward positioning of side cage panels 14 and 16.
In FIG. 11 and FIG. 12 additional useful applications of reinforced cage top panel 74 is disclosed. The partial view of pickup truck 40 in FIG. 11 shows truck tailgate 46 opened horizontally and reinforced cage top panel 74 affixed as a horizontally positioned work surface continuation supported at the end by pedestal 64. The perspective view of the bed area of pickup truck 40 in FIG. 12 illustrates use of the reinforced cage top panel 74 as a lengthwise railing-height decking over pickup truck bed 42 between truck side walls 44.
The back of the cab area of pickup truck 40 is illustration in part at FIG. 13 in a perspective view. Tailgate end rear cage panel 12 is shown attached to cab end front cage panel 10 for disassembled transporting. Tailgate end rear cage panel 12 is retained by two types of fittings designated S-type hangers 56 and frame attachment clips 84. The S-type hangers 56 hook through the expanded metal caging material 24 on both panels to hold them together. The frame attachment clips 84 snap over the frames 18 and 20 to secure the frames. Enlargements of both the S-type hangers 56 and the frame attachment clips 84 are shown in the drawings at FIG. 13.
The locking hinge pin 54, used exclusively for locking cage members together and for the pivotal hinging of the cage panels, is illustrated at FIG. 14. A ring 88 affixed through an aperture at one end of pin 54 is used as a locking means and as a stop preventing locking hinge pin 54 from being pulled on through locking hinge pin apertures 52. Spring biased ball bearings 90 partly protruding through the wall surface one adjacent each end of locking hinge pin 54 prevent vibrational dispositioning of locking hinge pin 54 when it is installed in locking hinge pin apertures 52.
FIG. 15 is illustrative of the utility cage installed on a wide pickup truck 92. Offset side wall inserts 60 are turned extended part outward to fit the stake apertures in truck side walls 44 and effect attachment of a standards sized utility cage. Side cage panels 14 and 16 have been detached, turned around, and reattached to produce yet another function of the present invention. With side cage panels 14 and 16 installed as illustrated in FIG. 15, a concave cargo or equipment are is produced paralleling truck side walls 44. As shown, illustrative ladder 86 can be carried in the concave cargo space. FIG. 16 is illustrative of the utility cage assemblage installed on a narrow bed pickup truck 94. Offset side wall inserts 60 have been turned with the extensions inward to fit a standard sized cage to stake apertures in the narrower truck side walls 44.
The utility cage for vehicles constituting the present invention is easy to assemble and install. Actually the cage can be assembled during installation. Cab end front cage panel 10 is attached adjacent the cab of pickup truck 40 (FIG. 6) by inserting side wall inserts 58 into the front stake apertures in truck side walls 44. The cage structure goes together as indicated in FIG. 1 by directional arrows 70. The upper ends of rear cage support members 26 and 28 are inserted into the tubular ends of cage panel hinge bar 34 with tailgate rear cage panel hingedly attached by strap and tube hinge fittings 48. The assembled rear structure is mounted on truck side walls 44 by side wall inserts 58 in stake apertures in truck side walls 44 adjacent truck tailgate 46. Driver left side cage panel 14 is attached by locking hinge pin 54 through locking hinge pin apertures 52 upwardly at the rear to left rear cage support member 28 and again at the front upwardly to front cage panel framing 18 similarly. Passenger right side cage panel 16 oppositely similarly attached. The utility cage for vehicles of the present invention is assembled, installed on the pickup truck, an ready for use. Animals or cargo can be carried safely inside the cage and locking is effected as previously described.
For top closure and additional security, reinforced cage top panel 74 can be installed and locked in the opened space at the top of the cage between side cage panels 14 and 16. Cargo or tools can be carried on top of the cage structure with reinforced cage top panel 74 installed. Top panel 74 is also useful as an internal raised decking and as a loading ramp as described.
Although we have supplied considerable details of our invention in the specification, it is to be understood that in practice we may modify the design and change the structure somewhat so long as changes made do not depart from the intent of the scope of the appended claims. | A utility cage for vehicles is particularly shaped half octagon upwardly from a wide horizontal base. The cage is primarily designed for use on the bed of a pickup truck and has adjustable attachment fittings compatible with stake apertures in the pickup truck bed side walls. The cage has tubular frame support members and tubular framed panels fully covered on one side by expanded metal material. Conformingly shaped side panels removably pivotally attached to a frontal end panel and rear support members can be exchanged, reversed, and turned over for placement into a variety of use positions. A rear panel is upwardly hinged to the rear support members for opening, closing or removal. A reinforced removable top panel can be used as a secondary bed in a pickup truck, as a loading ramp, or as a table-like extension the pickup truck tailgate. The side panels can be turned upwardly and a covering placed over the caged area. | 1 |
This invention relates to an automated system for locking an aircraft lavatory door from a remote location to reserve it for crew use.
BACKGROUND
In some large commercial passenger aircraft, a lavatory is provided solely for crew use so they do not have to wait in line. However, this lavatory takes floor space which could be used for seats for paying passengers. Therefore, means have been sought for eliminating the crew lavatory without inconveniencing either crew or passengers.
One viable solution is for the crew to selectively lock one of the passengers' lavatory doors from the cockpit or a flight attendants' station and allow access to it by key entry only. Passengers could then use one of the other lavatories with little or no inconvenience and the crew could use the locked lavatory without waiting. However, a suitable locking system must prevent a passenger's being inadvertently locked in the lavatory without invading his privacy.
A number of automatic locking systems were considered, but none was deemed acceptable. For example, a broken light beam detector was not reliable because people might avoid breaking the beam and cabin pressurization cycles could mislocate the beam with respect to the receiver. Pressure pads in the lavatory floor are unreliable for lightweight passengers. Not all passengers lock the door when they enter a lavatory, so sensing a locked door only could possibly trap someone inside.
This invention solves the problem by an externally activated door locking system incorporating a heat and motion sensor and an electronic logic circuit controlling a secondary door lock.
BRIEF SUMMARY
In accordance with a preferred embodiment, a lavatory door locking system is provided which is actuated by a crew member from the cockpit or elsewhere in the aircraft. Once activated, a specially adapted electrical circuit uses a heat and/or motion sensor located in the lavatory to determine whether it is in use. If it is not in use and the door is closed, a secondary door lock is activated bolting the door shut and the occupied sign is lit. Until the automatic system is turned off by the crew, a key or other means is required to unlock the door. If a person is in the lavatory when the automatic system is turned on, the system recycles every few seconds until the presence of the person is no longer sensed and the door has been shut. Only then is the door bolted shut at the secondary lock.
FIGURES
The invention will be better understood in terms of the several figures in which:
FIG. l is a front view of an aircraft lavatory having bifold doors and a locking system in accordance with the invention.
FIG. 2 is a side sectional view of the lavatory of FIG. 1.
FIG. 3 is a plan view, partly in section, of the lavatory of FIG. 1 showing the bifold door open and the heat and motion sensor in the ceiling.
FIG. 4 is a front view of a locking mechanism at the top of a lavatory bifold door in accordance with the invention showing the bolt extended (locked) into the door top channel.
FIG. 5 is a sectional side view of the locking mechanism of FIG. 4 showing a door contact reed switch which senses the position of the door.
FIG. 6 is a side sectional view of the locking mechanism of FIG. 4.
FIG. 7 is like FIG. 6 with the bolt in the retracted (unlocked) position.
FIG. 8 is a schematic diagram of the control circuitry for a preferred embodiment of the subject door locking system.
DETAILED DESCRIPTION
Our invention will be better understood in view of the following detailed description of a preferred embodiment thereof. FIG. 1 is a front view of an airline lavatory module 2. Preferably, this lavatory is the one closest to the cockpit. Lavatory 2 comprises a fixed front wall 4 with a bifold door 6 which can be locked from the inside by sliding bolt 8 in the handle plate 7 into a strike 10 in fixed wall 4 when the door is closed. This also lights the lavatory occupied sign (not shown). Pins 12 and 14 on either side of the top of bifold door 6 travel in track 16 located near the top of lavatory 2. Locking mechanism 18 of this invention is located above bifold door 6, although its location could be moved to the side, bottom or elsewhere on the door edge if desired.
FIG. 2 is a side sectional view of the interior of lavatory 2 showing back wall 20, commode 22 and sink 24. Ceiling 26 of lavatory 2 slopes downward from front wall 4 of the unit towards back wall 20. Heat and motion sensor 28 is mounted in ceiling 26. Sensor 28 is positioned in the top of unit 2 so that the area within its generally cone-shaped range will encompass anyone within the lavatory. A sensor which detects both heat and motion is preferred so the system will not be operative when only heat or only motion is sensed. Some heat and motion sensors can be fooled when a person remains perfectly still for several seconds. However, the subject system is such that the automatic door lock will be unlocked when motion is again sensed. FIG. 3 shows heat and motion sensor 28 in a cutaway plan view of lavatory 2 as it is mounted in ceiling 26.
FIG. 4 is a more detailed view of a locking mechanism 18 in accordance with the invention. The locking mechanism is secured to face plate 30. Bolts 32 fasten plate 30 to the bulkhead of the airplane (not shown) directly above bifold door 6. As seen in the cutaway section of door track or channel 16, door 6 is locked by the extension of bolt 34 and lock plate 36 into strike plate 38 attached to the top of bifold door 6. Door 6 is locked by energizing door lock solenoid 40 so that spring 42 is compressed and bolt 34 moves downward. Manual solenoid lock override slide 44 is attached to solenoid 40 so that bolt 34 can be manually pulled upwards and out of door channel 16, if desired. Door contact switch 46 and key override switch 48 are located next to solenoid 40. Door contact switch 46 senses whether door 6 is closed. Key override switch 48 deenergizes solenoid 40 when key 50 is turned in barrel 52, withdrawing lock plate 36 from strike plate 38. Face plate 30 and its attached elements are above door 6 and out of the line of sight of a passenger so their presence is not apparent.
FIG. 5 shows a sectional side view of FIG. 4 between door contact switch 46 and key override switch 48. In particular, reed 54 of door contact switch 46 is shown in the door closed position. Switch 46 is shown as it would be in the open position in broken lines.
Door pins 12 and 14 slide in channel 16 created by flange 56 adjacent door channel molding 58. The front of flange 56 serves both decorative and functional purposes. It conceals the top of bifold door 6 and is biased against fixed front piece 60 above door 6. Front piece 60 wedges rear mounting plate 62 for switches 46 and 48 between itself and flange 56. Backing plate 64 behind face plate 30 has a top section 66 which overhangs the airplane's cabin ceiling 68. Lock barrel 52 is mounted through face plate 30 and backing plate 64.
FIGS. 6 and 7 are sectional side views of the locking mechanism showing particularly solenoid 40 and bolt lock plate 36 in the door locked--system engaged, and door unlocked--system unengaged, positions respectively. In the door locked position, energized solenoid 40 compresses spring 70 which lowers bolt 34. Accordingly, the system fail mode where no voltage is applied to solenoid 40 leaves the system in the unlocked position as seen particularly in FIG. 7. This is preferred for safety reasons. Solenoid 40 is mounted through lower extension 72 of backing plate 64 and secured in place by nut 74 screwed on to the solenoid locating threads 76. Slide plate pin release button 78 extends through face plate 30, reinforcing plate 80 and backing plate 64 for quick release of entire locking mechanism 18. Strike plate 38 is mounted on top of bifold door 6 where bolt lock plate 36 extends through door channel 16. Lock plate 36 itself is fastened to the bolt by locating flange 82.
The operation of the subject system is controlled by a circuit shown diagrammatically in FIG. 8. The system is primarily powered by 28 volt DC aircraft power source 84. The voltage is dropped across resistor 86 to the passive infra-red sensor circuit 88. The sensor has a secondary battery power supply 90 which is recharged continually so long as the airplane power is available. Infra-red sensor 88 drives a relay 92 which opens a switch 94 when it senses the presence of a person by detecting heat and/or motion, and closes it when there is no heat or motion sensed. The cycle time of the circuit is about two seconds which is determined by the time delay relay 96.
When the sensor switch is closed 98, it provides power to the switching relay which opens switch 94. Opening switch 94 provides power to lavatory occupied signal relay 100 which in turn powers the door locked solenoid time delay relay 96 when the door contact switch 102 indicates the door is closed. Closing the lavatory occupied signal relay causes the door locks solenoid 104 to be powered if the system switch 106 has been turned on by the crew, key override switch 108 is closed and inline timer 110 has cycled. Inline timer 110 delays the door lock solenoid 104 long enough to allow the bifold door to stop vibrating, making sure that the lock plate extends through the slot in the door channel and latch plate.
Once the system has been electronically activated, it continues to function until system switch 106 is turned from the on to the off position. The crew can use the door by inserting a key in the barrel of the lock which overrides the door lock switch 108, deactivates the door lock solenoid 104, and allows entry. The lavatory occupied sign remains on so long as the system is activated.
While this preferred embodiment of the invention has been described in terms using a key and lock entry, any other suitable locking means may be used. For example, a number pad coded lock or other combination lock could be employed.
While our invention has been described in terms of specific embodiments thereof, other forms could be readily adapted by one skilled in the art. For example, like locking means and circuitry could be used in any situation where it is desired to lock a door from a remote location without inadvertently trapping someone inside. Therefore, the scope of the invention is to be limited only in accordance with the following claims. | A system for automatically locking a lavatory door on an aircraft from a remote location comprises means for activating the system, means for sensing the presence of a person in the lavatory, means for locking the lavatory when it is unoccupied and means for selectively overriding the system to allow entry by authorized personnel. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional application of U.S. patent application Ser. No. 11/833,434, filed on Aug. 3, 2007, which was a continuation of International Application No. PCT/EP2005/005969, filed Jun. 3, 2005, and which designates the U.S. The disclosures of the referenced applications are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The invention relates to a method for manufacturing a crimped compound thread, and an apparatus for carrying out said method.
BACKGROUND OF THE INVENTION
[0003] In a method of manufacturing a crimped compound thread in a single-stage process, first a plurality of synthetic individual threads are produced by extruding a plurality of filament strands, cooling these, and drawing (stretching) them. The individual threads have different characteristics, in particular they may have different colors, so that the coloration of the compound thread depends on the combination of the individual threads. For different applications, the requirements for the appearance (particularly coloration) of the compound thread will differ. It may be particularly desirable to have a compound thread appearance wherein the separate threads do not dominate, but wherein there is not complete mixture of the threads. The dominance of a given color component in the compound thread, if too long (comprising a long segment of the compound thread in which one color dominates), may lead to so-called “flames”. However, often such “flames” are in fact desirable.
[0004] EP 0485871 A1 discloses a method and apparatus for manufacturing a multicolored compound thread, which method and apparatus have proven to be particularly useful for producing so-called “tricolor threads” for use in carpets. Here a compound thread is produced from multifilament individual threads by common crimping. To achieve such crimping, the individual threads are introduced together into a crimping chamber with the aid of an advancing nozzle. In the crimping chamber, the filaments of the individual threads are laid down into bends and loops, wherewith a common thread plug is formed. Along with the crimping, a certain intermingling of the filaments of the individual threads occurs.
[0005] To promote a certain color separation in the compound thread, each of the individual threads is separately subjected to whirl-tangling prior to the crimping, so that the interlacing of filaments in a given thread provides thread cohesion of the component thread. In this way, the intermingling of the individual threads in the compound thread can be improved with regard to color separation. In practice it is desirable to have the color characteristics of the compound thread controllable such that it is possible to manufacture a compound thread with a mixed color wherein the individual threads are intensively intermingled, or to manufacture a compound thread with strong color separation properties wherein the individual threads are not intensively intermingled.
[0006] EP 0874072 A1 discloses a method and apparatus wherein the individual threads are separately subjected to whirl-tangling and are separately crimped, prior to combining them to form the compound thread. A basic drawback of this method is that the separation in the compound thread is too pronounced, which is undesirable if one seeks to avoid the appearance of so-called “flames” in a carpet. A further drawback is that the individual threads must be separately crimped, substantially increasing equipment costs, and complicating the process (rendering it more subject to problems) in the case of a multi-thread apparatus.
[0007] DE 4202896 A1 discloses another method and apparatus, wherein the individual threads are given a “false twist” before being fed into the crimping device. This creates a risk that certain individual threads will be too dominant in the compound thread, and further that the crimping (texturizing) effect in the individual threads will be hindered.
[0008] An underlying problem of the present invention was to devise a refined method and apparatus of the type described initially supra, which enable maximum flexibility to attain particular color effects in the compound thread, in the range from mixed colors to highly separated colors.
[0009] A second underlying problem was to enable reproducible adjustability of the color appearance of the compound thread.
SUMMARY OF THE INVENTION
[0010] These problems are solved according to the invention by a method described herein, and an apparatus described herein.
[0011] Advantageous refinements of the invention are set forth in the features and combinations of features of the various embodiments described herein.
[0012] The invention is based on the concept that one can achieve very wide-ranging effects with the appropriate application of whirl-tangling of multifilament threads. E.g., by whirl-tangling a multifilament thread one can achieve intermingling or snarling of the filaments of the thread. This determines the intensity of the thread cohesion, depending on the stage of treatment of the thread. According to the invention, at least one of the multifilament threads is subjected to multiple whirl-tanglings. In particular, at least one of the multifilament individual threads is subjected to whirl-tangling a plurality of times, in a plurality of pre-treatment stages, to provide a desired filament cohesion, prior to the crimping of the individual threads. Another advantage of the invention is that the common texturizing of the individual threads can be retained in the compound thread. The multiple whirl-tangling of the individual threads enables the coloration of the compound thread to be varied within wide limits not attainable by other methods. Thus, if one seeks a high degree of color separation one will subject each of the individual threads to whirl-tangling in a number of pre-treatment stages. If one seeks the appearance of mixed coloration in the compound thread, one will preferably subject only one of the multifilament individual threads to whirl-tangling (in a plurality of pre-treatment stages).
[0013] The variant method according to which each of the multifilament individual threads is separately subjected to whirl-tangling in a first pre-treatment stage prior to drawing is distinguished in that the individual threads can be passed through the drawing device very smoothly, and disposed very close together. In this connection, the whirl-tangling of the individual threads in the first pretreatment stage can be adjusted to achieve an optimum degree of filament cohesion for the drawing of the individual threads.
[0014] In order to achieve special effects in the nature of mixing or separation of colors in the compound thread, according to a preferred variant of the method at least one of the individual threads is, or all of said threads are, subjected separately to whirl-tangling in a second pre-treatment stage following the stretching. In this way, the filament cohesion brought about via the whirl-tangling of the individual threads can be adjusted specifically for the subsequent common crimping of the individual threads.
[0015] The adjustability and range of variability of the coloration of may be improved if, in at least one of the pre-treatment stages, whirl-tangling is carried out on the individual threads, wherewith the set-point values of the compressed air in the compressed air feed are at respective different values for the different threads. In this way, one can provide different degrees of whirl-tangling in different parallel advanced individual threads. E.g. if it is desired to produce a compound thread wherein in addition to a dominant individual thread a second component is present which contributes a mixing color, the individual thread having the color-determining contribution may be subjected to whirl-tangling with a relatively high set-point value of the compressed air. It turns out that this value is proportional to the points of intermingling (“intermingling knots”) in the thread.
[0016] It is also possible to carry out whirl-tangling of the individual threads in the pre-treatment stages wherewith the set-point values of the compressed air in the compressed air feed are at respective different values for different such stages. Thus, e.g. for the drawing process the thread should have a relatively low filament cohesion, in order not to inhibit the stretching of the individual filaments. In contrast, for the common crimping of the individual threads it is desirable for the whirl-tangling to be adjusted for the desired color characteristics.
[0017] Also, it is possible to carry out whirl-tangling with pulsation of the pressure, e.g. in the second pre-treatment stage, in order to vary the mixing of the colors. This also enables the creation of special yarn effects for manufacture of “fancy yarns”.
[0018] In order to intensify the whirl-tangling treatment prior to the crimping of the individual threads, it has been found advantageous to employ a variant method according to which the multifilament individual threads are subjected to whirl-tangling with the aid of heated compressed air. Alternatively, the individual threads may be heated prior to the whirl-tangling. This has been found to exert influence on the intermingling of the filaments in the individual threads, and on the crimping of the compound thread.
[0019] In order to provide appreciable tension in the threads at the point of the crimping of the individual threads, independently of the tension in the threads in the course of the preceding stage(s) of whirl-tangling, according to a variant method it is advantageous if, prior to the crimping, the individual threads are passed multiple times around a galette unit, and are subjected to whirl-tangling in a thread segment of the resulting loops in said galette unit, prior to leaving the galette unit.
[0020] If one employs heated galettes, one may advantageously accomplish temperature-controlled simultaneous whirl-tangling of the individual threads.
[0021] In order to achieve the thread cohesion necessary for final processing of the compound thread, the compound thread is subjected to tangling after the crimping of the individual threads and prior to the winding onto a bobbin, wherewith the coloration of the compound thread which has been imparted in the pre-treatment stages and via the crimping of the individual threads is substantially preserved.
[0022] The inventive method is particularly well suited to the manufacture of a compound thread comprised of a plurality of component threads each of which preferably is different. However, the scope of the invention is not limited to situations with component threads having different characteristics, in light of the fact that, in particular, individual pre-treatment of identical individual threads can advantageously be employed to produce a compound thread. E.g., the individual threads may be given specific structural properties in the course of pre-treatment by whirl-tangling in two different stages.
[0023] In another advantageous variant of the inventive method, the individual threads undergo separate whirl-tangling in a first stage of pre-treatment and then all of them undergo a common whirl-tangling in a second stage of pre-treatment. The multi-stage whirl-tangling prior to the texturizing according to the invention provides a very high degree of flexibility in the pre-treatment of the individual threads prior to said texturizing. Thus it is also possible to subject the individual threads to a common whirl-tangling in the first pre-treatment stage and to separate whirl-tangling in the second pre-treatment stage.
[0024] Further, the scope of the inventive method is not limited to situations with common crimping of the individual threads. It is basically also possible to separately texturize each of the individual threads, prior to combining them. In another possible method, texturizing of the individual threads (commonly or separately) and combining of the individual threads to form a compound thread are carried out, following which, after cooling, the compound thread is separated again into component threads, and then said threads are subjected to common whirl-tangling prior to winding as the final compound thread. Such a variant method may be employed with individual threads of different colorations, in order to achieve additional coloration effects.
[0025] The apparatus for carrying out the inventive method is comprised of a whirl-tangling device comprised of a plurality of whirl-tangling units which are disposed in succession in the path of advance of the individual threads.
[0026] In order to be able to carry out processing steps on the individual threads between the individual whirl-tangling steps, advantageously a first whirl-tangling unit is disposed upstream of the drawing device, wherewith said first whirl-tangling unit has a respective whirl-tangling nozzle for each of the individual threads.
[0027] Advantageously a second whirl-tangling unit having a plurality of whirl-tangling nozzles is disposed between the drawing device and the crimping device.
[0028] In order to be able to carry out the whirl-tangling of the individual threads in the individual pre-treatment stages with different set-point values of the compressed air pressure, each of the whirl-tangling nozzles has a controllable compressed air supply. In this connection, a plurality of whirl-tangling nozzles may simultaneously have a common compressed air supply, or one or more whirl-tangling nozzles may have separate compressed air supplies.
[0029] In order to obtain special effects which previously were obtained by thermal whirl-tangling, the inventive apparatus may be expanded to comprise heating means associated with at least one of the whirl-tangling units, whereby certain compressed air is heated.
[0030] Alternatively, a heating device may be provided upstream of the whirl-tangling unit, for heating the individual threads.
[0031] To achieve independent adjustment of thread tension in the whirl-tangling of the individual threads and in the crimping process, preferably in the inventive apparatus the drawing device is comprised of a galette unit disposed upstream of the crimping device, wherewith the individual threads are guided over said galette unit in multiple loops; and the whirl-tangling nozzles of a second whirl-tangling unit are arranged such that the individual threads can be subjected to whirl-tangling prior to leaving the galette unit.
[0032] If the whirl-tangling nozzles of the second whirl-tangling unit are disposed in a segment looped around galettes, which segment is between two galettes, namely in the last loop, the tension of the thread(s) in the whirl-tangling process can be reduced to a desired value if the individual threads at the point of leaving the galette unit are passed over a reduced diameter step in the galette. Basically any of the segments between the two galettes is acceptable as a location for disposing the whirl-tangling nozzles for carrying out whirl-tangling in the second pre-treatment stage.
[0033] In order to achieve additional thermal effects in the whirl-tangling of the filaments, according to an advantageous refinement of the invention the galette unit is comprised of at least two driven galettes, wherewith at least one of the galettes is configured so as to be heatable.
[0034] For final establishment of the thread cohesion in the compound thread, a tangling device is disposed between the crimping device and a winding device which is provided for winding the compound thread onto a bobbin or the like.
[0035] To provide intensive and uniform crimping of the individual threads, a variant apparatus been found to be particularly advantageous in which the crimping device comprises an advancing nozzle and an associated crimping chamber, wherewith the individual threads are advanced as a group into the crimping chamber by means of the advancing nozzle, wherewith a thread plug is formed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The inventive method will be described in more detail hereinbelow with the aid of an exemplary embodiment of the inventive apparatus, with reference to the accompanying drawings.
[0037] FIG. 1 is a schematic drawing of a first exemplary embodiment of the inventive apparatus for carrying out the inventive method;
[0038] FIG. 2 is a schematic drawing of a second exemplary embodiment of the inventive apparatus;
[0039] FIG. 3 is a schematic drawing of a variant of the exemplary embodiment of FIG. 1 ;
[0040] FIG. 4 is a schematic drawing of a variant of the exemplary embodiment of FIG. 2 ;
[0041] FIG. 5 is a schematic drawing of a variant of the exemplary embodiments of FIGS. 1 and 2 ; and
[0042] FIG. 6 is a schematic drawing of an exemplary embodiment of a separating thread guide.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0043] FIG. 1 shows schematically an exemplary embodiment of an inventive apparatus for carrying out the inventive method. The apparatus has a spinning device 1 which is connected to one or more melters (not shown). The spinning device has a heated spinning frame 2 which bears a plurality of spinnerets (“spinning nozzles”) ( 3 . 1 - 3 . 3 ) arrayed side by side. Each spinneret ( 3 . 1 - 3 . 3 ) has on its underside a plurality of orifices through which the polymer melt stream fed to said nozzle is extruded under pressure to form a respective individual filament. A cooling device 4 is disposed below the spinning device 1 ; the extruded filaments, which leave the spinning device at a temperature close to their melting temperature, are guided through the cooling device in order to cool said filaments. The cooling device 4 may comprise, e.g., a blower which blows cooling air essentially transversely against the filaments. After the filaments are cooled, the filament strands ( 13 . 1 - 13 . 3 ) associated with the respective spinnerets ( 3 . 1 - 3 . 3 ) are combined, at the exit of the cooling device 4 , to form respective individual threads ( 6 . 1 - 6 . 3 ).
[0044] At the outlet of the cooling device 4 , a “preparation device” 7 is provided, along with respective thread guides ( 5 . 1 - 5 . 3 ) for each of the individual threads ( 6 . 1 - 6 . 3 ).
[0045] To draw out the individual threads ( 6 . 1 - 6 . 3 ) from the spinnerets ( 3 . 1 - 3 . 3 ), a drawing device 10 is provided which comprises at least one galette device 18 (dashed lines) which is configured for drawing-out. The individual threads ( 6 . 1 - 6 . 3 ) are guided in parallel paths through the drawing device 10 . In this, the individual threads can be drawn in a common arrangement, or individual delivery devices may be employed (one for each thread).
[0046] After the drawing-out and stretching of the individual threads ( 6 . 1 - 6 . 3 ) by the drawing device 10 , the individual threads ( 6 . 1 - 6 . 3 ) are brought together in a crimping device 11 and combined to form a compound fiber 21 .
[0047] In this exemplary embodiment, the crimping device 11 is comprised of an advancing nozzle 15 and a crimping chamber 16 which cooperates with the nozzle 15 . The advancing nozzle 15 is connected to a pressure source (not shown) by means of which a conveying medium is fed to the advancing nozzle 15 . The conveying medium causes the individual threads ( 6 . 1 - 6 . 3 ) to be drawn into the advancing nozzle 15 and then advanced into the crimping chamber 16 where they are formed into a “fiber plug”. This involves a partial intermingling of the individual threads ( 6 . 1 - 6 . 3 ). The thread plug 22 , which preferably is farmed by means of a hot conveying medium, is then passed to a cooling drum 17 and cooled.
[0048] For pre-treatment of the individual threads ( 6 . 1 - 6 . 3 ), a first whirl-tangling unit 8 . 1 is provided between the preparation device 7 and the drawing device 10 ; and a second whirl-tangling unit 8 . 2 is provided between the drawing device 10 and the crimping device 11 . The first whirl-tangling unit 8 . 1 has a plurality of whirl-tangling nozzles ( 9 . 1 - 9 . 3 ), each associated with a respective individual thread ( 6 . 1 - 6 . 3 ). Each whirl-tangling nozzle ( 9 . 1 - 9 . 3 ) has a thread channel through which the individual thread is guided. A pressure channel opens out laterally into the thread channel, to introduce a high energy compressed fluid, preferably compressed air, into the thread channel. The pressure channels are connected to a pressure source via a compressed air supply line 12 . 1 and pressure adjusting means 14 . 1 . A control device 24 is provided, which is connected to the pressure adjusting means 14 . 1 , for setting the set-point for control of the compressed air.
[0049] The structure and configuration of the whirl-tangling nozzles ( 9 . 1 - 9 . 3 ) is generally known, and is described in, e.g., DE 10 2004 007073 A1.
[0050] The second whirl-tangling unit 8 . 2 associated with the crimping device 11 also has a plurality of whirl-tangling nozzles ( 9 . 4 - 9 . 6 ), having a structure and configuration essentially identical to the structure and configuration of the whirl-tangling nozzles ( 9 . 1 - 9 . 3 ) of the first whirl-tangling unit 8 . 1 . The whirl-tangling nozzles ( 9 . 4 - 9 . 6 ) are connected to a pressure source (not shown) via a compressed air supply line 12 . 2 and pressure adjusting means 14 . 2 . The pressure adjusting means 14 . 2 are connected to the control device 24 , for setting and varying the set-point for control of the compressed air. This allows the whirl-tangling units ( 8 . 1 , 8 . 2 ) to be operated mutually independently in carrying out whirl-tangling of the threads ( 6 . 1 - 6 . 3 ).
[0051] For post-treatment of the crimped compound thread 21 produced from the individual threads ( 6 . 1 - 6 . 3 ), the crimping device 11 has disposed downstream of it a “tangling device” 19 , inside which the compound thread 21 receives a final treatment required for the further processing.
[0052] Following this “tangling”, the compound thread 21 is taken up on a winding device 20 wherewith it is wound on a bobbin or the like 23 .
[0053] In the process, the winding device 20 serves simultaneously as a drawing organ, to draw the crimped compound thread 21 from the thread plug 22 . In order to be able to adjust the tension in the compound thread 21 in the winding and in the “tangling”, said thread may be drawn from the thread plug 22 by means of a galette device; and a second galette unit may be provided downstream of the “tangling device” 19 , as the thread is passed to the winding device 20 . The configurations of the devices in the post-treatment zone do not bear upon the invention—any suitable processing means and treatment stages may be chosen for influencing the compound thread 21 prior to winding onto the bobbin 23 .
[0054] In the exemplary embodiment of the inventive apparatus illustrated in FIG. 1 , three bundles of filaments ( 13 . 1 - 13 . 3 ) disposed side by side are spun in the spinnerets ( 3 . 1 - 3 . 3 ); each of these bundles has a plurality of filament strands. The filament bundles ( 13 . 1 - 13 . 3 ) may have different properties; preferably the basic polymers of which they are comprised have different colors. Indeed, the basic polymers may have different compositions or may contain different amounts of additives.
[0055] Each of the filament bundles ( 13 . 1 - 13 . 3 ) is combined to form an individual thread ( 6 . 1 - 6 . 3 ). For this purpose, the filament bundles ( 13 . 1 - 13 . 3 ) are subjected to addition of preparation agents by means of the preparation device 7 , and are passed through the thread guides ( 5 . 1 - 5 . 3 ), from which the individual threads emerge.
[0056] For further treatment of the individual threads ( 6 . 1 - 6 . 3 ), in a first pre-treatment stage immediately following the “preparation” a first whirl-tangling is carried out, in whirl-tangling unit 8 . 1 . For this, each individual thread ( 6 . 1 - 6 . 3 ) is passed through a whirl-tangling nozzle ( 9 . 1 - 9 . 3 ). The whirl-tangling unit 8 . 1 has a pressure set-point value for the compressed air which is supplied, which leads to intermingling (interlacing) of the filaments of which the individual threads are comprised. In this process, one achieves uniformization of the preparation, as well as the minimum filament cohesion required for the subsequent drawing by the galette in the drawing device 10 . In the setting of the pressure set-point value, one should take care to avoid excessive snarling of the filaments of the individual threads.
[0057] After the individual threads ( 6 . 1 - 6 . 3 ) have been drawn out and stretched, a second whirl-tangling of said threads is carried out via the whirl-tangling unit 8 . 2 , in the second pre-treatment stage. In this unit 8 . 2 , the individual threads ( 6 . 1 - 6 . 3 ) are individually separately guided and whirled, by means of the whirl-tangling nozzles ( 9 . 4 - 9 . 6 ). In this process, the intermingling of the filaments in the individual threads ( 6 . 1 - 6 . 3 ) which is brought about is chosen such that a certain intermingling is achieved in the crimping of the individual threads ( 6 . 1 - 6 . 3 ) which are combined into the compound thread 21 . In particular, in producing a multicolored crimped compound thread the coloration of the compound thread 21 can be influenced within wide bounds. Thus, e.g., a compound thread with strong color separation can be produced by setting the set-point value of the pressure of the compressed air supply in the second whirl-tangling unit 8 . 2 relatively high. This causes intensive intermingling of the filaments of the individual threads, wherewith the subsequent crimping process will not be able to substantially undo this intermingling. If the set-point value of the pressure in the whirl-tangling unit 8 . 2 is set relatively low, the compound thread 21 will have an appreciably mixed coloration.
[0058] After the whirl-tangling in the second pre-treatment stage, the individual threads ( 6 . 1 - 6 . 3 ) are jointly crimped and are combined to form the compound thread 21 . In this process, the individual threads ( 6 . 1 - 6 . 3 ) are advanced through the advancing nozzle 15 by means of an advancing fluid, into an adjoining crimping chamber 16 . In the crimping chamber 16 , the filaments of the individual threads ( 6 . 1 - 6 . 3 ) are laid down into bends and loops in the course of formation of a thread plug 22 , which is subjected to thermal treatment and is then opened to yield the crimped compound thread 21 . To produce the final thread characteristics (thread cohesion, body, strength, etc.), the compound thread 21 undergoes “tangling” in the tangling device 19 prior to being wound on the bobbin 23 .
[0059] The inventive method and apparatus may be employed to produce, e.g., multicolored crimped compound threads which have high color uniformity. If necessary or desirable, particular visual characteristics can be imparted by adjusting the pre-treatment.
[0060] FIG. 2 illustrates a second exemplary embodiment of an inventive apparatus for carrying out the inventive method. This embodiment is substantially the same as the above-described embodiment; accordingly, reference is made here to the description of that embodiment, and the emphasis hereinbelow will be on describing the differences. Components with identical functions have been assigned like reference numerals.
[0061] In the exemplary embodiment according to FIG. 2 , the drawing device 10 may be comprised of, e.g., two galette units ( 18 , 27 ) for drawing out, each of which is comprised of two driven galettes or a driven galette with an “overflow roll”, wherewith the individual threads ( 6 . 1 - 6 . 3 ) are guided in parallel paths over the galettes. The galette units ( 18 , 27 ) are driven at different speeds, causing stretching of the threads ( 6 . 1 - 6 . 3 ).
[0062] In order to provide a second pre-treatment stage wherein the individual threads ( 6 . 1 - 6 . 3 ) are prepared for the crimping, a second whirl-tangling unit 8 . 2 is provided between the drawing device 10 and the crimping device 11 . The whirl-tangling unit 8 . 2 has a plurality of whirl-tangling nozzles ( 9 . 4 - 9 . 6 ), each of which is associated with a respective individual thread. These nozzles ( 9 . 4 - 9 . 6 ) are mutually independently controllable. Each of the whirl-tangling nozzles ( 9 . 4 - 9 . 6 ) has a respective compressed air feed ( 12 . 3 - 12 . 5 ) with respective pressure adjusting means ( 14 . 3 - 14 . 5 ), each of which pressure adjusting means is connected to the control device 24 , which enables providing a set-point value for the pressure for each of the whirl-tangling nozzles ( 9 . 4 - 9 . 6 ). It should be noted that the pressure adjusting means ( 14 . 3 - 14 . 5 ) are devised such that they can completely shut off the compressed air feed. This provides a high degree of flexibility in the pre-treatment of the individual threads ( 6 . 1 - 6 . 3 ) immediately upstream of the crimping stage.
[0063] Thus it is seen that the exemplary embodiment for carrying out the inventive method as illustrated in the FIG. 2 has somewhat higher flexibility to attain particular effects in a compound thread comprised of the differently whirl-tangled individual threads ( 6 . 1 - 6 . 3 ). Thus, e.g., is it possible to produce a multicolored compound thread the appearance of which results from a strongly separated pair or trio of colors, resulting from, e.g. the use of three differently colored individual threads ( 6 . 1 - 6 . 3 ) wherewith one of the threads is subjected to whirl-tangling in the second pre-treatment stage and the other threads do not receive any additional whirl-tangling in said second pre-treatment stage.
[0064] The exemplary embodiments of the inventive apparatus illustrated in FIGS. 1 and 3 can be varied by additional means, agents, and combinations, in order to, e.g., achieve special effects in the pre-treatment prior to the crimping of the individual threads. E.g., FIG. 3 shows a variant of the exemplary embodiment according to FIG. 1 ; in FIG. 3 only the drawing device 10 , whirl-tangling unit 8 . 2 , and crimping device 11 are illustrated (again, schematically). Since the components which are not illustrated are essentially identical to the corresponding components in FIG. 1 , reference is made to here the preceding descriptions, and only the differences will be described hereinbelow.
[0065] For each of the threads ( 6 . 1 - 6 . 3 ), the whirl-tangling unit 8 . 2 has a respective whirl-tangling nozzle ( 9 . 4 - 9 . 6 ), connected to a pressure source via the compressed air supply line 12 . 2 and pressure adjusting means 14 . 2 . The compressed air supply line 12 . 2 additionally has heating means 26 , for preheating the fluid introduced via the whirl-tangling nozzles ( 9 . 4 - 9 . 6 ). The heating means 26 and pressure adjusting means 14 . 2 are connected to a control device 24 .
[0066] In the exemplary embodiment illustrated in FIG. 3 the whirl-tangling of the individual threads ( 6 . 1 - 6 . 3 ) in the second pre-treating stage is accomplished with a heated fluid, which causes heating of the filaments of the individual threads. This heating influences the intermingling of the said individual filaments and leads to intensified crimping. This early intermingling substantially survives the subsequent processing.
[0067] FIG. 4 is a detail view of a variant embodiment of the inventive apparatus according to FIG. 2 . The structure and configuration of the process aggregate not shown is generally the same as in the preceding exemplary embodiment, and therefore does not require further description here. The drawing device 10 , whirl-tangling unit 8 . 2 , and crimping device 11 are included in the detail view shown in FIG. 4 . The drawing device 10 is comprised of a first galette unit 18 configured for drawing and a second galette unit 27 configured for drawing, each of which has two galettes ( 28 . 1 , 28 . 2 ) around which the individual threads ( 6 . 1 - 6 . 3 ) are passed multiple times. The galettes ( 28 . 1 , 28 . 2 ) of the galette unit 27 are heated, so that the individual threads ( 6 . 1 - 6 . 3 ) on the periphery of the galettes ( 28 . 1 , 28 . 2 ) undergo heating. The whirl-tangling unit 8 . 2 is disposed between the heated galettes ( 28 . 1 , 28 . 2 ). This whirl-tangling unit 8 . 2 is identical to that of the exemplary embodiment illustrated in FIG. 2 ; each individual thread ( 6 . 1 - 6 . 3 ) is acted on by (“has associated with it”) a respective whirl-tangling nozzle. The whirl-tangling unit 8 . 2 here is disposed in a segment of the threads between the galettes 28 . 1 and 28 . 2 . E.g., the whirl-tangling unit 8 . 2 may be disposed in the last such segment of the individual threads ( 6 . 1 - 6 . 3 ).
[0068] After the individual threads ( 6 . 1 - 6 . 3 ) leave the heated galette, they are sent together to the crimping device 11 where they are compressed to form a thread plug 22 .
[0069] In a variant of the inventive apparatus according to FIG. 4 , the whirl-tangling of the heated individual threads can be carried out with the individual thread(s) being heated, and the tensioning of the individual threads as part of the texturizing of said threads in the crimping device 11 can be chosen to be independent of the tensioning of the individual threads in the whirl-tangling in the second pre-treating stage. Thus, e.g., a diameter step may be provided on the heated galette 28 . 1 to enable setting different tensioning values for the whirl-tangling. The diameter step 33 of the galette 28 . 1 in the last segment of the individual threads is shown as a dotted line in FIG. 4 , and is implemented immediately downstream of the whirl-tangling unit 8 . 2 . Another advantage of the variant illustrated in FIG. 4 is that the individual threads have a defined point of leaving from the galettes 28 . 1 . The individual threads pass from the last galettes to the crimping device in a very smooth manner.
[0070] The arrangement illustrated in FIG. 4 may advantageously have galettes which are un-heated, wherewith the whirl-tangling is carried out at ambient temperature.
[0071] FIG. 5 illustrates yet another exemplary embodiment of a variant method and apparatus applicable to the system according to FIGS. 1 and 2 .
[0072] In the variant embodiment illustrated in FIG. 5 , there are disposed between the cooling drum 17 and the winding device 20 a first drawing galette device 29 . 1 , a separating thread guide 30 , a “tangling device” 19 , and a second drawing galette device 29 . 2 . The components disposed upstream of the cooling drum 17 may be as in the exemplary embodiment according to FIG. 1 or 2 , to which reference is made here.
[0073] In the variant embodiment illustrated in FIG. 5 , the compound thread 21 , after crimping and after cooling on the periphery of the cooling drum 17 , is drawn off via the first galette device 29 . 1 . The galette device 29 . 1 is shown here as a driven galette with an associated coordinated roll. For post-treatment, the compound thread 21 is separated into individual threads ( 6 . 1 - 6 . 3 ), by passing the individual threads through a separating thread guide 30 before they enter the tangling device 19 . In the tangling device 19 , the separately advancing individual threads ( 6 . 1 - 6 . 3 ) are once again subjected to whirl-tangling, and re-combined into a compound thread 21 . The compound thread 21 is drawn off via the drawing galette 29 . 2 and is passed on to the winding device 20 , where it is wound onto the bobbin 23 . The separation of the compound thread prior to post-treatment allows production of additional special visual effects. In this connection it is possible that, prior to the post-treatment, at least one of the individual threads is subjected to additional treatment in the form of whirl-tangling, after said separation.
[0074] In the variant embodiment illustrated in FIG. 5 , the compound thread 21 is separated into the individual threads ( 6 . 1 - 6 . 3 ). In this, preferably a separating thread guide 30 is employed which preferably is configured according to the exemplary embodiment illustrated in FIG. 6 . The separating thread guide 30 has a disc-shaped support member 32 which is fixed laterally to a machine frame. The support member 32 has a plurality of guiding eyes ( 31 . 1 - 31 . 3 ) on its periphery which are disposed at mutual distances apart. In the embodiment illustrated in FIG. 6 , these eyes ( 31 . 1 - 31 . 3 ) are disposed at the apices of an equilateral triangle. Preferably each such eye has a ceramic insert, which enables the individual threads ( 6 . 1 - 6 . 3 ) to be separately fed to the tangling device 19 , in this embodiment.
[0075] The described exemplary embodiments for carrying out the inventive method are in the nature of examples, in their arrangements and in the choice of processing devices. Thus, additional pre-treatment and post-treatment stages and means may be introduced, e.g. for the purpose of subjecting the individual threads to additional treatments prior to texturizing, or subjecting the compound thread to additional treatments after the texturizing, etc. Likewise the characteristics and form of the crimping device are in the nature of examples. To realize particular crimping characteristics, the individual threads may be texturized using different parameters. Separately performed crimping also enables the use of different crimping methods, wherewith the crimped individual threads will then be combined into a compound thread. The number of individual threads illustrated in the exemplary embodiments is, of course, in the nature of an example. A compound thread may be formed from two or more individual threads. | The invention relates to a method and a device for producing a crimped composite thread, wherein the inventive method consists in extruding, cooling and in drawing several yarns in the form of a plurality of strand filaments and in jointly crimping them in order to obtain a crimped composite thread. The aim of said invention is to make it possible to pre-treat the threads in a manner adaptable to each treatment step. The aim is attained by that at least one multi-treaded yarn is whirl-tangled many times during several operations prior to crimping. For this purpose, a whirl-tangling device provided with a plurality of whirl-tangling units following each other in a direction of the yarn displacement is used. | 3 |
BACKGROUND
The present invention relates to vehicles of the type that include an internal combustion engine, a cranking motor, and a battery normally used to power the cranking motor. In particular, this invention relates to improvements to such systems that increase of the reliability of engine starting.
A problem presently exists with vehicles such as heavy-duty trucks. Drivers may on occasion run auxiliary loads excessively when the truck engine is not running. It is not unusual for heavy-duty trucks to include televisions and other appliances, and these appliances are often used when the truck is parked with the engine off. Excessive use of such appliances can drain the vehicle batteries to the extent that it is no longer possible to start the truck engine.
The present invention solves this prior or problem in a cost-effective manner.
SUMMARY
The preferred embodiment described below supplements a conventional vehicle electrical system with a capacitor. This capacitor is protected from discharging excessively when auxiliary loads are powered, and it is used to supply a cranking current in parallel with the cranking current supplied by the vehicle battery to ensure reliable engine starting. A battery optimizer automatically increases the voltage to which the capacitor is charged as the capacitor temperature falls, thereby increasing the power available for engine cranking during low temperature conditions.
This section has been provided by way of general introduction, and it is not intended to limit the scope of the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an electrical system for a vehicle that incorporates a preferred embodiment of this invention.
FIG. 2 is a graph illustrating operation of the circuit 42 of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
Turning down to the drawings, FIG. 1 shows an electrical system of a vehicle 10 that includes an internal combustion engine 12 . The engine 12 can take any suitable form, and may for example be a conventional diesel or gasoline engine. The engine 12 drives a generator 14 that generates a DC voltage. As used herein, the term “generator” is intended broadly to encompass the widest variety of devices for converting rotary motion into electrical power, including conventional alternators, generators, and the like. The engine 12 is also mechanically coupled to a cranking motor 16 . The cranking motor 16 can take any suitable form, and it is conventionally an electrical motor that is powered during cranking conditions by current from a storage battery 18 such as a conventional lead acid battery. Current from the battery 18 is switched to the cranking motor 16 via a switch such as a conventional solenoid switch 20 . The solenoid switch 20 is controlled by a conventional starter switch 22 .
All of the elements 10 through 22 described above may be entirely conventional, and are well-known to those skilled in the art. The present invention is well adapted for use with the widest variety of alternative embodiments of these elements.
In addition to the conventional electrical system described above, the vehicle 10 also includes a supplemental electrical system including a capacitor 30 . The capacitor 30 is preferably a double layer capacitor of the type known in the art has an electrochemical capacitor. Suitable capacitors may be obtained from KBI, Lake in the Hills, IL under the trade name KAPower. For example, in one alternative the capacitor 30 has a capacitance of 1000 farads, a stored energy capacity of 60 kilojoules, an internal resistance at −30 degrees Celsius of 0.004 ohms, and a maximum storage capacity of 17 kilowatts. In general, the capacitor should have a capacitance greater than 320 farads, and an internal resistance at 20° C. that is preferably less than 0.008 ohms, more preferably less than 0.006 ohms, and most preferably less than 0.003 ohms. The energy storage capacity is preferably greater than 15 kJ. Such capacitors provide the advantage that they deliver high currents at low temperatures and relatively low voltages because of their unusually low internal resistance. Further information about suitable capacitors for use in the system of FIG. 1 can be found in publications of ESMA, Troitsk, Moscow region, Russia and on the Internet at www.esma-cap.com.
The capacitor 30 includes a negative terminal that is connected to system ground, and a positive terminal that is connected to the electrical system of the vehicle via a first signal path 32 and a second signal path 36 . The first signal path 32 is used for charging the capacitor 30 , and it includes two circuits 34 , 42 . The first circuit 34 operates to prevent excessive discharging of the capacitor 30 . The circuit 34 can take many forms. In one example, the circuit 34 includes a low voltage disconnect circuit that disconnects the capacitor 30 from the electrical system of the vehicle when the voltage on the first path 32 falls below a preselected level. For example, the circuit 34 may open the first path 32 when the voltage on the first path 32 falls below 11.8 volts. Higher or lower voltages may be used. In this example, the capacitor 30 receives charging currents from the generator 14 via the first path 32 , and the capacitor 30 supplies current to various loads in the electrical system of the vehicle until the voltage in the first path 32 falls below the selected level. A suitable device for performing this function can be obtained from Sure Power Industries, Inc., Tualatin, Oreg. as model number 13600.
In another example, the circuit 34 may simply include a suitably sized diode oriented to pass charging currents from the generator 14 to the capacitor 30 while blocking discharging currents from the capacitor 30 via the first path 32 . Many other alternatives are possible, as long as the first circuit 34 achieves the desired function of protecting the capacitor 30 against excessive discharge, thereby ensuring that the capacitor 30 maintains an adequate charge to start the engine 12 .
The circuit 42 is included in the first path 32 to optimize the charging voltage applied to the capacitor 30 for the presently prevailing temperature. The circuit 42 increases the charging voltage applied to the capacitor 30 at low temperatures, when engine starting requirements are increased and conventional battery performance is decreased. FIG. 2 shows one example of a suitable voltage profile as a function of temperature. Note that the temperature is preferably the temperature of the capacitor 30 , and the charging voltage applied to the capacitor 30 is greater below a selected temperature (such as zero degrees Celsius) than it is at a higher temperature (such as +30 degrees Celsius). The profile of FIG. 2 is intended by way of example and many other profiles can be used, including profiles that are continuous in slope as well as stepwise profiles.
The circuit 42 can take many forms. For example, a conventional battery optimizer can be used, such as that supplied by Purkey's Fleet Electric, Inc., Rogers, Ariz. Such battery optimizers control the voltage applied to the voltage sense input of the generator 14 , thereby altering the regulated voltage generated by the generator 14 . Alternately, the circuit 42 can include a DC to DC converter that converts a voltage generated by the generator 14 to the desired charging voltage, which can vary as a function of temperature in accordance with the profiles discussed above.
The second path 36 connects the capacitor 30 to the cranking motor 16 via a high amperage switch 38 . The switch 38 may for example be a MOSFET switch such as that sold by IntraUSA under the trade name Intra switch.
The switch 38 is controlled by a switch controller 40 that is in turn coupled with the starter switch 22 of the vehicle 10 . The controller 40 holds the switch 38 in an open circuit condition except when the starter switch 22 commands engine cranking, at which time the switch 38 is closed. Thus, the controller 40 causes the switch 38 to be closed during cranking conditions and opened during non-cranking conditions. The controller 40 can take many forms, including conventional analog and digital circuits. Microprocessors can also readily be adapted to perform the functions of the controller 40 . It is not essential in all cases that the switch 38 be in an open circuit condition at all times other than when the engine 12 is being cranked. For example, the controller 40 may allow the switch 38 to remain in the closed circuit condition after engine cranking has terminated, as long as the voltage supplied by the capacitor 30 does not fall below a desired level, one that which the capacitor 30 stores sufficient power to start the engine 12 reliably. In this case, the first path 32 and the circuit 34 may be eliminated, and the circuit 42 may be placed in the second path 36 .
The system of FIG. 1 provides a number of important advantages.
First, the supplemental electrical system including the capacitor 30 provides adequate current for reliable engine starting, even if the battery 18 is substantially discharged by auxiliary loads when the engine 12 is not running. If desired, the supplemental electrical system including the capacitor 30 may be made invisible to the user of the vehicle. That is, the vehicle operates in the normal way, but the starting advantages provided by the capacitor 30 are obtained without any intervention on the part of the user.
Additionally, the capacitor 30 provides the advantage that it can be implemented with an extremely long life device that can be charged and discharged many times without reducing its efficiency in supplying adequate cranking current.
As used herein, the term “coupled with” is intended broadly to encompass direct and indirect coupling. Thus, first and second elements are said to be coupled with one another whether or not a third, unnamed, element is interposed therebetween. For example, two elements may be coupled with one another by means of a switch.
The term “battery” is intended broadly to encompass a set of batteries including one or more batteries.
The term “set” means one or more.
The term “path” is intended broadly to include one or more elements that cooperate to provide electrical interconnection, at least at some times. Thus, a path may include one or more switches or other circuit elements in series with one or more conductors.
Of course, many alternatives are possible. The functions of the elements of 34 , 38 , 40 , 42 may if desired all be integrated into a single device. Is anticipated that such integration may simplify packaging requirements and reduce manufacturing costs. Any appropriate technology can be used implement the functions described above.
The foregoing description has discussed only a few of the many forms that this invention can take. For this reason, this detailed description is intended by way of illustration, not limitation. It is only the claims, including all equivalents, that are intended to define the scope of this invention. | A vehicle having an internal combustion engine that drives a generator and a cranking motor that cranks the engine is provided with a standard electrical system as well as a supplemental electrical system. This supplemental electrical system includes a capacitor that is charged by the primary electrical system of the vehicle and is protected against excessive discharge. When it is desired to start the engine, the capacitor is connected to the cranking motor to supply adequate cranking power to the cranking motor, regardless of the state of charge of the batteries. | 5 |
BACKGROUND
The invention relates to the true-to-quantity introduction of ions of a wide mass range into a very strong magnetic field in the direction of the magnetic field lines to an ion storage device, for example: a measuring cell in an ion cyclotron resonance mass spectrometer. The development of magnetic field generators with superconducting solenoids for very strong magnetic fields is advancing very rapidly. This type of magnet is used both for nuclear magnetic resonance spectrometry (NMR) and also for ion cyclotron resonance mass spectrometry (ICR-MS). For the latter, magnets with field strengths of 7, 9, 12 and 15 Tesla are now available and supplied. Instruments with 21 Tesla magnets are planned. Several of the performance specifications for ICR mass spectrometers increase linearly with the field strength. Some other important performance specifications, such as the resolution or the ion collection capacity of the measuring cells without interfering with the scan, even increase with the square of the field strength, making it easy to understand why researchers are trying to achieve higher field strengths.
Every magnet for an ICR mass spectrometer has a so-called open bore (also called “room-temperature bore”), usually with a diameter of around eleven centimeters, which allows access to the inner region with the highest and most homogeneous field strength. The axis of the bore coincides with the axis of the magnetic field. A long, tubular vacuum recipient, which contains the measuring cell for analyzing the ions in the form of an ion storage device, is inserted into this bore. The aim of the investigations is usually to determine the mass of the ions, which is obtained by measuring the circular cyclotron motions which an ion assumes after appropriate excitation. A very good vacuum of better than 10 −6 Pascal is required to keep the ions moving freely and without collisions over periods of several seconds.
In the past, magnets of this type were passively shielded by several layers of thick iron sheets, which meant that 12 Tesla magnets weighed more than 15 tons. Nowadays such magnets use active shielding. This means that an inner coil system and an outer coil system are used to feed most of the field lines of the magnetic field of the inner solenoid back through the outer coil system, thus producing only very small magnetic fringe fields at the entrances and exits of the bores. This gives a very steep magnetic field increase at the entrance of the magnet. The superconducting coils are located in helium cryostats, which, in turn, are usually enclosed in liquid nitrogen cryostats. The walls of the bores are at room temperature; the magnets are therefore technically very complex to manufacture.
The steep increase of the magnetic field leads to difficulties when introducing the ions, which are generated outside the magnetic field and introduced into it. Only ions which are injected exactly on the axis of the magnetic field and its fringe field have a chance of reaching the measuring cell; all other ions injected either at a slight angle or slightly off-axis are reflected by the fringe field as if they were in a magnetic bottle. Asymmetric distortions of the fringe field mean that no ions at all can be injected. Unless special measures are taken, it sometimes requires several days of adjustments until an alignment of the recipient to the magnet is achieved which allows a satisfactory number of ions to reach the measuring cell. This adjustment has to be repeated after each new insertion of the recipient unless special measures are taken to maintain the alignment.
About two decades ago, a way of greatly simplifying this adjustment for magnets of medium field strength was described. This used an RF quadrupole rod system (R. T. McIver, U.S. Pat. No. 4,535,235). The system, consisting of four long pole rods, extends through the magnetic field increase to the measuring cell in the homogeneous magnetic field. The two phases of an RF voltage are applied alternately to the pole rods of the quadrupole system, in whose interior a radially focusing pseudopotential is produced. In this way, the ions can be more easily and reproducibly guided from the outside through the fringe field to the measuring cell.
If ions of a very wide mass range are to be transported more or less uniformly into the measuring cell, then it is favorable, according to recent research, to increase the number of poles when using magnets with higher magnetic field strengths, i.e., to change from quadrupole rod systems to hexapole, octopole, or even higher multipole systems. But even then, this ion guide does not work for very strong, short magnets, especially for light ions. Heavy ions are transported fairly satisfactorily, but many light ions do not arrive at the strong magnetic field.
Research has shown that the light ions are lost in the region of the magnetic field increase where their cyclotron frequency just equals the RF frequency of the pole rod system. The cyclotron motions of the ions are resonantly excited by the electric fields, which have components at right angles to the magnetic field lines inside the pole rod systems. As a result, the ions are moved out of the system until they collide with the pole rods. The RF fields can also excite harmonics of the ion motion, or the cyclotron motion of harmonics of the RF. In any case, no true-to-quantity transport of the ions of different masses takes place.
To achieve maximum sensitivity, the ions under investigation are usually collected in a temporary store outside the magnetic field and introduced into the magnetic field from this temporary store. The easiest method is to accelerate the ions simultaneously as an ion cluster from the temporary store, and to transfer them to the measuring cell. The capture of the ions in the ion storage device acting as a measuring cell in the magnetic field is greatly simplified if the ions of all masses enter with low energies and at the same time. The aim is to achieve entrance energies of approx. 0.3 electron-volts. The long path from the ion supply to the measuring cell, however, causes a temporal mass dispersion of the ion cluster which has been transferred, so that the ions arrive at the measuring cell separated according to their mass: first the lighter and faster ions, then increasingly the heavier ones. This temporal mass dispersion can be greatly reduced, but not eliminated, by strongly accelerating the ions from the temporary store and decelerating them before they enter the measuring cell. The large overall length of strong magnets, which represents a long flight path, therefore presents a further problem for a highly efficient, and also true-to-quantity, capture of the ions from the temporary store.
The greatest successes with ICR mass spectrometry have been achieved in the field of proteomics, and especially in the field of “top-down analysis” of proteomes, where the masses of hundreds or even thousands of digest peptides are simultaneously analyzed in the measuring cell and subsequently assigned to the undigested proteins of the proteomes. For reasons which are not yet fully understood, the larger the number of different types of ions in the measuring cell, the better the ICR mass spectrometry operates. Accuracies of much better than one millionth of the mass can be achieved in the mass determination; no other type of mass spectrometry can measure this accurately. This application (and also other methods in proteomics) works optimally when both the ions of individual, cleaved amino acids (so-called immonium ions) with masses from 50 Daltons upwards and peptides with mass-to-charge ratios of approximately 5,000 Daltons can be measured together. It should therefore be possible to introduce ions of the mass range of 1:100 into the measuring cell. The velocities of these ions extend over a range of 1:10 at the same kinetic energy. This data explains the problem for the true-to-quantity, efficient introduction of the ions into the measuring cell.
The term “mass” here always refers to the “mass-to-charge ratio” m/z, which is the only parameter of importance in mass spectrometry, and not simply to the “physical mass” m. The number z is the number of elementary charges, i.e., the number of excess electrons or protons which the ion possesses, which act externally as the ion charge. All mass spectrometers without exception can measure only the mass-to-charge ratio m/z, not the physical mass m itself. The mass-to-charge ratio is the mass fraction per elementary ion charge. The terms “light” and “heavy” ions here analogously refer to ions with a low and high mass-to-charge ratio m/z respectively. Similarly, the term “mass spectrum” always relates to the mass-to-charge ratios m/z.
SUMMARY
In accordance with the principles of the invention, an ion guide made of coaxial ring diaphragms is substituted for the conventional multipole rod system to guide the ions in the region where the magnetic field increases. The coaxial rings are connected alternately to the phases of an RF voltage, although it is also possible to use superpositions of several RF voltages across groups of ring diaphragms to increase the mass range. These ring diaphragms are similar to multipole rod systems in that they have pseudopotential distributions which repel the ions radially toward the axis of the ring system. Pseudopotentials are not real potentials; they only describe the time-averaged effect of inhomogeneous RF fields on the ions, which constantly tries to expel ions of both polarities out of the RF field. The effect of the pseudopotential is based on the imposed forced oscillations of the ions in the RF field. In contrast to multipole rod systems, in coaxial ring systems the forced oscillation of the ions in the RF field is imposed not in the direction at right angles to the magnetic field, but predominantly in the direction of the magnetic field lines. Thus, excitation of the cyclotron motion is avoided, even if the cyclotron frequency is the same as the RF frequency over a narrow range.
In another embodiment, the ion guide comprising coaxial ring diaphragms can additionally be supplied with an axial DC electric field to drive the ions forward. Further ion guides can be used outside the ring diaphragm system, for example pole rod systems, although here, as well, measures can be taken to increase the range of guided masses.
The ions which are to be introduced originate from an ion supply outside the magnetic field. This ion supply can be an ion source which continuously delivers ions over a period of time, or a temporary store from which ions can be extracted in portions or in their entirety. The temporary store can also be designed so that it can store ions of a wide mass range.
With a temporary store, the ions can be extracted mass-selectively in a time-controlled manner and sent to the ion storage device (first heavy, then light ions). It is preferable to set the time control so that ions of different masses but the same acceleration energy arrive in the ion storage device at the same time. The mass-selective extraction can be carried out using a grid structure with pseudopotentials, for example; the pseudopotentials being decreased under time control so that they initially admit only heavy ions, then increasingly lighter and lighter ions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of an ion cyclotron resonance mass spectrometer (ICR-MS) according to the prior art. Ions from an ion source ( 1 ) are guided by an ion guide ( 2 ) into a temporary store ( 3 ) and from there by a further ion guide ( 4 ) into the measuring cell ( 5 ), which is located inside the bore of a magnet system ( 6 ), enclosed by a vacuum recipient ( 11 ). In order to generate an ultrahigh vacuum, the vacuum system is divided into chambers ( 7 , 8 , 9 , 10 and 11 ), which are differentially evacuated by pumps ( 12 , 13 , 14 , 15 and 16 ).
FIG. 2 is likewise a schematic representation of an ICR-MS according to this invention, in which the ion guide ( 4 ) has been replaced by two ion guides ( 17 ) and ( 19 ) of the conventional type, between which the system of ring diaphragms ( 18 ) according to the invention is located. The system of ring diaphragms ( 18 ) is located in the region of greatest increase in the magnetic field and makes it possible to transfer ions of a wide mass range true-to-quantity into the measuring cell.
FIG. 3 shows a section of a system comprising closely spaced ring diaphragms ( 20 ) with a special type of configuration for the transfer of ions of a wide mass range. In particular, two phases of an RF voltage U 1 with relatively low frequency are connected alternately to adjacent ring diaphragms, thus keeping ions of high masses away from the ring diaphragms. This pseudopotential near field is only effective immediately in front of the inner edges of the ring diaphragms. The RF voltage U 2 has a higher frequency and both its phases are applied alternately to groups of two ring diaphragms; the pseudopotential of this RF voltage penetrates further toward the axis of the system of ring diaphragms and keeps the lighter ions, in particular, close to the axis. The configuration with capacitors ( 21 , 22 ) makes it possible to also apply DC voltages to generate a DC gradient to drive the ions forward.
FIG. 4 is a schematic representation of a cross-section through a dodecapole rod system and a transformer for generating the RF, with a special configuration to guide ions of a wide range of masses close to the axis.
FIG. 5 shows a partial cutaway view including two of the four sides of a square wire loop system which can serve as a temporary store with a storage capability for ions of a high mass range. The rows ( 31 ) of wire loops are embedded in ceramic plates ( 30 ). RF voltages of the same phase but different amplitude are applied to adjacent wire loops in each row. As an RF dipole grid field, these RF voltages generate a pseudopotential near field which keeps heavy ions away from the wire loops. The averaged RF voltages, which are applied crosswise to the four rows of wire loops, generate a quadrupole field and keep light ions in the axis of the system.
FIG. 6 shows a wire loop system according to FIG. 5 which is terminated with grid wires ( 32 ), which generate a pseudopotential barrier for the ions in the temporary store by the application of the two phases of an RF voltage. Rows of wire loops ( 31 ) are embedded in a total of four ceramic plates ( 30 ) and are supplied with voltages by printed circuits ( 33 ) with electronic components ( 34 ). Decreasing the RF voltage across the grid wires ( 32 ) allows the time-controlled emergence first of heavy ions, then of increasingly lighter ions, from the temporary store and allows them to be accelerated and sent in the direction of the measuring cell. This makes it possible for all the ions of the temporary store to reach the measuring cell simultaneously despite their different masses.
DETAILED DESCRIPTION
While the invention has been shown and described with reference to a number of embodiments thereof, it will be recognized by those skilled in the art that various changes in form and detail may be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
Several measures need to be taken to achieve the objective. The most important and therefore highest-priority measure is to guide the ions of different masses undisturbed through the magnetic field gradient.
The ions are successfully guided in this way by means of an ion guide made of ring diaphragms. This type of ring diaphragm system, onto which an axial DC potential to drive the ions forward can be also superimposed, has already been described in patent specification U.S. Pat. No. 5,572,035 A (J. Franzen). It is operated with an RF voltage whose two phases are usually applied in turn to the ring diaphragms. The electric field lines are aligned largely parallel to the axis in the interior of such a ring diaphragm system, and therefore the RF field causes the ions to oscillate in the direction of the magnetic field lines. Practically no cyclotron motions are excited, even if the cyclotron frequency of the ions coincides with the frequency of the RF voltage. There are weak components of the RF electric field in the radial direction, but these scarcely have any influence if the ions are guided relatively quickly through the increase in the magnetic field.
The form and the strength of the radial pseudopotential in the interior of such a ring system depend on the distance between the ring diaphragms in relation to their internal diameter. In a ring system with closely spaced ring diaphragms, the pseudopotential drops off very quickly toward the axis; depending on their space charge, the ions then collect far from the axis, in front of the inner edges of the ring diaphragms. This effect is undesirable for the guiding of the ions through the magnetic field increase; it is much more favorable to keep the ions on the axis of the ion guide as far as possible.
An arrangement where the ring diaphragms are further apart is better for keeping the ions close to the axis, but this system resembles a series of individual three-dimensional quadrupole ion traps with a very undulating pseudopotential along the axis.
Even if the ring diaphragms are close together it is still possible to keep the ions closer to the axis and at the same time guide heavy ions well. FIG. 3 shows the principle of a ring diaphragm system configured for this purpose. Applying a first RF voltage U 1 with medium frequency alternately to the ring diaphragms achieves good guidance of the heavy ions. The pseudopotential is mass- and frequency-dependent; it is inversely proportional to the mass and inversely proportional to the square of the frequency. By applying a second RF voltage U 2 with a higher frequency, the phases of which are connected alternately to groups of two neighboring ring diaphragms each, a pseudopotential is generated which penetrates further in the axial direction and keeps particularly the lighter ions close to the axis. Such an ion guide can guide ions of a wide mass range. Such an embodiment where RF voltages of different frequencies are fed to groups of ring diaphragms can also be extended to groups with three or four ring diaphragms each. The frequencies and amplitudes of the individual RF voltages can be adjusted with respect to each other in such a way that ions of an optimal mass range are guided.
Instead of a system of ring diaphragms, it is also possible to use a double helix, as is also described in the patent specification U.S. Pat. No. 5,572,035 A. Although the double helix exhibits small radial components of its electric field lines, it is still greatly better for guiding ions through the magnetic field gradient than rod systems.
In order to achieve the objective of this invention well, the ion guides ( 17 ) and ( 19 ) of FIG. 2 must also be designed so as to guide ions of a wide mass range efficiently. If simpler pole rod systems are to be used, this can be achieved by means of a specially configured dodecapole rod system according to FIG. 4 , for example. Close to the axis, this system provides a quadrupole-like pseudopotential, with its advantageous guiding of light ions, in contrast to a conventional dodecapole system with alternately applied phases of an RF voltage. Far from the axis, in front of the pole rods, on the other hand, the heavy ions are held back well; much more efficiently than with a quadrupole rod system. Since the ion guide ( 17 ) begins in a region where the pressure is above approx. 0.01 Pascal, the kinetic energies of the ions are removed sufficiently by collisions for the ions to collect close to the axis. The dodecapole system described collects light ions on the axis itself, while heavier ions are collected around the light ions. This arrangement of the ions is largely maintained when the ions enter a region of very good vacuum after the differential pumping chambers.
In order to achieve highly efficient utilization of the ions, they must be collected in a temporary store. The collection can also extend temporally over the measuring phases of the ICR measuring cell, and therefore encompass practically all ions supplied by an ion source. The temporary store must, however, be designed so that it can store ions of a wide mass range. For example, a normal quadrupole storage device can only store ions over a mass range of approx. 1:20; this is too small by far. In higher multipole rod systems, which can be used as storage devices, ions of a far wider mass range are stored. However, the ions are not stored on axis, but predominantly close to the pole rods. This makes it more difficult to extract the ions close to the axis.
There are several embodiments for ion storage devices which store ions of a wide mass range and at the same time collect ions close to the axis. An example of such an ion storage device is shown in FIG. 5 , where a view into the interior of the ion storage device is made possible by omitting two of the four wall elements in the drawing. The storage device consists of four wall elements made of insulating material, preferably ceramic, into each of which a row of wire loops has been embedded. Electric circuits can be mounted on the back of the wall elements to supply the wire loops with the necessary RF and DC voltages. The electric circuits can be printed or vacuum-deposited and be equipped with the necessary electronic components.
The four rows of wire loops are supplied crosswise with the two phases of an RF voltage; this generates a quadrupole field close to the axis, which collects the ions on axis. Since such a quadrupole field has only very small focusing power for heavy ions, these must be kept in the storage device in a particular way. This is achieved by applying an RF voltage of the same frequency but different amplitude to adjacent wire loops of the same row. This generates a dipole grid with a short-range pseudopotential, i.e., a near field, which repels heavy ions. By selecting the amplitudes appropriately, the near field and the quadrupole field can be adjusted with respect to each other so that ions of an optimum mass range remain stored. The quadrupole field in this case is generated by the averaged RF voltages across the rows of wire loops. It is, however, also possible to select RF voltages with different frequencies for the near field and the quadrupole field. The RF voltages then have a different effect on ions of different masses.
This requires there to be a collision gas in the temporary store which removes the kinetic energy of the ions because, otherwise, light ions straying into the near field experience accelerations which catapult them out of the storage device. The lower mass limit for storage is considerably higher for the near field than for the quadrupole field.
Other storage systems which collect ions on axis can also be constructed as pole rod systems, for example. It is thus possible to generate both a central quadrupole field and also stronger repulsive pseudopotentials in front of the rods by using appropriate configurations in a multirod system, similar to the situation in the dodecapole system of FIG. 4 .
The problem which still remains to be solved is how to ensure that the ions of all masses arrive at the ion storage device at the same time. This problem can be solved, for example, by first extracting the heavier ions from the temporary store and sending them to the ion storage device, then increasingly lighter and lighter ions, and to time this so that ions of all masses arrive at the ion storage device at the same time. This method of extracting first heavier ions, then increasingly lighter ions can be achieved by using an adjustable high-pass filter for ions. The temporary store must only be filled to the level necessary to fill the ion storage device in the strong magnetic field because the temporary store is completely emptied each time. It is therefore expedient to fill the temporary store ( 3 ) with a sufficient quantity of ions from an upstream initial storage system, for instance the ion guide ( 2 ) in FIG. 2 .
The high-pass filter required can be realized by a pseudopotential barrier, for example. A pseudopotential is mass-dependent; its effect is inversely proportional to the mass of the ions. A pseudopotential barrier therefore allows ions above a certain adjustable mass limit to pass and holds back lighter ions.
A pseudopotential barrier can be produced, for example, by an exit grid, such as a Bradbury-Nielsen shutter, the grid wires of which alternately carry the two phases of an RF voltage. Only ions with masses higher than an adjustable mass threshold can pass through the exit grid. The ions pass the troughs of the pseudopotential between the grid wires; they cannot come into contact with the grid wires themselves. It is expedient if the ions are pushed against the exit grid by an axial DC voltage gradient inside the temporary store. Such a voltage gradient can easily be generated in a temporary store according to FIG. 5 . Decreasing the amplitude of the RF voltage at the exit grid allows increasingly lighter ions to pass though. With such a device it is therefore possible to achieve the desired effect of making the ions flow out in the sequence of heavy to lighter ions under time control. FIG. 6 shows a somewhat unusual exit grid at the end of an ion storage device according to FIG. 5 , which can be used to solve the problem described. The time control requires specially developed electronics to generate the RF voltage with time-controlled amplitudes. The time control of the amplitude can easily be adjusted by a skilled experimenter to ensure that, with a given intermediate acceleration of the ions, the ions of all masses enter the ion storage device in the strong magnetic field simultaneously.
The desired effect of simultaneous arrival of the ions can also be achieved by discharging all ions simultaneously from the temporary store and re-arranging the ions in flight. Their mass-dependent flight velocity can be reversed by so-called “bunching”, for example. They therefore reach a certain point at the same time but with different energies. Using a second, decelerating, bunching one can ensure that ions of all masses again arrive at a point simultaneously, but this time with the same energy. This somewhat difficult operation will not be discussed further here.
This invention gives those skilled in the art a collection of instrumental devices and methods for the optimum storage of ions of a wide mass range in an ion storage device in a strong magnetic field. | In a mass spectrometer that uses a space-restricted magnetic field, such as an ion cyclotron resonance mass spectrometer, ions with a wide mass range generated in an ion supply located outside the magnetic field are transported in the direction of the magnetic field lines to an ion storage device located inside the magnetic field without losing ions by guiding the ions through the region in which the magnetic field strength increases with a special ion guide. This ion guide consists of an arrangement of coaxial ring diaphragms which are alternately supplied with the phases of an RF voltage. In an alternative embodiment, the ion guide uses two wires wound in a double helix where each wire is supplied with one phase of a two-phase RF voltage. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a motor driven camera having a film feed and a plurality of frame speed modes, and more particularly to a device for controlling the frame speed as necessity arises.
2. Description of the Prior Art
Prior art proposals for automatically feeding blank frames of film by a prescribed number of frames had suggested using either a film counter or, as electronics developed, an electronic counter, as part of the control device for the camera. Even though most motor driven cameras have a mode selector for changing the frame speed, the frame speed at which blank frames are fed is limited to the value chosen for the preset modes of operation during shooting. When the preset mode is a slow speed, a drawback is introduced, namely, that the primary advantage of motorizing the camera is not fully utilized.
When loading film, the use of a slow frame speed makes the loading operation easy. Up to now, however, the operation had to preliminarily switch the mode selector to the slow speed frame mode. After the completion of the loading operation, the operator then had to reset the mode selector to the high speed frame mode for the purpose of feeding two or three blank frames of film to wind off the exposed leader. This troublesome operation gave rise to several problems.
SUMMARY OF THE INVENTION
A first object of the present invention is to provide a motor driven camera in which, when feeding blank frames of film, the frame mode is automatically set to the fastest speed, thereby fully utilizing the mobility of the motor driven camera.
A second object of the present invention is to provide a motor driven camera capable of selecting frame speed modes of film externally, wherein said blank frames of the film are fed, the frame speed mode is automatically set to the fastest speed, and, at completion of the blank frame feeding operation, is automatically returned to the preselected frame speed, whereby the mobility of the motor driven camera is fully utilized and good manageability is obtained.
A third object of the present invention is to provide a motor driven camera in which, when it is loaded with film, the frame speed is automatically set to a slow value effective, particularly, for a single shot, whereby good manageability is obtained.
Other objects of the present invention will become apparent from the following detailed description of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of a motor driven camera according to the present invention with portions broken away to illustrate the construction thereof.
FIG. 2 is a control circuit diagram of the motor driven camera of FIG. 1.
FIG. 3 is a signal flow chart of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will next be described in connection with an embodiment thereof by reference to the drawings.
FIG. 1 illustrates a motor driven camera wherein 1 is a body of the motor driven camera. A release button 2 is arranged upon its first stroke to turn on a light metering switch SW1 and upon its second stroke to turn on a release switch SW2. A shutter dial 3 gives shutter speed information to an exposure control circuit (not shown). A back cover 4 serves as an actuator for a switch SWB. A mode selector 5 is operatively connected to a frame speed changeover switch (not shown). Gears 6, 7, 8, and 9 in a train transmit the output of a motor Mot to film winding and camera charging mechanisms (not shown). An exposure completion switch SW5 is arranged to turn on when the trailing curtain of a shutter has run down. A motor driven unit 10 may be either built in, or releasably attached to, the camera body 1.
FIG. 2 illustrates a control circuit for the motor driven camera of FIG. 1. Switches SW1, SW2, SW5 and SWB are the switches shown in FIG. 1. D type flip-flops DF0 to DF3 have their D input terminals connected to junctions of the switches SW1, SW2, SW5 and SWB and resistors R0, R1, R2, and R3, respectively. Component NO is a NOR gate; A0 to A9 are AND gates; O0 to O5 are OR gates. The output at the output state Q of the flip-flop DF0 is applied to the AND gate A5, and the output at the output stage Q of the flip-flop DF1 is applied to the AND gate A1. The output of the output stage Q of the flip-flop DF2 is applied to the AND gate 2 while the output at the output stage Q is applied to the AND gate A3. The output at the output stage Q of the flip-flop DF3 is applied to the AND gates A0 to A4, while the output at the output stage Q is applied to the OR gate O5. The output of the NOR gate NO is applied to the AND gate A0. Flip-flops FF0, FF1 and FF2 are SR type flip-flops, and flip-flops DF4, DF5, and DF6 are D type flip-flops. The output of the AND gates A0 and A1 are applied through the OR gate O0 to the set terminal S of the flip-flop FF0, and the output of the AND gate A2 is applied to the reset terminal R of the flip-flop FF0. The output of the AND gate A3 is applied to the set terminal S of the flip-flop FF1. The outputs of the AND gates A4 and A5 are applied through the OR gate O1 to the OR gate O2, the output of the AND gate A6 is applied to the OR gate O2, and the output of the OR gate O2 is applied to the reset terminal R of the flip-flop FF1. The outputs of the OR gate O3 is applied to the AND gate A7, and the output of the AND gate A7 is applied to the set terminal S of the flip-flop FF2. Applied to the reset terminal R of this flip-flop FF2 is the output of the OR gate O1. Applied to the input terminals A, B, and C of a decoder DEC are, respectively, the outputs at the output states Q of the flip-flops FF0, FF1, and FF2. The outputs at the output stages Q of the flip-flops FF0, FF1, and FF2 are applied through the OR gate O4 to the input terminal D of the flip-flop DF4. The output at the output stage Q of this flip-flop DF4 is applied to the input terminal St of the decoder DEC. The output CCO of the decoder is applied to the AND gates A0 and A1, and the output CC1 is applied to the AND gate A3 and also through a resistor R13 to the base of a transistor T0. Connected to this transistor T0 are a resistor R12 and a electromagnetic coil Mg in series. A diode D2 is connected in parallel to the electromagnetic coil Mg, and a condenser C3 is connected in parallel to a series-connected circuit of the electromagnetic coil Mg and the transistor T0. The output CC2 of the decoder DEC is applied to the AND gate A2 and also through a resistor R14 to the base of a transistor T1. Transistor T1 is connected to a relay RL connected in parallel with a diode D3. A relay contact l is switchable from one of the electrical power supply throw to a motor Mot and the motor Mot braking throw to the other. The output CC3 of the decoder DEC is applied to the AND gates A6, A7, and A8, and the output CC4 is applied to the AND gates A4 and A5. COU is a counter. The output CC4 of the decoder DEC is applied to the CL terminal of a counter COU through an inverter N6. A parallel connected circuit of resistors R4, R5, and R6, is connected to counter COU to apply the voltage of an electrical power source thereto. A changeover switch SWM is operatively connected to the mode selector 5 of FIG. 1. This changeover switch SWM has fixed contacts H, M, L, and S. Fixed contacts H, M, and L, are connected to the junctions of resistors R4, R5, and R6, and the counter COU, respectively. The opposite or electrical power source side ends of the resistor R4, R5, and R6 is connected through a resistor R7 to the fixed contact S and also to the AND gate A4. The output terminal CR of the counter COU is connected through an inverter N1 to the AND gate A4. A power up clear circuit comprises a condenser C0 across which is connected a diode D0, a resistor R8 and an inverter N3 connected to the junction of the condenser C0 and the resistor R8. The output of this power up clear circuit (hereinafter referred to as "PUC" circuit), or the output of the inverter N3, is applied to the CL terminals of the flip-flops DF0 to DF3 and FF0 to FF2. The output of the inverter N3 along with the output at the output stage Q of the flip-flop DF3 is applied through the OR gate O5 to the P terminals of the flip-flops DF5 and DF6. A condenser C2 and a resistor R11 constitute a differentiation circuit, and a diode D1 is connected in parallel to the resistor R11. The output at the output stage Q of the flip-flop DF3 is applied through the differentiation circuit and a buffer circuit B0 to the CL terminals of the flip-flops DF5 and DF6. The outputs at the output stages Q of the flip-flops DF5 and DF6 are applied to the AND gate A9, and the output of this AND gate A9 is applied to the NOR gate NO, the AND gate A4 and the OR gate O3. The output of the AND gate A9 is also applied through an inverter N2 to the CK terminal of the flip-flop DF5, together with the output CC3 of the decoder DEC, through the AND gate A8. The output at the output stage Q of the flip-flop DF5 is applied to the input terminal D of the flip-flop DF5 and also to the CK terminal of the flip-flop DF6. The output at the output stage Q of the flip-flop DF6 is applied to the input terminal D of the flip-flop DF6, and also to the AND gate A6, and the output at the output stage Q is applied to the NOR gate NO and the OR gate O3. Resistors R9 and R10 are connected in parallel with each other and an inverter N5 is connected between them. A condenser C1 is connected in parallel to the resistor R9 and an inverter N4 is connected between them. These resistors R9 and R10, condenser C1 and inverters N4 and N5 form an oscillation circuit. The output of the oscillation circuit is applied to the CK terminals of the flip-flops DF0 to DF4 and FF0 to FF2 and to the counter COU.
The frame speed changeover switch SWM is for changing the number of frames per second during continuous shooting, and the resistors R4 to R7 have resistance values related thereto. When the H mode is selected, because the preset value of the counter COU is the lowest, as soon as a count start signal enters the CL terminal of the counter COU, an end signal is produced from the CR terminal. When the switch SWM selects the L mode, because the preset value of the counter COU becomes the highest, responsive to the count start signal at the CL terminal of the counter COU, a timer of relatively long duration works. When the switch SWM selects the M mode, another timer of intermediate duration between those of the H and L modes works.
The operation of the control circuit will next be described by reference to FIG. 3.
When an electrical power source switch (not shown) is turned on, the PUC circuit produces an output signal which is then applied to all the flip-flops, thereby setting each flip-flop to the initial value, and presetting flip-flops DF5 and DF6.
With the back cover 4 closed and the switch SwB open, the output at the output stage Q of flip-flop DF3 is applied through the differentiation circuit and buffer circuit B0 to the CL terminals of the flip-flops DF5 and DF6. Thereby, the flip-flops DF5 and DF6 are cleared. However, because the time constant of the differentiation circuit is shorter than the PUC signal, soon after that the flip-flops DF5 and DF6 are set again. Before a release is actuated, the output stages Q of the flip-flops DF0 and DF1 are binary "0", and therefore the output of the AND gate A1 is "0" and does not set the flip-flop FF0. The other flip-flops FF1 and FF2 are also similar, the flip-flops FF0 to FF2 being left reset by the PUC signal. Therefore, the decoder DEC selects the CC0 output and the camera awaits in a CC0 state of FIG. 3. When the release is actuated, the switches SW1 and SW2 are both turned on, changing the outputs at the output stages Q of the flip-flops DF0 and DF1 to "1". Since the AND gate A1 has its inputs connected to the output Q of the flip-flop DF1 and the output CC0 of decoder DEC, the AND gate A1 now produces an output "1", which is applied through the OR gate O0 to the set terminal S of the flip-flop FF0. For this reason, the output at the output state Q of the flip-flop FF0 becomes "1". As the inputs A, B, and C of the decoder DEC become "1", "0" and "0", respectively, for the present time, the CC1 output is selected. This output is applied through the resistor R13 to turn on the transistor T0, thereby driving magnet Mg for camera release actuation. Thus, the shutter runs down, initiating an exposure.
When the exposure is completed, the switch SW5 is turned on, changing the output at the output stage Q of the flip-flop DF2 to "1". Since the inputs of the AND gate A3 are connected to the output CC1 and the output of the flip-flop DF2, the AND gate A3 produces an output "1" which is applied to the set terminals S of the flip-flop FF1, thereby setting flip-flop FF1. Therefore, as the inputs, A, B, and C of the decoder DEC become "1", "1", and "0", respectively, for the present time, the CC2 output is selected. This output is applied through the resistor R14 to drive the relay RL, and the relay contact l is switched to connect the motor Mot to the electrical power source. As the motor Mot rotates, the film is wound up.
When the film advances one frame, the switch SW5 is turned off, changing the output at the output stage Q of the flip-flop DF2 to "1". Since the inputs of the AND gate A2 are connected to the output CC2 and the output stage Q of the flip-flop DF2, the output of the AND gate A2 becmes "1" and is applied to the reset terminal R of the flip-flop FF0. Therefore, as the inputs A, B, and C of the decoder DEC become "0", "1", and "0", respectively, the decoder DEC selects the output CC3.
Meanwhile, the flip-flops DF5 and DF6 remain set by the PUC signal from the PUC circuit. Therefore, both the inputs of the AND gate A9 are "1", and it produces an output "1". This output of AND gate A9 is applied through the OR gate O3 to the AND gate A7. Now, when the output CC3 of the decoder DEC is applied to the other input of the AND gate A7, the output of the AND gate A7 is changed to "1" and is applied to the set terminal S of the flip-flop FF2. Thereby the inputs A, B, and C of the decoder DEC become "0", "1", and "1", respectively, and the decoder DEC produces the output CC4.
Assuming that the switch SWM selects the H mode, then when the decoder DEC produces the output CC4, the output DD4 is applied through the inverter N6 to the counter COU at the CL terminal thereof. Therefore, the counter COU starts a counting operation, but immediately an end signal is produced and is applied to the AND gate A4. Because all the inputs of the AND gate A4 are "1", its output is applied through the OR gate O1 to reset the flip-flop FF2, and also through the OR gates O1 and O2 to reset the flip-flop FF1. Therefore, the inputs A, B, and C of the decoder DEC become "0", "0", and "0", and the decoder DEC selects the output CCO. If the release switch remains ON, this procedure repeats itself with the result that a continuous series of shots are made at the highest frame speed. When the L mode is selected by the switch SWM, because the timer period of the counter COU is long, a continuous series of shots are made at the lowest frame speed as compared with the above. On the other hand, when the switch SWM selects the S mode, the output CC4 is produced at the termination of one cycle of the release actuating followed by the film winding operation. However, since the input of AND gate A4, which is connected to one end of the resistor 7 remains "0", the AND gate A4 does not produce the output "1". If the switch SW1 is left ON, the Q output of the flip-flop DF0 is "0", and because this is applied to the AND gate A5, the AND gate A5 does not produce the output "1". Therefore, the flip-flops FF1 and FF2 are not reset, causing the output CC4 to retain itself. When the switch SW1 is turned off, however, the AND gate A5 produces the output "1", which is applied through the OR gate O1 to reset the flip-flop FF2, and through the OR gates O1 and O2 to reset the flip-flop FF1. Therefore, the decoder DEC produces the output CC0. Thus, the initial state is regained. When the back cover is then opened, the switch SWB is turned on, thereby changing the output at the output stage Q of the flip-flop DF3 to "0". Therefore, the flip-flops DF5 and DF6 are not cleared, and the output at the output stage Q of the flip-flop DF3 is applied through the OR gate O5 to the P terminals of the flip-flops DF5 and DF6. Therefore, the flip-flops DF5 and DF6 are left set, the input of the AND gate A9 becomes "1", and the output of this AND gate A9 is inverted by the inverter N2 and applied to the AND gate A8. For this reason, the flip-flops DF5 and DF6 are not responsive to the CC3 pulse due to the next release. Since both inputs of the OR gate O3 are "1", and AND gate A7 is supplied with "1". Since the other input is supplied with the output CC3, the AND gate A7 produces the output "1". As the flip-flop FF2 is set, the inputs A, B, and C of the decoder DEC become "0", "1", and "1", respectively, and the decoder DEC produces the output CC4. Meanwhile the switch SWB is ON, and the Q of the flip-flop DF3 is "0", which is applied to the AND gate A4. Therefore, the AND gate A4 also produces the output "0". Since the switch SW1 remains ON, the Q output of the flip-flop DF0 is "0", which is applied to the AND gate A5. Therefore, the output of the AND gate A5 is also "0". Therefore, since this state is maintained, only one cycle of the releasing and winding operation is effected as the release switch is turned on one time. When the switch SW1 is next turned off, the Q output of the flip-flop DF0 becomes "1", and, because the inputs of the AND gate A5 are connected to the outputs CC4 and the output CC4 and the output stage Q of the flip-flop DF0, the AND gate A5 produces the output "1". Therefore, the flip-flops FF1 and FF2 are reset. As the inputs A, B, and C of the decoder DEC become "0", "0", and "0", the decoder DEC selects the output CC0. A similar operation is repeated each time the shutter button is pushed down. That is, with the back cover open, the single frame operation takes place regardless of what frame speed mode has been preset in the camera.
When the back cover is closed, the switch SWB is turned off and the Q output of the flip-flop DF3 is changed to "1". Meanwhile, the Q output of the flip-flop DF3 is applied through the OR gate O5 to the P terminals of the flip-flops DF5 and DF6, so that the flip-flops DF5 and DF6 are responsive to the clock input. At the same time, the Q output of the flip-flop DF3 is applied through the differentiation circuit to the CL terminals of the flip-flops DF5 and DF6, so that the flip-flops DF5 and DF6 are reset by the differentiation pulse. Therefore, the output of the AND gate A9 is "0", thereby releasing AND gate A8 from clock input hindrance. Now, when the release switches SW1 and SW2 are turned on, the flip-flops DF0 and DF1 produce the Q outputs "1" which are applied through the AND gate A1 and OR gate O0 to the S terminal of the flip-flop FF0, thereby setting flip-flop FF0. Therefore, the decoder DEC produces the output CC1 and an exposure is initiated. At the termination of the exposure, the switch SW5 is turned on, thereby changing the Q output of the flip-flop DF2 to "1". This output is applied through the AND gate A3 to the S terminal of the flip-flop FF1, thereby setting flip-flop FF1. Therefore, the decoder DEC produces the output CC2 and the film starts to advance. When the film has advanced one frame, the switch SW5 is turned off, thereby changing the Q output of the flip-flop DF2 to "1". This output is applied through the AND gate A2 to the R terminal R of the flip-flop FF0, thereby resetting the flip-flop FF0. The decoder DEC then produces the output CC3. Since the outputs of the AND gate A8 are connected to the output CC3 and the output of the inverter N2, because at this time the output of the inverter N2 is "1", one clock pulse is applied to the CK terminal of the flip-flop DF5. Thus, the Q output of the flip-flops DF5 and DF6 become "1" and "0". The Q output of the flip-flop DF6 is "1" is applied to the AND gate A6, and the output of the AND gate A6 is applied through the OR gate O2 to the R terminal of the flip-flop FF1, thereby resetting flip-flop FF1. Therefore, the decoder DEC produces the output CC0. If the switches SW1 and SW2 then continue closing, the next cycle of releasing and advancing operation proceeds. When the film has advanced one frame, the decoder produces the output CC3. Because the CK terminals of the flip-flops DF5 and DF6 receive the second clock pulse, their Q outputs become "0" and "1", respectively. The Q output of the flip-flop DF6 is applied through the OR gate O3 to the AND gate A7. Because the other input of the AND gate A7 is CC3, the AND gate A7 produces an output of "1" which is applied to the S terminal of the flip-flop FF2, thereby setting flip-flop FF2. Therefore, the decoder DEC produces the output CC4. However, because the Q output of the flip-flops DF5 and DF6 are "0" and "1", the output of the AND gate A9 is "0". Responsive to this, the AND gate A4 also produces the output "0". Additionally, since the inputs of the AND gate A5 are connected to the output CC4 and the Q output of the flip-flop DF0, if the switch SW1 is ON, it holds this state. That is, regardless of the position of the mode switch SWM, after two frames have been shot at the fastest frame speed, the camera stops. Then when the switch SW1 is turned off, the Q output of the flip-flop DF0, which is "1", is applied to the AND gate A5. The output of the AND gate A5, which is "1", is applied through the OR gates O1 and O2 to the R terminal of the flip-flop FF1 thereby resetting flip-flop FF1. When the release switch turns on again, the third cycle of releasing and winding operation proceeds, producing output CC3. Since, at this time, a clock pulse is applied through the AND gate A8 to the flip-flops DF5 and DF6, their Q outputs both become "1", and the output of the AND gate A9 becomes "1". Therefore, from this time onward, any clock pulse is prohibited from entering the CK terminal of the flip-flop DF5. That is, hereinafter, shots are recycled in the selected mode by the mode switch SWM.
The AND gate A0 and the NOR gate NO are connected as shown in the dashed line block of FIG. 2 so that when the back cover is closed and the switch SWB is turned off, the Q output of the flip-flop DF3 changes to "1" and clears the flip-flops DF5 and DF6, because they are connected to the CL terminals through the differentiation circuit and the buffer amplifier B0. At the same time, because the inputs of the N0R gate NO are both "0", it produces the output "1". Since the other two inputs of AND gate A0 are connected to the Q output of the flip-flop DF3 and the output CC0, the AND gate A0 produces the output of "1", which is applied through the 0R gate O0 to the S terminal of the flip-flop FF0, thereby setting flip-flop FF0. The decoder DEC then produces the output CC1, initiating an exposure followed by advancing the film. After that, the decoder DEC produces the output CC3, which is applied through the AND gate A8 to the CK terminals of the flip-flops DF5 and DF6. Therefore, their outputs become "1" and "0", respectively. At this time, similar to the above, the Q output of the flip-flop DF6, which is now "1", is applied to the AND gate A6. The output of the AND gate A6, which is "1", is applied through the 0R gate O2 to set the flip-flop FF1. Therefore, the decoder DEC produces the output CC0. This procedure repeats itself once more. Then, when the decoder DEC produces the output CC3, the flip-flops DF5 and DF6, responsive to the clock at the CK terminals thereof, change their outputs to "0" and "1", respectively. Thus, the initial state is regained with the output CC0. At this time, one of the inputs of the N0R gate NO is "1" and its output is "0". Therefore, the output of the AND gate A0 becomes "0". From this time onward, it is possible to actuate a release with switch SW2. It is to be understood that when the back cover is closed, feeding of two blank frames at the fastest speed mode is automatically effected, and after that the camera is automatically stopped.
Although the foregoing embodiment has been described with the limitation of the number of blank frames to two, it is needless to say that the necessary number of blank frames may be varied depending on the construction of the camera until a fresh area of the film appears at the exposure aperture.
As has been described above, according to the present invention, either when the release switch is turned on just after the back cover has been closed, or when the back cover is closed, the camera is switched to the fastest frame speed mode, in which the film is automatically fed a prescribed number of frames, regardless of what frame speed mode has been preset, thereby giving the advantage that the shot preparing operation is carried out most quickly and the mobility of the motor driven camera can be fully utilized.
When the blank frame feeding operation is terminated, the camera is automatically switched from the fastest frame speed mode to the preset mode by the mode switch, so that the photographer does not need to renew the setting operation of the preset mode after the termination of the blank frame feeding operation and is permitted to proceed to take shots directly after the camera has been loaded with film.
In the present invention, film feeding under the condition that the back cover of the camera body is open is regarded as a film loading operation. To perform the film loading operation, therefore, the camera is automatically switched to the lowest frame speed mode effective, particularly, for a single shot mode thereby carrying out the film loading operation with ease. | The disclosed device controls the speed of a camera's motor driven film feed. Upon detection of the initiation of a blank frame feed operation, the high speed frame mode is selected to automatically feed the film a predetermined number of frames and then automatically return to a preset frame speed mode. Upon detection of the initiation of a film load operation, the slow speed frame mode is selected. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of and claims the benefit of and priority to U.S. patent application Ser. No. 14/263,144 filed Apr. 28, 2014 entitled “Portable Spa Construction” and to U.S. Provisional Application Ser. No. 61/927,396, filed Jan. 14, 2014, of the same title, the contents of each of which applications are hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE DISCLOSURE
[0002] Field of the Disclosure
[0003] The subject disclosure relates to spas, tubs, and the like and more particularly to an improved portable spa structure and the construction thereof.
[0004] Related Art
[0005] Portable spas have become quite popular as a result of their ease of use and multiplicity of features such as varied jet and seating configurations.
SUMMARY
[0006] The following is a summary of description of illustrative embodiments of a new spa structure, and more particularly a new portable spa structure. It is provided as a preface to assist those skilled in the art to more rapidly assimilate the detailed design discussion which ensues and is not intended in any way to limit the scope of the claims which are appended hereto in order to particularly point out the invention.
[0007] According to an illustrative embodiment, a spa structure is provided comprising a plurality of corner pieces, each positioned at a respective corner of the structure and a plurality of trapezoidal shaped side panels positioned between the corner pieces. Each side panel is positioned with its respective side edges located in grooves defined by the corner pieces and their mounting brackets such that each side panel may move or slide both horizontally and vertically with respect to the corner pieces and other structural parts so as to accommodate expansion or contraction of the side panels. In this configuration, a lower edge of each side panel is held in place by a plurality of panel clips, each of which is pivotable into and out of a panel retaining position, which facilitates panel installation and disassembly.
[0008] Such an illustrative structure may further include a generally rectangular base pan of smaller width and length than a generally rectangular outer upper rim of the spa, with the base pan being centrally positioned within and beneath the outer upper rim and including a plurality of downwardly and inwardly swept back lower side surfaces extending from the lower edges of the side panels to lower edges of the base pan. A plurality of vertical support members are configured to support an upper rim of a spa shell, and a plurality of angled force transfer members are attached at respective lower ends of the vertical support members to transfer force from each respective vertical support member to an inner bottom surface of the base pan.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a portable spa according to an illustrative embodiment;
[0010] FIG. 2 is a perspective view illustrating the internal structure of the spa of FIG. 1 ;
[0011] FIG. 3 is an inverted perspective view of illustrative frame structure of the spa of FIG. 1 ;
[0012] FIG. 4 is an inverted perspective view of the spa of FIG. 1 with side panels removed;
[0013] FIG. 5 is a perspective view illustrating a bottom pan component of the spa of FIG. 1 ;
[0014] FIG. 6 is a perspective fragmentary view illustrating internal support members of the spa of FIG. 1 according to an illustrative embodiment;
[0015] FIG. 7 is a perspective view illustrating assembly of angled force transfer member components according to an illustrative embodiment;
[0016] FIG. 8 is a top perspective view of an illustrative angled force transfer member;
[0017] FIG. 9 is a side perspective view of respective halves of an angled force transfer member according to an illustrative embodiment;
[0018] FIG. 10 is a side view illustrating internal structure of a first half of the illustrative angled force transfer member;
[0019] FIG. 11 is a side view illustrating internal structure of a second half of the illustrative angled force transfer member;
[0020] FIG. 12 is a first side view of the assembled angled force transfer member;
[0021] FIG. 13 is a second side view of the assembled angled force transfer member;
[0022] FIG. 14 is a front view of the assembled angled force transfer member;
[0023] FIG. 15 is a back view of the assembled angled force transfer member;
[0024] FIG. 16 is a fragmentary perspective view illustrating a corner portion of the spa of FIG. 1 ;
[0025] FIG. 17 is a fragmentary front view of the corner portion of FIG. 17 ;
[0026] FIG. 18 is a fragmentary side perspective view of the spa of FIG. 1 with a side panel removed;
[0027] FIG. 19 is a perspective view of an illustrative embodiment of a panel clip in an “open” position;
[0028] FIG. 20 is a perspective view of the panel clip of FIG. 19 in an “closed” position;
[0029] FIG. 21 is a side view of a latch component of the panel clip of FIG. 19 ;
[0030] FIG. 22 is a front view of a latch component of FIG. 21 ;
[0031] FIG. 23 is a rear perspective view of a pivot component of the panel clip of FIG. 19 ;
[0032] FIG. 24 is a front perspective view of the pivot component of FIG. 23 ;
[0033] FIG. 25 is a rear view of the panel clip of FIG. 19 ;
[0034] FIG. 26 is a rear view of the panel clip of FIG. 25 wherein the latch component has moved to the right in the Figure;
[0035] FIG. 27 is a top view of the panel clip of FIGS. 25 and 26 in the “open” position;
[0036] FIG. 28 is a fragmentary perspective view of the panel clip in a “closed” position;
[0037] FIG. 29 is a second fragmentary view of the panel clip of FIG. 28 ;
[0038] FIG. 30 is a front schematic view illustrating installation of a side panel according to an illustrative embodiment; and
[0039] FIG. 31 is a front schematic view illustrating the side panel of FIG. 30 in the installed position.
DETAILED DESCRIPTION
[0040] FIG. 1 illustrates a portable spa 11 having a spa shell 13 , side panels, e.g., 15 , 17 and tapered corner fascia pieces, e.g., 19 , 21 , 23 . The spa shell 13 has a generally rectangular rim 12 about its upper periphery and includes various features such as jets, e.g. 25 , 27 , a filter compartment 29 and a remote control 31 . As may be seen, the lower edges 33 of the side panels 15 , 17 do not extend to the bottom edges 35 of the corner pieces 19 , 21 , 23 but rather terminate at a distance “d” ( FIG. 2 ) above the slab, deck, ground or other surface 30 on which the spa rests, such distance “d” being, for example, 6 inches in one embodiment. In the illustrative embodiment, the corner pieces, e.g., 19 , 21 , 23 , are slightly spaced above, and do not contact, the surface 30 . Additionally, as shown in FIGS. 30 and 31 , the side panels 15 , 17 are trapezoidal in shape in one illustrative embodiment.
[0041] The spa 11 further includes a base pan 39 shown in FIGS. 2, 4, and 5 . As may be seen, the lower peripheral side surfaces 37 of the base pan 39 are recessed inwardly or swept back from the side panel edges 33 to provide a pedestal effect, giving the appearance that the spa 11 contacts the floor 35 only at its four corners and at the recessed edge 36 of the base pan 39 . The spa base pan 39 itself has four corners 40 , each of which lies within and is concealed by a respective corner fascia piece, e.g. 19 , 21 , 23 . As seen in FIG. 4 , the bottom of the base pan 39 further includes a grid work of rectangular areas 41 which include recessed fins or “thermal separators” 43 . The grid work is defined by perpendicularly disposed ribs 45 , 47 , whose flat bottom surfaces also rest on the surface 30 . The rib and thermal separator structure on the bottom of the base pan 39 minimizes the surface area of the base pan 39 which is in contact with the surface 30 and, hence, reduces heat transfer from the spa 11 to the surface 30 . In one embodiment, a wavelike shape is imparted to the ribs, assisting in the minimizing the contact area.
[0042] As shown in FIGS. 2 and 3 , in order to support the spa shell 13 , vertical support members 51 are provided to which are attached angled force transfer members 53 , for example, by gluing, snap-fitting, or other fastening mechanism. FIG. 6 particularly shows the inter-fitting relationship of the base pan side surface 37 and the force transfer members 53 according to an illustrative embodiment. As may be seen, the side surface 37 has an inner horizontally disposed top step 42 and a horizontally disposed lower step 44 . The angled force transfer member 53 includes a stepped edge 46 shaped to mate with the step 42 . The stepped edge 46 forms into an angled surface 48 , which rests on the swept back surface 37 . The angled surface 48 continues into a second step 43 , which mates with the lower step 44 . A slot or channel 50 is further formed in the base pan 39 and snugly receives a foot portion 34 of the angled force transfer member 53 . Mating surfaces of the base pan surface 37 and the force transfer member 53 may be glued, snap-fitted, or otherwise fastened together in position in various embodiments.
[0043] In one embodiment, the vertical support member 51 and the angled force transfer member 53 may be fabricated of extruded ABS plastic and injection molded ABS plastic, respectively. The base pan 39 may be a thermoformed ABS plastic sheet. Other materials and fabrication techniques may of course be used in other embodiments.
[0044] In one embodiment, the force transfer member 53 may be a two piece component comprising respective halves 131 , 133 , as shown in FIGS. 7 to 15 . The halves 131 , 133 , are mated together utilizing two tabs 141 , 143 , formed on the first half 131 and two tabs 150 , 151 formed on the second half 133 . These tabs 141 , 143 ; 150 , 151 may be seen in FIGS. 11 and 10 , respectively.
[0045] As further shown in FIG. 10 , the interior 137 of the first half 131 may have height markers, e.g. “ 29 ”, “ 33 ”, “ 36 ”, “ 38 ” molded or formed therein or applied thereto and located adjacent respective slots 139 a, 139 b, 139 c, and 139 d to indicate the particular spa rim height which can be accommodated by utilizing a particular slot. In operation, the two tabs 150 , 151 on half 133 (e.g. FIG. 10 ) slide into one of the four groove pairs 135 a, 134 a; 135 b, 134 b; 135 c, 134 c ; 135 d, 134 d, of the respective outer side surfaces of the first half 131 to select a particular height, while the tabs 141 , 143 enter into a pair of holes or apertures 147 , 149 ( FIG. 9 ) of the second half 133 . Thus, the first half 131 can be telescoped between positions - 38 -, - 36 -, - 33 -, - 28 - to increase or decrease the length of the angled force transfer member 53 and can be locked in position by the tabs 150 , 151 , as further described below.
[0046] The manner in which the first and second halves 131 , 133 are attached together is further illustrated in FIG. 7 . As may be seen, the tab 150 is riding in the second groove 135 c. The tab 151 is also riding in a generally parallel groove 134 c on the opposite side of the first half 131 . At the same time, the tabs 141 , 143 of the first half are passing through grooves 139 b, 140 b ( FIG. 10 ) of the second half 133 , thereby selecting the height of -33- inches. When the tabs 150 , 151 , reach the end of the respective grooves 135 c, 134 c, they snap down over the side surface 136 of the component 131 , e.g., as shown in FIG. 12 , to hold the respective halves 131 , 133 together. At the same time, the tabs 141 , 143 enter a pair of the slots 147 , 149 , as illustrated in FIG. 12 , to further hold the assembly together. It may be noted that FIGS. 12 and 13 illustrate the -28- inch assembly position, whereas the assembly shown in FIG. 7 would result in tabs 150 , 151 being positioned one groove up ( 135 c, 134 c ) and the tabs 141 , 143 being positioned one slot down from the positions shown in FIGS. 12 and 13 .
[0047] As shown in FIGS. 10 and 11 , for example, the first half 131 has a tongue 171 and a cavity 174 formed in its interior, and the second half 133 has a cavity 172 and a tongue 173 formed in its interior. When the first and second halves 131 , 133 are mated together, the tongue 171 on the interior of the first half 131 fits into the cavity 172 in the second half 133 , while the tongue 173 of the second half 133 fits into the cavity 174 formed in the first half 131 . The first half 131 further has an open or “cut-out” area 162 of rectangular cross-section formed therein ( FIG. 7 ). In one embodiment, the area 162 has a shape identical to that of area 161 ( FIG. 9 ). Additional open or hollow areas, e.g., 164 and area 165 ( FIG. 8 ), are formed in the components 131 , 133 to capture foam sprayed into the interior of the spa shell to thereby create a rigid foam/plastic structure.
[0048] As shown in FIG. 8 , the illustrative angle force transfer member 53 has an upper receptacle of generally rectangular cross-section formed as a part thereof having a rectangular rim 47 and a hollow interior 143 . First and second u-shaped projections 201 , 202 are formed in the hollow interior 143 . In one embodiment, the lower end of a vertical support member 51 is configured to snugly mate or snap fit with the structure of the receptacle 141 .
[0049] The illustrative embodiment is further constructed such that each side panel 33 may be slid into position and retained in place without abutting or being attached to the corner pieces 19 , 21 , 23 or other spa structure. For this purpose, corner piece groove structures 65 are provided as shown in FIGS. 16 and 17 , and three panel clips 69 are positioned along a lower surface 72 of the base pan 39 , as shown in FIG. 18 . While three panel clips 69 are shown in FIG. 18 , the number of clips could be one, two, or more in various embodiments.
[0050] FIG. 16 illustrates attachment of one of the tapered corner pieces 19 to respective vertical support members 51 using a number of “U”-shaped brackets 105 . A first leg of each bracket 105 attaches to the support member 51 and a second leg attaches to the corner piece 19 . The length “L” of the first leg of each bracket 105 increases as the edge 107 of the corner piece 19 tapers away downwardly. In one embodiment, the angle θ ( FIG. 17 ) between the corner piece's tapered edge 107 and the vertical is an acute angle, for example, such as six or seven degrees. The increasing bracket length effectively defines a gap or groove 65 between the brackets 105 and the corner piece 19 which lies along the dashed line 109 , effectively paralleling the tapered outside edge 107 . In the illustrative embodiment, the same type of groove 65 is formed by U-shaped brackets 105 associated with each of the other three corner pieces, e.g., 21 , 23 .
[0051] The structure and operation of the panel clips 69 is further illustrated in FIGS. 19-27 . Each panel clip 69 includes a pivot component 73 ( FIGS. 23, 24 ) and a latch component 75 ( FIGS. 21, 22 ). The latch component 75 has a hook-shaped back 79 , which is unitarily formed with a front portion 80 having first and second lips 81 , 83 , whose inner surfaces define a channel 85 . The hook-shaped back 79 includes a slot 87 and an elongated opening 89 .
[0052] As shown in FIGS. 23 and 24 , the pivot component 73 has an arcuate back surface 78 from which project two bosses 120 through which are formed respective holes 77 . As illustrated in FIGS. 28 and 29 , respective screws or other fasteners 82 are inserted through the holes and into a side surface 72 of the molded base pan 39 . The bosses 120 cause the arcuate back surface 78 to be spaced apart from the side surface 72 such that the hook shaped back 79 of the pivot component 73 can be slid into the latch component 75 . Thereafter, the latch component 75 may be pivoted from the open position shown in FIG. 19 to the locked position shown in FIGS. 20, 28 , and 29 in which the channel 85 is oriented vertically so as to retain and prevent downward movement of the bottom edge of a panel 33 while allowing the panel 33 to move laterally.
[0053] FIGS. 25-27 illustrate the operation of the panel clips 69 in more detail. FIG. 25 is a back view of the clip 69 in the locked position of, e.g., FIGS. 20 and 28 . In this position, the right boss 120 of the pivot component 73 extends through the opening 89 , and the left boss 120 extends through the slot 87 . Hence, the latch component 75 cannot pivot due to the abutment of the bosses 120 with the respective adjacent surfaces of the opening 89 and the slot 87 . In this position, in an illustrative embodiment, the screws 82 have further been tightened down to hold the components 73 , 75 in the locked position.
[0054] FIG. 26 is also a back view of the clip 69 , but in this case, the screws 82 have been unloosened slightly, and the latch component 75 has been moved to the right such that the left boss 120 has moved out of the slot 87 , and the right boss 120 has moved into position over a cut-out area 123 formed in the latch component 75 . In such position, the latch component 75 is free to pivot with respect to the pivot component 73 .
[0055] FIG. 27 is a top view of the clip 69 after the pivot component 75 has been pivoted to the unlocked position of FIG. 19 . In this position, the right boss 120 has pivoted into the cut out area 123 of the latch component 75 , and the left boss 120 lies adjacent an outer leg 124 of the latch component 75 .
[0056] The structure thus far described facilitates a side panel mounting method illustrated in FIGS. 30 and 31 . As shown in FIG. 30 , the spa 11 is positioned or raised off the mounting surface 30 . A trapezoidal side panel 33 is then inserted upwardly such that its upper corners and its sides slide into the grooves 65 defined by brackets 105 and the corner pieces 19 , 21 . The panel 33 is then slid further upwardly until its top edge 102 passes behind the rim 12 . At that point, the panel clips 69 are each moved into the locked position shown in FIGS. 20, 28, and 29 and the screws 82 are tightened to locking position.
[0057] The just-described side panel mounting method has the advantage that the side panels 33 are not rigidly attached to the corner pieces e.g. 15 , 17 , 19 or other structure, and therefore the panels 33 may expand and contract with temperature variations without the exertion of forces which would distort or otherwise damage the panels 33 if they were not free to expand or contract vertically or horizontally. This method has particular advantages in certain embodiments where the corner pieces, e.g., 17 , are made of plastic and the side panels 33 are constructed of wood or of a plastic which has a coefficient of expansion which is different than that of the corner piece plastic. In such embodiments, the side panels 33 may expand or contract as much as half-inch in very hot or cold conditions, which would likely damage the spa structure, for example, by warping or cracking the panels 33 .
[0058] Those skilled in the art will appreciate that various 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. | Spa side panels are trapezoidally-shaped and mounted in respective grooves defined by adjacent tapered corner pieces and their mounting brackets to accommodate differences in coefficients of expansion of the respective parts and prevent structural damage. Angled force transfer members are configured to mate with swept back side surfaces of a spa base pan to achieve a pedestal appearance, and the bottom surface of the base pan is constructed to reduce heat transfer to the spa support surface. | 0 |
BACKGROUND/SUMMARY
Performance of an engine can be enhanced via a turbocharger or a supercharger. The turbocharger or supercharger pressurizes ambient air to increase the density of air entering engine cylinders. The cylinder trapped air amount is increased as the cylinder charge may be denser than that of a non-turbocharged engine. This may allow increased amount of fuel injected to be into the engine cylinder compared to a non-turbocharged engine, hence result in increased torque.
Further performance gains and emissions reduction may be provided for a turbocharged engine via variable intake and/or exhaust valve timing. In particular, intake and exhaust valves of a turbocharged engine may be adjusted to reduce NOx formation, increase engine power, and reduce engine pumping losses. In some examples, intake and exhaust valves of a cylinder may be open at the same time to provide internal (e.g., within a cylinder) exhaust gas recirculation (EGR) or to help evacuate exhaust from a cylinder and increase engine output.
For example, internal EGR may be provided in an engine cylinder when intake and exhaust valves are simultaneously open and when engine intake manifold pressure is lower than engine exhaust manifold pressure. On the other hand, engine output power may be increased when intake and exhaust valves of a cylinder are simultaneously open and when engine intake manifold pressure is higher than engine exhaust manifold pressure. Pressurized air in the engine intake manifold can drive exhaust gases from the cylinder to the engine exhaust manifold so that cylinder fresh charge (e.g. air and fuel) may be increased. However, if engine control parameters (e.g., spark timing) are adjusted based on an uncorrected air amount or a bulk air amount that passes through a cylinder, the engine control parameters may be adjusted in an undesirable way. Further, the output of modeled systems (e.g., exhaust systems) that rely on cylinder trapped air amount may not track actual system conditions as close as is desired because of errors that may result from the uncorrected cylinder trapped air amount or the bulk air amount.
The inventors herein have recognized the above-mentioned disadvantages and have developed a method for operating an engine, comprising: adjusting a first actuator in response to an cylinder scavenging air amount, the cylinder scavenging air amount corrected via an oxygen sensor; and adjusting a second actuator in response to a cylinder trapped air amount, the cylinder trapped air amount corrected via the oxygen sensor apart from the cylinder scavenging air amount.
By correcting both cylinder trapped air amount and cylinder scavenging air amount via an oxygen sensor, it may be possible to improve control adjustments that are related to total cylinder air flow. Additionally, conditions that may affect cylinder trapped air amount but may not be sensed via a mass air sensor or MAP sensor may be compensated when cylinder trapped air amount and cylinder scavenging are adjusted via an oxygen sensor. For example, rather than adjusting spark timing based on a total or bulk air mass passing through a cylinder during a cylinder cycle, spark timing may be adjusted based on a corrected cylinder trapped air amount that reflects the amount of air participating in combustion. Further, intake and exhaust valve opening overlap of a cylinder may be adjusted in response to a corrected cylinder scavenging air amount. In this way, fractions or portions of an air amount flowing through a cylinder during a cylinder cycle that participate in combustion during a cylinder cycle can be corrected and compensated for separately. In addition, correcting cylinder trapped air amount and cylinder scavenging air amount via an oxygen sensor can remove sensitivities to changes in exhaust system manifold pressure and valve timing that may exist when cylinder trapped air amount and cylinder scavenging air amount are determined solely using a mass air flow sensor or a MAP sensor.
The present description may provide several advantages. In particular, the approach may reduce vehicle emissions by correcting cylinder trapped air amount and cylinder scavenging air amounts. Further, an engine actuator such as a camshaft phase actuator may be adjusted so as to control the amount of scavenging supplied to the exhaust gas after treatment device so that scavenging may closed-loop controlled. Additionally, the method provides for adjusting exhaust manifold pressure estimates so that exhaust gas residuals in a cylinder may be more accurately determined.
The above advantages and other advantages, and features of the present description will be readily apparent from the following Detailed Description when taken alone or in connection with the accompanying drawings.
It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a schematic depiction of an engine;
FIG. 2 shows a simulated intake MAP versus cylinder trapped air amount relationship for an engine operating at a constant speed;
FIG. 3 shows a simulated intake MAP versus indicated mean effective pressure (IMEP) relationship for an engine operating at a constant speed;
FIG. 4 shows a simulated exhaust MAP versus exhaust flow relationship;
FIG. 5 shows a control block diagram for correcting cylinder trapped air amount and cylinder scavenging with an oxygen sensor; and
FIG. 6 shows high level flowchart of a method for correcting cylinder trapped air amount and cylinder scavenging with an oxygen sensor.
DETAILED DESCRIPTION
The present description is directed to correcting cylinder trapped air amount and cylinder scavenging of a cylinder of an engine. The corrected cylinder trapped air amount and cylinder scavenging air amount may be used to adjust states of engine actuators. FIG. 1 shows one example system for determining and correcting cylinder trapped air amount and cylinder scavenging air amount. The system includes a turbocharger operated with a spark ignited mixture of air and gasoline, alcohol, or a mixture of gasoline and alcohol. However, in other examples the engine may be a compression ignition engine, such as a diesel engine. FIGS. 2 and 3 show how a change in engine backpressure can affect a MAP versus cylinder trapped air amount/IMEP relationship. FIG. 4 shows how a position of a turbocharger waste gate or vane can affect engine back pressure. FIG. 5 shows a block diagram for correcting cylinder trapped air amount and cylinder scavenging. FIG. 6 shows an example method for correcting cylinder trapped air amount and cylinder scavenging air amount.
Referring to FIG. 1 , internal combustion engine 10 , comprising a plurality of cylinders, one cylinder of which is shown in FIG. 1 , is controlled by electronic engine controller 12 . Engine 10 includes combustion chamber 30 and cylinder walls 32 with piston 36 positioned therein and connected to crankshaft 40 . Combustion chamber 30 is shown communicating with intake manifold 44 and exhaust manifold 48 via respective intake valve 52 and exhaust valve 54 . Each intake and exhaust valve may be operated by an intake cam 51 and an exhaust cam 53 . Alternatively, one or more of the intake and exhaust valves may be operated by an electromechanically controlled valve coil and armature assembly. The phase of intake cam 51 and exhaust cam 53 may be adjusted via cam phase actuators 59 and 69 . The position of intake cam 51 may be determined by intake cam sensor 55 . The position of exhaust cam 53 may be determined by exhaust cam sensor 57 .
Fuel injector 66 is shown positioned to inject fuel directly into cylinder 30 , which is known to those skilled in the art as direct injection. Alternatively, fuel may be injected to an intake port, which is known to those skilled in the art as port injection. Fuel injector 66 delivers liquid fuel in proportion to the pulse width of signal FPW from controller 12 . Fuel is delivered to fuel injector 66 by a fuel system (not shown) including a fuel tank, fuel pump, and fuel rail (not shown). Fuel injector 66 is supplied operating current from driver 68 which responds to controller 12 . In addition, intake manifold 44 is shown communicating with optional electronic throttle 62 which adjusts a position of throttle plate 64 to control air flow from intake boost chamber 46 .
Exhaust gases spin turbocharger turbine 164 which is coupled to turbocharger compressor 162 via shaft 161 . Compressor 162 draws air from air intake 42 to supply boost chamber 46 . Thus, air pressure in intake manifold 44 may be elevated to a pressure greater than atmospheric pressure. Consequently, engine 10 may output more power than a normally aspirated engine.
Distributorless ignition system 88 provides an ignition spark to combustion chamber 30 via spark plug 92 in response to controller 12 . Ignition system 88 may provide a single or multiple sparks to each cylinder during each cylinder cycle. Further, the timing of spark provided via ignition system 88 may be advanced or retarded relative to crankshaft timing in response to engine operating conditions.
Universal Exhaust Gas Oxygen (UEGO) sensor 126 is shown coupled to exhaust manifold 48 upstream of exhaust gas after treatment device 70 . Alternatively, a two-state exhaust gas oxygen sensor may be substituted for UEGO sensor 126 . In some examples, exhaust gas after treatment device 70 is a particulate filter and/or a three-way catalyst. In other examples, exhaust gas after treatment device 70 is solely a three-way catalyst.
Controller 12 is shown in FIG. 1 as a conventional microcomputer including: microprocessor unit 102 , input/output ports 104 , read-only memory 106 , random access memory 108 , keep alive memory 110 , and a conventional data bus. Controller 12 is shown receiving various signals from sensors coupled to engine 10 , in addition to those signals previously discussed, including: engine coolant temperature (ECT) from temperature sensor 112 coupled to cooling sleeve 114 ; a position sensor 134 coupled to an accelerator pedal 130 for sensing accelerator position adjusted by foot 132 ; a knock sensor for determining ignition of end gases (not shown); a measurement of engine manifold pressure (MAP) from pressure sensor 121 coupled to intake manifold 44 ; a measurement of boost pressure from pressure sensor 122 coupled to boost chamber 46 ; an engine position sensor from a Hall effect sensor 118 sensing crankshaft 40 position; a measurement of air mass entering the engine from sensor 120 (e.g., a hot wire air flow meter); and a measurement of throttle position from sensor 58 . Barometric pressure may also be sensed (sensor not shown) for processing by controller 12 . In a preferred aspect of the present description, engine position sensor 118 produces a predetermined number of equally spaced pulses every revolution of the crankshaft from which engine speed (RPM) can be determined.
In some examples, the engine may be coupled to an electric motor/battery system in a hybrid vehicle. The hybrid vehicle may have a parallel configuration, series configuration, or variation or combinations thereof. Further, in some embodiments, other engine configurations may be employed, for example a diesel engine.
During operation, each cylinder within engine 10 typically undergoes a four stroke cycle: the cycle includes the intake stroke, compression stroke, expansion stroke, and exhaust stroke. During the intake stroke, generally, the exhaust valve 54 closes and intake valve 52 opens. Air is introduced into combustion chamber 30 via intake manifold 44 , and piston 36 moves to the bottom of the cylinder so as to increase the volume within combustion chamber 30 . The position at which piston 36 is near the bottom of the cylinder and at the end of its stroke (e.g. when combustion chamber 30 is at its largest volume) is typically referred to by those of skill in the art as bottom dead center (BDC). During the compression stroke, intake valve 52 and exhaust valve 54 are closed. Piston 36 moves toward the cylinder head so as to compress the air within combustion chamber 30 . The point at which piston 36 is at the end of its stroke and closest to the cylinder head (e.g. when combustion chamber 30 is at its smallest volume) is typically referred to by those of skill in the art as top dead center (TDC). In a process hereinafter referred to as injection, fuel is introduced into the combustion chamber. In a process hereinafter referred to as ignition, the injected fuel is ignited by known ignition means such as spark plug 92 , resulting in combustion. During the expansion stroke, the expanding gases push piston 36 back to BDC. Crankshaft 40 converts piston movement into a rotational torque of the rotary shaft. Finally, during the exhaust stroke, the exhaust valve 54 opens to release the combusted air-fuel mixture to exhaust manifold 48 and the piston returns to TDC. Note that the above is described merely as an example, and that intake and exhaust valve opening and/or closing timings may vary, such as to provide positive or negative valve overlap, late intake valve closing, or various other examples.
Thus, the system of FIG. 1 provides for a engine operating system, comprising: an engine; an actuator in communication with the engine; a turbocharger coupled to the engine; an exhaust system coupled to the turbocharger, the exhaust system including an oxygen sensor; a controller including instructions for adjusting a total cylinder air amount in response to an output of the oxygen sensor, the controller including additional instructions for providing a corrected cylinder trapped air amount and a corrected cylinder scavenging air amount based on the total cylinder air amount. The engine operating system further comprises additional instructions for adjusting spark timing of a cylinder in response to the corrected cylinder trapped air amount.
In some examples, the engine operating system further comprises additional instructions for adjusting valve timing in response to the corrected cylinder scavenging air amount. The engine operating system further comprises including additional instructions to provide an equivalence ratio correction amount based on the output of the oxygen sensor. The engine operating system further comprises including additional instructions to adjust an estimated exhaust flow. The engine operating system includes where the engine includes two cylinder banks, where the total cylinder air amount applies to a cylinder of a first cylinder bank, where the controller includes additional instructions for adjusting a total cylinder air amount of a cylinder of a second cylinder bank, and where the controller includes additional instructions for providing a corrected cylinder trapped air amount and a corrected cylinder scavenging air amount based on the corrected total cylinder air amount of the cylinder of the second cylinder bank.
Referring now to FIG. 2 , an intake MAP versus cylinder air amount relationship for an engine operating at a constant speed is shown. The X axis represents cylinder air amount and cylinder air amount increases from the left side of the plot to the right side of the plot. The Y axis represents intake MAP and MAP increases from the X axis in the direction of the Y axis arrow. Cylinder air amount represents a total amount of air passing through a cylinder during a cycle of the cylinder. Consequently, when the engine is operating without scavenging air, the cylinder trapped air amount equals the total cylinder air. Thus, the total cylinder air amount participates in combustion within the cylinder. The total cylinder air amount during scavenging conditions includes a cylinder trapped air amount that participates in combustion and a cylinder scavenging air amount that does not participate in combustion within the cylinder.
Curve 202 represents intake MAP versus total cylinder air amount when a turbocharger waste gate is in a first position. It can be seen that total cylinder air amount increases with increasing MAP. In the first position, the waste gate position is fully closed.
Curve 204 represents intake MAP versus total cylinder air amount when a turbocharger waste gate is in a second position. Curve 204 initially follows the same trajectory of curve 202 , but after cylinder air amount begins to increase, cylinder air amount of curve 204 increases at a higher rate for an equivalent MAP increase as compared to curve 202 . In the second position, the waste gate position is fully opened. Arrow 206 shows one region of the MAP versus cylinder air amount plot where there is a 16% of mean difference in total amount of air passing through the cylinder between curve 202 and curve 204 . Thus, a 16% error in engine air-fuel ratio may result if the total cylinder air amount is not corrected when the engine is operating at the MAP level of arrow 206 .
Thus, from curves 202 and 204 , it can be seen that exhaust manifold pressure can affect an estimate of cylinder air amount that is based on MAP. Further, exhaust manifold pressure can affect an estimate of MAP that is based on cylinder air amount as determined via a mass air flow sensor in an engine intake system. Therefore, it may be desirable to correct air flowing through a cylinder for engine exhaust manifold pressure. However, the inaccuracies in cylinder trapped air amount that are related to exhaust backpressure may not be apparent by simply monitoring MAP or mass air flow (MAF). On the other hand, an exhaust gas oxygen sensor can detect the presence or absence of excess oxygen in engine exhaust gases. And, the presence or absence of excess oxygen in engine exhaust gases may be indicative of a change in engine backpressure that results in an increase or a decrease of engine scavenging. Thus, an output of an oxygen sensor may be a basis for correcting an amount of air passing through a cylinder.
Referring now to FIG. 3 , an IMEP versus cylinder trapped air amount relationship for an engine operating at a constant speed is shown. The X axis represents cylinder IMEP and cylinder IMEP increases from the left side of the plot to the right side of the plot. The Y axis represents intake MAP and MAP increases from the X axis in the direction of the Y axis arrow. IMEP may be correlated to the amount of air in a cylinder that participates in combustion within a cylinder. The relationship between cylinder trapped air and IMEP is near linear and may be expressed in an equation as a slope and an offset.
Curve 302 represents intake MAP versus cylinder IMEP when a turbocharger waste gate is in a first position. It can be seen that cylinder IMEP increases with increasing MAP; however, IMEP does not continue to increase when scavenging is present. In the first position, the waste gate position is fully closed.
Curve 304 represents intake MAP versus cylinder IMEP when a turbocharger waste gate is in a second position. Curve 304 initially follows the same trajectory of curve 302 , but in curve 304 , cylinder IMEP increases at a higher rate for an equivalent MAP increase as compared to curve 302 . In the second position, the waste gate position is fully opened.
Arrow 306 shows one region of the MAP versus cylinder IMEP plot where there is a 12% of mean difference in cylinder IMEP between curves 302 and curve 304 . Thus, a 12% error in engine torque estimate may be provided if the cylinder trapped air amount is not corrected when the engine is operating at the MAP level of arrow 306 .
Thus, curves 302 and 304 , confirm that an amount of air that participates in combustion in a cylinder (e.g., cylinder trapped air amount) may be affected by change in engine exhaust manifold absolute pressure (exhaust MAP). Therefore, it may be desirable to correct cylinder trapped air amount as determined from a MAP or MAF sensor.
Referring now to FIG. 4 , a plot of exhaust MAP versus exhaust flow, which equals the sum of total cylinder airflow and fuel injected, is shown. It may be desirable to accurately model exhaust MAP so that burned gas dilution (e.g., EGR) within a cylinder may be accurately determined. Further, in some examples, an accurate estimate of dilution may be desirable to control the position of a turbocharger waste gate so that a desired engine air flow may be provided to the engine while engine exhaust pressure is controlled to less than a threshold amount. In this way, engine efficiency may be maintained.
Curve 402 represents data of exhaust MAP versus exhaust flow. Curve 404 represents a curve regressed from the data of curve 402 . Thus, the data of curve 402 may be represented by curve 404 so that the exhaust MAP versus exhaust flow may be represented in a simplified form. Curves 402 and 404 represent exhaust MAP versus exhaust flow when a turbocharger waste gate is fully closed.
Curve 406 represents data of exhaust MAP versus exhaust flow. Curve 408 represents a curve regressed from the data of curve 406 . Thus, the data of curve 406 may be represented by curve 408 so that the exhaust MAP versus exhaust flow may be represented in a simplified form. Curves 406 and 408 represent exhaust MAP versus exhaust flow when a turbocharger waste gate is fully opened.
Thus, it can be seen from FIG. 4 that exhaust back pressure may be significantly increased during some engine operating conditions. In some examples, curves 404 and 408 may be boundaries for determining limits to exhaust pressure adaptation.
Referring now to FIG. 5 , a control block diagram for correcting cylinder trapped air amount and cylinder scavenging air amount via an oxygen sensor is shown. Instructions to correct cylinder trapped air amount and cylinder scavenging air according to the block diagram of FIG. 5 may be executed by controller 12 in the system shown in FIG. 1 .
At 502 , the controller shown in block diagram 500 multiplies total cylinder air flow (e.g., the total amount of air flowing through a cylinder during a cycle of the cylinder) by one over a stoichiometric air-fuel ratio (e.g., 14.64 for gasoline) of the fuel being combusted by the engine.
At 504 , the output of 502 is multiplied by desired equivalence ratio φ to provide an open-loop fuel amount fuel_ol. Equivalence ratio is defined as the mixture's fuel to air ratio (by mass) divided by the fuel to air ratio for a stoichiometric mixture. A stoichiometric mixture has an equivalence ratio of 1.0; lean mixtures have a value of less than 1.0; and, rich mixtures are value greater than 1.0.
At 508 , total cylinder air flow and engine speed are used to index tables that output empirically determined fuel modulation values for improving catalyst efficiency. For example, if an engine is operating at 1500 RPM with a cylinder air flow of 2.0×10 −3 lb-mass it may be determined that it is desirable to oscillate air-fuel ratio of a cylinder by 0.3 air-fuel ratio (about 2%) at a frequency of 0.5 Hz. The output of 508 provides fuel adjustments to oscillate engine air-fuel ratio at the given total cylinder air amount. The output of 508 is added to the output of 504 at 506 .
The closed-loop portion of controller block diagram 500 includes summing junction 514 where actual φ as measure by UEGO sensor 126 is subtracted from desired φ to provide a term φ trim . Desired φ may be empirically determined and stored in memory that may be indexed using engine speed and load. The closed-loop portion of controller 500 is also shown with proportional and integral adjustments at block 516 that are based φ trim .
The proportional and integral adjustments from block 516 , fuel_trim, and the sum of the open-loop fuel amount fuel_ol from 504 and the catalyst modulation fuel from 508 are added together at 510 to determine an amount of fuel to be provided to an engine cylinder based on a total cylinder air flowing through a cylinder during a cylinder cycle.
At 518 , the amount of fuel to be provided to an engine cylinder is converted to a fuel injector pulse width for driving a fuel injector. In one example, a fuel injector transfer function that relates fuel amount to fuel pulse width is stored in memory and indexed by fuel amount. The transfer function is indexed by fuel amount and the fuel pulse width is delivered to a fuel injector supplying fuel to a cylinder of the engine 10 . The engine expels combustion byproducts which are sampled by UEGO 126 to determine whether or not a desired amount of fuel is matched to the total amount of air determined to be flowing through a cylinder. Note that the total amount of air flowing through the cylinder may be determined via a MAP sensor or a MAF sensor.
At 522 , controller 500 judges whether or not the engine is operating at a condition for scavenging. In one example, selected engine operating conditions are logically combined to determine if scavenging is present. As an example, scavenging may be determined via the logic:
if ((RPM>1000) AND (RPM<2500)) AND (MAP>0.9·BP) AND (overlap>30)blow_through_region=TRUE;
else
blow_through_region=FALSE;
where RPM is engine speed, BP is barometric pressure, overlap is a number of crankshaft degrees where intake and exhaust valves of a cylinder are simultaneously open, and blow_through_region is a logical variable that reflects scavenging is present when asserted. The scavenging logical variable selects whether cylinder trapped air amount and cylinder scavenging air amount are corrected and output at 530 .
At 524 , the total cylinder air flow is corrected based on output of an oxygen sensor. In one example, the cylinder air flow is corrected via the equations below:
air_phi _ratio = ϕ trim ϕ dsd - min { max { ϕ trim ϕ dsd , - q } , q } air_phi _corr _tmp = min { max { air_phi _ratio , phi_ratio _max } , phi_ratio _min } air_phi _corr = rolav ( tc_corr , air_phi _corr _tmp ) air_tot _corr = air_chg _tot * ( 1 + air_phi _corr )
where q is a calibratable value fuel-air ratio adjustment boundary limit (e.g., 0.03 or 3%), where air_phi_ratio is a bounded φ adjustment ratio, where φ dsd is the desired fuel-air ratio,
ϕ dsd = { 1 stoich exhaust air_chg / air_chg _tot stoich in - cylinder , lean exhaust ,
and where φ trim is the closed loop fuel-air ratio trim (the ratio of fuel_trim signal, the output of 516 , and total cylinder air charge), where air_phi_ratio_max is a maximum φ ratio correction, where air_phi_ratio_min is a minimum φ ratio correction, where air_phi_cor_tmp is a temporary variable for correcting total cylinder air flow, where rolav is a first order low pass filter having a time constant tc_corr, where air_phi_corr is the amount to correct total cylinder air flow, where air_chg_tot is a total amount of air flowing through a cylinder during a cylinder cycle, and where air_tot_corr is the corrected total cylinder air flow. The total corrected cylinder air flow is directed to 530 , 526 and 528 .
At 526 , the cylinder trapped air amount correction is determined. In one example, the cylinder trapped air amount correction is determined according to the following equation:
air_chg_corr=min{air_tot_corr, air — c· (1 −r _pb)·MAP}
where air_c is volumetric efficiency for full cylinder volume at the bottom dead center of the intake stroke, r_pb is a push-back ratio that account for exhaust entering the engine intake manifold from the cylinder.
At 528 , the cylinder scavenging air amount correction is determined. In one example, the cylinder scavenging air amount correction is determined according to the following equation:
air_bt_corr=max{0, air_tot_corr−air — c· (1 −r _pb)·MAP}
or
air_bt_corr=air_tot_corr−air_chg_corr
The corrected cylinder trapped air amount and the corrected cylinder scavenging air amount are supplied to block 530 where corrected cylinder trapped air amount and corrected cylinder scavenging air amount are selectively output based on the state of variable blow_through_region. In particular, if the variable blow_through_region is asserted, then both corrected cylinder trapped air amount air_chg_corr and corrected cylinder scavenging air amount air_bt_corr are output for adjusting cylinder spark advance, engine torque amount, and exhaust temperature. If the variable blow_through_region is not asserted, then (un-corrected) cylinder trapped air amount air_chg is output and corrected cylinder scavenging air amount air_bt_corr is set to zero.
At 532 , cylinder spark timing is adjusted in response to the corrected cylinder trapped air amount. In one example, the cylinder spark timing is empirically determined and stored in memory that is indexed via engine speed and cylinder trapped air amount. The table outputs the desired spark timing and the spark is delivered to the engine via an ignition coil.
The corrected cylinder trapped air amount may also be the basis for determining engine torque at 534 . In one example, engine torque may be empirically determined and stored in a table or function that is indexed via engine speed, spark timing, and cylinder trapped air amount. The table outputs the engine torque based on empirical values stored in the table. In some examples, the tables may further include engine torque values that are adjusted according to valve timing. In other examples, engine torque may be determined according to the method described in U.S. Pat. No. 7,072,758 which is hereby fully incorporate by reference for all intents and purposes.
At 536 , the corrected cylinder trapped air amount and the corrected cylinder scavenging air amount may be input to a model to determine exhaust exotherm temperature. In one example, the exhaust exotherm is determined according to the method described in U.S. patent application Ser. No. 12/481,468 which is hereby fully incorporated by reference for all intents and purposes.
Thus, the controller of FIG. 5 provides for adjusting fuel injection amount and fuel injection timing based on oxygen sensor feedback. FIG. 5 also provides for correcting cylinder trapped air amount and cylinder scavenging air amount based the oxygen sensor output.
Referring now to FIG. 6 , a high level flowchart of a method for correcting cylinder trapped air amount and cylinder scavenging air amount with an oxygen sensor is shown. The method of FIG. 6 may be executed via instructions of controller 12 in the system shown in FIG. 1 .
At 602 , method 600 determines engine operating conditions. Engine operating conditions may include but are not limited to engine speed, engine temperature, ambient temperature, MAP, cylinder air amount, exhaust gas oxygen concentration, valve timing, and engine torque requested. Method 600 proceeds 604 after engine operating conditions are determined.
At 604 , method 600 computes corrected amount of fuel injected to an engine in response to oxygen sensor output. The oxygen sensor may be positioned in an exhaust system as shown in FIG. 1 .
An amount of fuel injected to a cylinder may be comprised of two or more fuel injection amounts. In one example, the fuel injected to a cylinder may be expressed as:
fuel_cyl = fuel_ol + fuel_trim fuel_ol = ϕ dsd * air_chg _tot AF_stoic ( ϕ dsd = 1 stoich exhaust ϕ dsd = air_chg / air_chg _tot stoich in - cyl . , lean exhaust ) fuel_trim = ϕ trim * air_chg _tot AF_stoic ( ϕ trim is the closed loop fuel - air - ratio trim )
where fuel_cyl is an estimate of the fuel delivered to a cylinder, fuel_ol is an open loop fuel amount, φ dsd is a desired equivalence ratio for engine operation based on engine speed and cylinder trapped air amount, air_chg_tot is total amount of air flowing through a cylinder during a cylinder cycle, air_chg is a cylinder trapped air amount that participates in combustion within the cylinder, AF_stoic is a stoichiometric air-fuel ratio for the fuel being combusted in the engine, fuel_trim is a closed-loop fuel amount adjustment that is based on a fuel-air ratio trim that is determined via subtracting determined from output from an oxygen sensor from a desired as described in FIG. 5 . It should be noted that the closed loop fuel system allows for trim to not respond to a square wave modulation imposed on fuel injection for catalyst efficiency. By denoting the actual total mass of air that passes by the intake valve in one event by m tot , equivalence ratio as inferred from exhaust gas oxygen content can be described as:
ϕ exh = fuel_cyl + Δ fuel m tot * AF_stoic = ( ϕ dsd + ϕ trim ) * air_chg _tot m tot + Δ fuel m tot * AF_stoic
where Δfuel is a left-over fuel mass due to inaccuracies in compensating for various other sources (e.g. incomplete transient fuel or purge flow compensation). In quasi steady state conditions, the closed loop fuel correction (fuel_trim) makes the exhaust fuel-to-air ratio φ exh =φ dsd . Solving for φ trim yields:
ϕ trim = ϕ dsd ( m tot air_chg _tot - 1 ) - Δ fuel air_chg _tot * AF_stoic
Thus, it may be observed that the closed loop correction φ trim compensates for air_chg_tot not being equal to the actual total air mass (m tot ) and for various residual errors in fuel compensation. Method 600 proceeds to 606 after the injected fuel amount compensation is determined.
At 606 , method 600 judges whether or not scavenging conditions are present. In one example, scavenging may be determined according to the logic described for block 522 of FIG. 5 . If scavenging conditions are determined, method 600 proceeds to 608 . Otherwise, method 600 proceeds to 614 .
At 608 , method 600 corrects a total amount of air flowing through a cylinder during a cylinder cycle. In one example, the total amount of air flowing through the cylinder is corrected according to the following instructions:
if ( blow_through _region = TRUE ) air_phi _ratio = ϕ trim ϕ dsd - min { max { ϕ trim ϕ dsd , - q } , q } air_phi _corr _tmp = min { max { air_phi _ratio , phi_ratio _max } , phi_ratio _min } else air_phi _corr _tmp = 0 end air_phi _corr = rolav ( tc_corr _ , air_phi _corr _tmp ) air_tot _corr = air_chg _tot * ( 1 + air_phi _corr )
where blow_through_region is a logic variable that indicates the presence or absence of scavenging conditions, where air_tot_corr is the corrected total air-charge (in-cylinder air+scavenging air), where phi_ratio_max and phi_ratio_min are clips or limits for the air-fuel ratio corrections used in total cylinder air flow correction (e.g., +/−0.15), where min and max denotes an operation of taking the minimum or maximum of the respective variables in parentheses, where rolav is a first order low-pass having a time constant tc_corr set to about 2 to 3 times the UEGO closed loop response time constant. Method 600 proceeds to 610 after the total amount of air flowing through the cylinder is corrected.
At 610 , the cylinder trapped air amount and the cylinder scavenging air amount are separately corrected based on the corrected total amount of air flowing through the cylinder. In one example, the cylinder trapped air amount and the cylinder scavenging air amount are determined according to the following equations:
air_chg_corr=min{air_tot_corr, air — c* (1 −r _pb)*MAP}
air_bt_corr=max{0,air_tot_corr−air — c* (1 −r _pb)*MAP}
where air_c is the volumetric efficiency for full cylinder volume and where r_pb is the push-back ratio. Method 600 proceeds to 612 after cylinder trapped air amount and cylinder scavenging air are corrected.
At 612 , method adjusts inferred exhaust manifold pressure. In one example, method 600 adjusts inferred exhaust manifold pressure according to the following equations:
exhmap_slope( k+ 1)=min{slope1, max{slope2,exhmap_slope( k )−ε_adapt*(air_tot_corr( k )−air_chg_tot( k ))}
where ε_adapt is a (small) adaptive gain and slope1 and slope2 are correction limits that may be set at +/−1.6 based on the slope values shown in FIG. 4 . The scavenging region entry condition described at 606 may be the basis for updating the exhaust pressure. The slope correction may be used as a basis to adjust the estimate of the exhaust manifold pressure:
air_exhmap_corr=air_exhmap+exhmap_slope*exh_mass_flow
where exh_mass_flow may be estimated based on total air flow through the engine. In one example, flow through each engine cylinder may be added together to determine engine air flow and engine exhaust flow may be set equal to engine air flow. Method 600 proceeds to 614 after engine exhaust manifold pressure is corrected.
At 614 , method 600 adjusts actuators in response to corrected cylinder trapped air amount, corrected cylinder scavenging air amount, and corrected exhaust pressure. Alternatively, when scavenging is not present, actuators are adjusted according to uncorrected cylinder trapped air amount. In one example, timing of spark delivered to an engine cylinder is determined via indexing a table or function of empirically determined spark values using engine speed and corrected cylinder trapped air amount. The table outputs spark advance timing based on the engine speed and corrected cylinder trapped air amount and spark is delivered to the cylinder at the timing output from the table.
In another example, cam phase is adjusted based on the corrected scavenging air amount. For example, if a scavenging air amount is greater than a desired scavenging air amount, a scavenging error is determined via subtracting corrected scavenging air amount from desired scavenging air amount. The phase of intake and/or exhaust cams is adjusted according to the scavenging error. In one example, when the scavenging error is negative, intake and exhaust valve overlap is reduced so that intake and exhaust valves of a cylinder are simultaneously open for a shorter period of time. In another example, intake and exhaust valve overlap is increased when the scavenging error is positive so that intake and exhaust valves of a cylinder are simultaneously open for a longer period of time.
PCV valve operation and EGR valve operation similar to the way spark timing is adjusted in response to corrected cylinder trapped air amount. For example, if corrected cylinder trapped air amount is increased to a lower value, flow from PCV and EGR valves may be reduced. Method 600 proceeds to exit after engine actuators are adjusted to corrected cylinder trapped air amount and corrected cylinder scavenging air amount.
Thus, the methods of FIGS. 5 and 6 provide for a method for operating an engine, comprising: adjusting a first actuator in response to an cylinder scavenging air amount, the cylinder scavenging air amount corrected via an oxygen sensor; and adjusting a second actuator in response to a cylinder trapped air amount, the cylinder trapped air amount corrected via the oxygen sensor apart from the cylinder scavenging air amount. In this way, cylinder trapped air amount and cylinder scavenging air amount may be separately adjusted base on a corrected total air amount flowing through a cylinder during a cycle of the cylinder.
The method also includes where the first actuator is a valve timing actuator and where the second actuator is an ignition coil providing spark to the engine. The method also includes where the first actuator and the second actuator are a same actuator. In another example, the method includes where the cylinder scavenging air amount and the cylinder trapped air amount are based on a total cylinder trapped air amount. The method further comprises determining presence of cylinder scavenging air in response to engine speed, MAP, and valve overlap. The method also includes where valve overlap is a duration when intake and exhaust valves of a cylinder are simultaneously open.
The methods of FIGS. 5 and 6 also provide for operating an engine, comprising: adjusting fuel injection timing in response to a corrected total cylinder trapped air amount flowing through a cylinder during a cycle of a cylinder; adjusting a cylinder trapped air amount based on the corrected total cylinder trapped air amount flowing through the cylinder; adjusting a cylinder scavenging air amount based on the corrected total cylinder trapped air amount flowing through the cylinder; and adjusting a first actuator in response to the cylinder trapped air amount. In some examples, the method further comprises estimating an exhaust parameter in response to the cylinder scavenging air amount. The method also includes where the exhaust parameter is an exhaust catalyst exotherm.
The method also includes where the first actuator is an ignition coil, and further comprising adjusting a second actuator in response to the cylinder scavenging air amount. The method further includes where the second actuator is a camshaft phase actuator. The method further comprises increasing intake valve and exhaust valve opening overlap to increase the cylinder scavenging air amount when the cylinder scavenging air amount is less than a desired cylinder scavenging air amount. The method also includes where the corrected total cylinder trapped air amount flowing through the cylinder is corrected via an output of an oxygen sensor.
As will be appreciated by one of ordinary skill in the art, the methods described in FIGS. 5 and 6 may represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Likewise, the order of processing is not necessarily required to achieve the objects, features, and advantages described herein, but is provided for ease of illustration and description. Although not explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending on the particular strategy being used.
This concludes the description. The reading of it by those skilled in the art would bring to mind many alterations and modifications without departing from the spirit and the scope of the description. For example, single cylinder, I2, I3, I4, I5, V6, V8, V10, V12 and V16 engines operating in natural gas, gasoline, diesel, or alternative fuel configurations could use the present description to advantage. | A method for correcting a total cylinder air flow during scavenging by way of an oxygen sensor is disclosed. Additionally, cylinder trapped air amount and cylinder scavenging air amount are adjusted based on the corrected total cylinder air flow. The approach may reduce sensitivity between cylinder air flow estimates and fuel supplied for combustion. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method for removing amorphous dithiazine from a surface.
BACKGROUND OF THE INVENTION
[0002] Hydrogen sulfide (H 2 S) and organic sulfides are found within geological formations associated with oil and gas reserves. Due to their toxicity and corrosive nature, they are generally reduced or removed from hydrocarbon streams during production in a process called “sweetening.” A common approach is to use an H 2 S scavenger, particularly triazine, which is produced by an aldehyde and an amine reaction. The H 2 S scavenger subsequently reacts with the hydrogen sulfide converting it to a more non-volatile product, which can be more easily removed from the hydrocarbon stream. Typical formulations use a low molecular weight aldehyde such as formaldehyde, but ketones can also be used. The amines can be alkylamines as disclosed in U.S. Pat. No. 5,674,377 (filed Jun. 19, 1995), alkanolamines as disclosed in U.S. Pat. No. 4,978,512 (filed Dec. 18, 1989), or even a combination of amines as disclosed in U.S. Pat. No. 6,267,938 B1 (filed Nov. 4, 1996), U.S. Pat. No. 5,347,004 (filed Oct. 9, 1992), and U.S. Pat. No. 5,554,349 (filed Sep. 8, 1994).
[0003] While amine-based H 2 S scavengers are effective at removing hydrogen sulfide from hydrocarbon streams, they are also known to form an unwanted dithiazine byproduct. This so-called amorphous dithiazine is exceptionally insoluble, and substantial quantities can deposit throughout the gas processing system. Dithiazine deposits are a significant problem to the gas processing industry. They can form blockages in gas processing equipment, storage tanks, truck tanks, and water disposal wells. Cleanup procedures are time consuming and difficult. Often, the equipment has to be taken off-line so the deposits can be manually chipped away. The industry places much effort and incurs great cost in the treatment of amorphous dithiazine buildup.
SUMMARY OF THE INVENTION
[0004] The present invention relates to a method of treatment for the problem of amorphous dithiazine buildup on a surface. It has been found that a solution of hydrogen peroxide will react and dissolve the amorphous dithiazine precipitate, allowing for easy removal.
BRIEF DESCRIPTION OF THE FIGURES
[0005] FIG. 1 depicts a glass rod covered in amorphous dithiazine.
[0006] FIG. 2 depicts the glass rod of FIG. 1 after treatment with hydrogen peroxide.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0007] Illustrative embodiments of the invention are described below as they might be employed in the operation and treatment of oilfield applications. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but may nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. Further aspects and advantages of the various embodiments of the invention will become apparent from consideration of the following description.
[0008] It is well established that the byproduct from the use of the common H 2 S scavenger 5-(2-hydroxyethyl)hexahydrotriazine (structure I) is 5-(2-hydroxyethyl)dithiazine (structure II). See, e.g., Jan M. Bakke, Janne Buhaug & Jaroslav Riha, Hydrolysis of 1,3,5,- Tris (2- hydroxyethyl ) hexahydrodithiazine and Its Reaction with H 2 S , 40 I ND . E NG . C HEM . R ES. 6051 (2001); Grahame N. Taylor & Ron Matherly, Gas Chromatographic - Mass Spectroscopic Analysis of Chemically Derivatized Hexahydrotriazine - based Hydrogen Sulfide Scavengers: Part II, 49 I ND . E NG . C HEM . R ES. 6267 (2010).
[0000]
[0009] When initially produced (II) exists in the form of a lower, dense liquid layer in the gas tower which can under certain conditions actually crystallize to form a low melting, highly crystalline solid. However, another form of this material is also very common and has been referred to as amorphous dithiazine. See Formulation For Hydrogen Sulfide Scavenging From Hydrocarbon Streams And Use Thereof, WO/2008/049188 (filed Oct. 26, 2006). It is a fine, powdery, highly insoluble solid that represents a “so-called” different physical form of the same chemical species. Recently, amorphous dithiazine has been synthesized under laboratory conditions and compared with amorphous dithiazine found in oil field operations. Grahame N. Taylor & Ron Matherly, Structural Elucidation of the Solid Byproduct from the use of 1,3,5,- Tris (2- hydroxyethyl ) hexahydro - s - triazine Based Hydrogen Sulfide Scavengers 50 I ND . E NG . C HEM . R ES. 735 (2011). X-ray diffraction analysis, elemental analysis, IR spectroscopy and NMR spectroscopy were performed on these samples and the data indicate that the amorphous dithiazine structure has repeating units of sulfur bonds. It is believed that the polymeric structures of amorphous dithiazine in idealized form are shown by structures (III) and (IV).
[0000]
[0010] Taylor and Matherly proposed that the mechanism for the polymer propagation is shown in Scheme 1. Id. at 739-740. These structures can be explained by the transient generation of the highly reactive species, thioformaldehyde, which rapidly reacts with the hydroxyl terminus of the dithiazine and builds a linking chain. Sulfur insertion occurs at some point to generate the polysulfide linkages. The terminus reacts with another dithiazine molecule by nucleophilic substitution and ring opening via protonation of the nitrogen. Once the second dithiazine molecule has been incorporated into the growing chain, further thioformaldehyde molecules are added and the process repeats. The molecular structures shown depict the average content of the side chains which have a degree of variability within the bridging portion. It is these sulfur containing side chains that give the amorphous dithiazine its amorphous structure and insoluble nature.
[0000]
[0011] It is believed that the thioformaldehyde is generated as the scavenger fluid is spent with hydrogen sulfide and the pH drops increasing the extent that (I) hydrolyzes back to formaldehyde and monoethanolamine. As soon as the formaldehyde is formed it competes with (I) in reacting with the hydrogen sulfide producing thioformaldehyde. Id. at 740.
[0012] While not wanting to be bound by any mechanism or theory, it is believed that the dissolution of amorphous dithiazine is caused by the oxidation of sulfide (S valence state 2) to the more soluble sulfoxide (S valence state 4) as shown in Scheme 2. Hydrogen peroxide is particularly effective at oxidizing the sulfur atoms of the side chains. This leads to the breaking apart and dissolution of the amorphous dithiazine precipitate.
[0000]
[0013] In a preferred embodiment of the present invention, a surface that is partially covered in amorphous dithiazine buildup is put in contact with an aqueous solution of hydrogen peroxide. The surface may be prepped by having any extraneous oxidizable material rinsed from the amorphous dithiazine coated surface. For example, any gas processing fluids may be rinsed away. The rinse may be done with water or any solvent that would effectively remove the extraneous oxidizable material. This permits the oxidizing power of hydrogen peroxide to react primarily with the amorphous dithiazine. Then, an aqueous solution of hydrogen peroxide is introduced onto the surface partially covered in amorphous dithiazine. The concentration of hydrogen peroxide may be between about 5% to about 50% by volume. The concentration may be of commercial strength of about 34% by volume; however, this solution may be concentrated or diluted upon what the user determines to be effective at removing amorphous dithiazine. Also, the user may decide to dilute the hydrogen peroxide for safety reasons.
[0014] The solution of hydrogen peroxide is between ambient temperatures and 80° C. The solution may be heated prior to introducing onto the amorphous dithiazine coated surface or after it has already been placed in contact with the surface.
[0015] The solution of hydrogen peroxide is left to react and dissolve a portion of the amorphous dithiazine. The user may find it necessary to leave the hydrogen peroxide in contact with the amorphous dithiazine for several hours before an effective amount has dissolved. During this time, the mixture may be stirred or triturated to increase the effectiveness of the reaction. Sonication of the mixture may also be used.
[0016] After the user has determined that an effective amount of amorphous dithiazine has been dissolved, the solution of hydrogen peroxide and dissolved amorphous dithiazine is removed from the surface or substrate. The surface may be rinsed with water or any solvent that would remove any remaining remnants.
[0017] After the amorphous dithiazine precipitate has been treated with hydrogen peroxide, the user may want to use physical removal of a portion of the amorphous dithiazine. This may include manual chipping and scrapping of the amorphous dithiazine precipitate. This physical removal may be used to expose an unreacted layer of amorphous dithiazine buildup.
[0018] The user may decide that another treatment of hydrogen peroxide may be used to remove additional amorphous dithiazine from the substrate. The substrate containing the amorphous dithiazine may again be placed in the contact with the hydrogen peroxide to further react and dissolve. The user may use a recursive procedure of chemically removing a portion of the amorphous dithiazine with hydrogen peroxide and physically removing a portion of the amorphous dithiazine until an effective amount of the amorphous dithiazine has been removed.
[0019] Amine-based H 2 S scavengers are used in gas tower contactors; hence, large deposits of amorphous dithiazine are typically found there. In an aspect, the present invention may be used to remove a portion of the amorphous dithiazine from the gas tower contractors. The gas tower contractors may be flushed with water or any solvent that would remove any leftover hydrocarbon processing fluids. A solution of hydrogen peroxide is then be injected into the gas tower contactor. The solution may be heated before or after injection. After an effective amount of the amorphous dithiazine had been dissolved the solution is removed. Sequential treatments of hydrogen peroxide may be used.
[0020] After a hydrocarbon stream has been sweetened with amine-based H 2 S scavengers, precipitation of amorphous dithiazine occurs throughout the hydrocarbon processing conduit. In an aspect, the present invention may be used to remove a portion of the amorphous dithiazine from conduit. A solution of hydrogen peroxide is injected into the flow conduit. The solution is kept in contact with the amorphous dithiazine until an effective amount has been removed. The hydrogen peroxide may be heated prior to or after the injection.
[0021] Amorphous dithiazine tends to precipitate in restrictions and “dead spots” of hydrocarbon processing systems. Places in the system where there is abrupt physical change, such as a change in temperature or pressure, can be prone to amorphous dithiazine buildup. For example, injection ports and valves are susceptible. In an aspect, the present invention may be used to remove the amorphous dithiazine from smaller pieces of hydrocarbon systems. A part that is partially covered in amorphous dithiazine is removed from the hydrocarbon system and placed in a reservoir of hydrogen peroxide solution. The part may be partially or fully submerged. The reservoir of hydrogen peroxide may be attached to a heating apparatus to bring the solution to the desired temperature. The reservoir may be partially or fully enclosed to limit the vapor release.
[0022] Hydrocarbons that have been sweetened with amine-based H 2 S scavengers and have been sitting stationary for long periods of time tend to have amorphous dithiazine precipitate out of solution and form deposits on the bottom of their storage vessels. For example, truck tanks and disposal wells can have dithiazine buildup. In an aspect, the present invention may be used to remove the amorphous dithiazine from contained areas. A solution of hydrogen peroxide is applied to the surface that is coated with the amorphous dithiazine. The solution of hydrogen peroxide may be heated and sprayed onto the surface. After a portion of the amorphous dithiazine buildup has reacted with the hydrogen peroxide, water or another solvent may be used to rinse away the solution and any remnants that have formed due the reaction. In an aspect, a portion of the amorphous dithiazine may be removed physically. Physical removal may include manually chipping and scrapping at the amorphous dithiazine deposit. After a layer of unreacted amorphous dithiazine has been exposed, another treatment of hydrogen peroxide may be applied to further react and breakdown the amorphous dithiazine. The user may try multiple treatments of hydrogen peroxide until an effective portion of amorphous dithiazine buildup has been removed.
Example
[0023] The following example describes the preferred embodiments of the present invention. Other embodiments within the scope of the claims will be apparent to one skilled in the art from the consideration of the specification or practice of the invention disclosed herein.
[0024] Amorphous dithiazine can be prepared in a laboratory experiment or gathered from highly spent fluids in field locations. A field strength solution (30% by mass of active hexahydrotriazine), typical for the oilfield application of (I), was spent with pure hydrogen sulfide in a glass gas tower. The mass of hydrogen sulfide absorbed by the fluid was measured by the mass increase of the gas tower. A considerable exotherm of between 20-30° C. was observed during the reaction to form the expected dithiazine. At reaction completion, full theoretical mass of hydrogen sulfide had been absorbed, namely 4 moles of hydrogen sulfide per mole of (I). Initially, (II) was seen to separate in the bottom of the gas tower as a lower colorless liquid but within one hour a very heavy white solid deposited in the fluid of the gas tower and the lower layer solidified into a fine white powder. Attempts to arrest the solidification of the lower layer by separating and dissolving in methanol were not successful. The fine white solid was the laboratory analogue of amorphous dithiazine observed in the field use of (I).
[0025] Several field locations where (I) was in use were known to deposit heavy quantities of amorphous dithiazine as a somewhat troublesome byproduct. Samples of spent fluid were obtained that contained both liquid (II) and amorphous dithiazine solids. It was convenient to separate these as follows. At elevated temperatures (II) existed in a liquid phase containing amorphous dithiazine floating throughout the bulk of the fluid. This heterogeneous fluid was filtered hot under reduced pressure. The liquid dithiazine, when collected in the filtration flask, was free of the amorphous dithiazine, and may often solidify and form large, high quality crystals of (II). The oil field derived samples of amorphous dithiazine were washed with methanol and dried under vacuum to produce a fine off-white to grey free flowing powder. The laboratory synthesized amorphous dithiazine and the purified field amorphous dithiazine were examined by X-ray diffraction analysis, elemental analysis, IR spectroscopy and NMR spectroscopy. The results indicated that the laboratory-produced, amorphous dithiazine and the field purified, amorphous dithiazine had similar chemical composition and structure.
[0026] For both laboratory prepared and field purified amorphous dithiazine, the solid was gathered by initial filtration and re-suspended by stifling in deionised water followed by another filtration. The solid filter cake is pressed to remove as much water as possible. It was then washed again with deionised water to remove contaminants. The wet filter cake was washed with isopropanol to remove excess water. The filter cake was broken up and dried to a constant weight in a vacuum oven at 60° C. The dry solid was crushed into a fine, free-flowing powder and used for the solid dissolution studies.
[0027] The hydrogen peroxide solution was made by dilution of commercial 34% (vol) strength (e.g. Fisher Scientific). The solid amorphous dithiazine was then added to the aqueous solution of hydrogen peroxide. The mixture was stirred and heated. At a temperature of about 65-70° C. the dissolution process occurred. Stirring at this temperature for approximately 1 hour, the amorphous dithiazine dissolved according to the data shown in Table 1.
[0000] TABLE 1 Strength of Hydrogen Peroxide Solution (vol %) Maximum Solubility Observed (%) 34.0 4.5-5.0 17.0 4.5-5.0 8.5 3.0 0.0 0.0
The aqueous solution of hydrogen peroxide reacted and dissolved amorphous dithiazine up to 5% (mass) readily.
[0028] Other embodiments within the scope of the claims herein will be apparent to one skilled in the art from consideration of the description set forth herein. It is intended that the specification, together with the examples, be considered exemplary only, with the scope and spirit of the invention being indicated by the claims which follow. | A method for the dissolution of amorphous dithiazine buildup on a surface is presented. The method consists of treating the dithiazine buildup with a solution of hydrogen peroxide, which reacts and breaks apart the buildup for easy removal. | 2 |
This Application is a CIP of Ser. No. 09/549,271 filed Apr. 14, 2000 now U.S. Pat. No. 6,237,315 and claims Benefit of Provisional of Application Ser. No. 60/129,422 filed Apr. 15, 1999.
TECHNICAL FIELD OF THE INVENTION
The present invention relates in general to the field of processing of buffalo hair, and more particularly, to the creation and production of a yarn useful for the creation of garments made of buffalo hair and buffalo down.
BACKGROUND OF THE INVENTION
Without limiting the scope of the invention, its background is described in connection with the formation of fibers and yarn, as an example.
Heretofore, in this field, animal fibers have been used for the creation, formation and manipulation of yarns that are useful for the manufacture of clothing. In order to produce sufficient yarn of sufficient strength a number of yarn types have been created that take advantage of different weaves and weave patterns to produce yarns. More recently, the introduction of synthetic fibers for the production of yarn yields increases in production and the strength of fibers.
For production of wool yarn, for example, the wool fibers must be spun on worsted system or on woolen system. On a worsted system, the wool staple length is long and distribution of the length usually is extremely uneven compared to those of cotton. Wool top is virtually impossible to draft with roller drafting, mechanism. Good uniformity of product requires faller bar incorporation into the process.
If a distance between drafting rollers could be set in accordance with the longest fiber length, shorter fibers would be floated, when being drafted, while longer fibers that exceed the distance between the rollers, would be broken or cut. In the former case, fallers must be applied on gill frame to control these floating fibers.
Cotton-wool blended yarns have been spun with squared wool fiber, but all-wool yarns like worsted yarns cannot be spun by means of the conventional cotton system until now. With worsted yarns produced by the conventional worsted yarn system, long fibers of more than 120 mm length of wool top occupies only about 10% of the total. Therefore, for the purpose of uniform drafting, gilling should be used. In general, however, worsted spinning system is considered as of higher cost and lower in productivity, which results in much higher spinning costs in worsted system than in cotton system. Likewise, the creation of a yarn based on buffalo has always required that, at a minimum, a significant amount of wool be interspersed with the buffalo hair and/or fibers. At least one problem with the buffalo-wool blend is that it is more characteristic in feel, comfort and durability to wool than to buffalo.
To date, no one has been able to produce a yarn based solely on buffalo or bison hair (termed collectively herein “buffalo”) at a lower cost, as well as higher productivity and good quality. Whole buffalo hair and buffalo down blended with a minimum of 40% wool fibers have long been used for providing durable, warm and comfortable protection in cold and warm weathers. A yarn based solely on buffalo hair and fibers would be expected to have similar or improved characteristics, however, the inability to produce such yarn in an efficient, cost-effective manner has not been achieved.
SUMMARY OF THE INVENTION
It has been found, however, that the present invention may be used to produce yarn from buffalo hair and fibers in an efficient and cost-effective manner. In the industry it has long been felt that buffalo hair could not be formed into yarn due to characteristics of the fibers that were incompatible with the yarn manufacturing systems, viz., the woolen, worsted and cotton systems.
A significant problem of the woolen, worsted and cotton systems is that they were not designed for the formation of yarn from complex fleece, such as buffalo fleece. One problem with buffalo fleece is that it may contain up to 5 different types of hair fibers, that is, it is a multi-layered fleece.
What is needed is a method of preparing buffalo hair and fibers for the creation of buffalo based yarn, and in particular, yarn that is made solely with buffalo hair. In the present invention, a pure buffalo yarn is produced that does not include wool or other fiber fillers.
More particularly, the present invention is a method of producing yarn solely from buffalo hair including the steps of, scouring a buffalo fleece with detergent and water at a temperature of at least 80 degrees centigrade to clean the fleece and separating the coarse from the down hair of the buffalo fleece. Next, the buffalo fleece is dehaired to remove unwanted course hair from the fleece to produce dehaired fleece, followed by blending the dehaired fleece with an oil and water emulsion in a mixing picker to produce a mixed fiber.
A modified carding step follows the blending step in which the mixed fibers produce a roving of straight and parallel fibers. In the modified carding step it has been found that passing the blended hair at between about 30 to 70 percent of the normal weight before the second carding step enhances the yarn. Carding at 40 to 60 percent or even at 50 percent weight percent has been found to be particularly useful to improve the smoothness and wear-ability of the yarn in garments.
Following the modified carding step, it has been further found that spinning both roving ends together also improves the features of the yarn. Finally, less twist and lower draft are applied to the double roving to create a softer and stronger yarn. The method of the present invention may also include the collection of the fleece from a buffalo hide using sheep shears prior to the step of scouring the fleece.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
FIG. 1 is a flow diagram of a process for the creation of buffalo yarn and the processing of buffalo hair of the present invention; and
FIG. 2 is a flow diagram of the separation step of the present invention that allows for the production of pure buffalo yarn using the steps of the woolen system.
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 that 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.
It is well known by the skilled in the art that in a spinning process of woolen type yarns, after the carding operation through two or more sets, a number of bands are split from the sheet or web of fibers by a “condenser”, which pass the bonds on leather tapes to a series of double leather endless belts or “rubbers”, and the reciprocating movement of these, rubs and compresses the fibers of each band into narrow, round untwisted slivers or slubbings (i.e., having a false or “mock” torsion) that are wound on to elongated spools to be generally mounted as coaxial spool pairs on a spinning frame, being ready to feed a section of same for the final spinning.
One such method of using and improving upon the Woolen system for use with the creation of wool-based yarn is disclosed in U.S. Pat. No. 3,979,893, issued to Gelli, et al. These inventors disclose a mechanical system and method for continuous working woolen type yarn from cards to spinning frame in which a working web of woolen type yarns leaving a finisher card is produced with reduced steps. More particularly, they take advantage of a condenser head that splits the web into parallel bands. The bands are delivered to pairs of rubbing rolls, which reciprocate relative to one another to convert the bands to slubbings having false torsion. The slubbings are conveyed to spinning frames. In most cases such slubbings are arranged as four coaxial and side-by-side elongated spools, and the “mock” torsion thereof is provided by the rubbing and compressing action of said double leather endless belts during the reciprocating movement of same. The relevant portions of U.S. Pat. No. 3,979,893 are incorporated herein as reference to teach the basic woolen system as would be known to those of skill in the art of wool-based yarns spun according to the woolen system and modifications thereof.
As an example of the Woolen system when the winding phase of slubbings on to elongated spools through the condenser is completed, these elongated spools are collected and carried to the spinning frames to continue the spinning process as final spinning of the woolen yarn as desired. Some of the problems often encountered with using the woolen system is that following a period of spinning forced interruptions occur in the process that include: (a) forming elongated spool of woolen slubbing through the condensers of prior art, which are provided with mechanical means for said purposes; (b) unloading said elongated spools and collecting same waiting for the next use on a spinning frame; and (c) carrying said elongated spools both for collection and loading of same on the spinning frames. The interruption results in a loss of time, which is by-itself not indifferent, but also a consequently higher manufacturing cost.
More particularly, the present invention is used to produce a pure buffalo down hair yarn and even a buffalo hair that includes both down and coarse hair. The method and yarn produced using the present invention begins with obtaining shaved buffalo or bison hair. Two types of yarn may be produced: a down yarn or a whole-hair yarn. The down yarn has had at least about 90 percent of the coarse hair taken out prior to processing and spinning, and preferably at least 95 percent. The whole-hair yarn, on the other hand, is yarn that has not had the coarse hair removed. Alternatively, whole hair yarn may have 50 percent buffalo down and 50 percent coarse hair. In some cases, about 10 percent wool may be added to strengthen the whole-hair yarn. The down hair grows underneath the coarse hair of the bison to keep it warm. The whole-hair yarn has been processed the same way that the down hair has except that it has not been dehaired.
In operation, the general steps of the present invention are described in conjunction with FIG. 1 in a flow chart generally designated as 10 . The first step involves the collection of the buffalo or bison hair at step 12 . Next, in step 14 , the collected hair or fleece is scoured to remove dirt and unwanted hair contaminants. To form a more homogeneous mixture of fine soft fibers the whole hair may be dehaired in step 16 by opening the fibers. Next, in step 18 the separated hair, now generally a down hair, is emulsified with oil, water and even if necessary an anti-static compound.
In the present invention, at step 20 , the hair fibers are carded at 30 to 70 the normal weight, or as used herein the “weight percent” relative to a normal roving operation. In one example, the hair is carded at one-half the normal weight to produce a mat of straightened fibers to produce a superior roving of buffalo hair. At step 22 , the roving is spun into a primary buffalo yarn, however, it has been found that by spinning both roving ends together on the spinning frame to produce a double roving. Finally, at step 24 , the primary buffalo yarn is twisted with less twist and low draft to the double roving to produce a yarn that is stronger, less dense and generally softer to the touch thereby providing a fabulous soft, silky feeling. Each of the steps in FIG. 1 is described in greater detail hereinbelow.
Collecting the Bison Hair
The bison hair is shaved from the torso of the bison the day it is slaughtered for meat. The hair is shaved before the hides are salted down. The bison hair may be shaved using, e.g., sheep shears. Generally, the buffalo hair is only shaved during the winter months. The raw bison fleece may be stored in 300 pound burlap bags in unheated barns that stay at about 15 degrees Fahrenheit until it is transported to the scouring plant where it is cleaned.
Scouring
Dirt and grease are removed from the raw Buffalo fleece. After the dirt and grease are removed the fleece is passed through a series of washing tanks filled with hot water and soap or detergent. It may then be rinsed and dried prior to further processing or stored.
Dehairing
The cleaned fleece is fed into a dehairing machine. The dehairing process removes the unwanted coarse hair leaving at least about 90 percent fine soft fibers, and preferably, about 95 percent fine soft fibers. The cleaned fleece is fed to the dehairing machine which moves it once slowly through eight large heads in the machine taking out about 95 percent of the unwanted coarse hair. The coarse hair cannot be completely removed because it breaks the fibers down to run them through the machine again. The dehairing process creates a very fine soft fiber.
Blending
First, the dehaired Buffalo fiber is fed into a mixing picker, which opens the fiber. Secondly, the opened fiber now receives a fine spray of emulation consisting of water oil and an anti static compound. The anti-static compound may be added before, during or after the oil and water emulsion and will generally be non-foaming. An anti-foam may also be added with the emulsion. Finally, the emulsified fiber is now blown into a large mixing chamber to thoroughly mix the fiber and the emulation. This process may be repeated several times to achieve a homogeneous mixture of both fiber and emulation.
Carding
The mixed fiber is now placed in a feeding machine that delivers an even amount of blended Buffalo fiber to a feed apron. The feed apron delivers the fiber to the carding machine. The carding machine is made up of a large number of rolls covered with the fine pointed wire, similar to a hairbrush. These rolls are of different sizes and run at different speeds. The fiber passes from one roll to another moving through the machine. As the fiber makes its way through the machine the fibers are being straightened and paralleled. It has been found that by feeding the mixed fibers at between about 30 to 70 percent the normal weight a softer, stronger product may be achieved.
This mat of straightened fiber leaves machine in a web form and is delivered to a set of dividing rolls. These rolls divide the web into ½″ sections and deliver them to a condensing unit that rubs them into a cylindrical form looking like a long spaghetti. This is now called buffalo roving and many ends are wound onto a large spool. In the present invention, both roving ends may be spun as one on the spinning frame.
Spinning
The buffalo roving, now in the form of a spool or spooled fibers, is placed on the spinning machine that unwinds the roving from the spool. The roving passes through two sets of rolls running at different speeds. These are called drafting rolls. As the roving passes through these rolls it is reduced in size. The drafted roving is now wound onto a bobbin turning at very high speeds. This applies twist to the drafted roving locking the fiber together and giving it strength. It is now called buffalo yarn.
Twisting
As a result of spinning both ends in a single roving less twist may be applied to the yarn. Two ends of yarn are fed through a set of feed rolls onto a bobbin spinning at a high rate of speed. As the yarn is wound to the bobbin twist is applied to the two ends of yarn. This twist is applied in opposite direction of the single spun yarn. By removing twist from the single spun end and applying it to the two-ply ends the yarn becomes softer and bulkier. Less twist and low draft are applied to the double roving creating a softer hand and stronger yarn.
The present invention is based on the realization that prior attempts to spin buffalo yarn had failed to produce a yarn of sufficient strength and consistency. To avoid the problems associated with the production of pure buffalo yarn, prior users of buffalo based fleece have had to resort to the addition of wool fibers to provide scaffolding for the formation of a yarn that included buffalo. A key step to overcoming the problem of spinning pure buffalo yarn was the realization that the components of the buffalo hair had to be separated prior to the spinning operation. The un-separated hair could not be consistently matted in the carding process to form a consistent yarn. Therefore, the present inventor separated the coarse buffalo hair from the down buffalo hair prior to entering the basic woolen yarn procedure.
The details of the separation procedure are described in the flowchart of FIG. 2 . In step 32 , the buffalo or bison hair is removed from the hide with shears, preferably sheep shears or other like shears as will be known to those of skill in the art of shearing to produce a dual fiber fleece. After scouring and/or washing the fleece the coarse hair is removed or separated from the down by dehairing. The present inventor realized that the coarse and the down hair had to be separated prior to the yarn making procedure in order to make down yarn from buffalo hair. Once the down and coarse hair are separated, as indicated in step 34 , about 95% of the down fiber is coarse hair free, with the remaining coarse hair being too small to further separate. When making whole hair yarn, on the other hand, both the course hair and the down are not separated, however, the inventor has found that this yarn requires the addition of extra down.
In step 36 , the fibers are once again mixed in a mixing picker and sprayed with an emulsion or water and oil, as is generally done in the standard Woolen procedure. The oil and water mixture may also include other additives such as anti-static and other additives. Finally, in step 38 , the fibers are once again joined by mixing in a large mixing chamber, which is then followed by the remaining steps of the woolen yarn making procedure.
While this invention has been described in 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. | A method for making a pure buffalo yarn is disclosed and includes the steps of, scouring a buffalo fleece with detergent and water at a temperature of at least 80 degrees centigrade to clean the fleece, dehairing the buffalo fleece to remove unwanted course hair from the fleece to produce dehaired fine soft fibers, blending the dehaired fine soft fibers with an oil and water emulsion in a mixing picker to produce a mixed fiber, carding the mixed fiber at 50 weight percent of normal to produce a roving of straight and parallel fibers, spinning the roving to produce a yarn and twisting the yarn to increase the bulk and softness of the yarn. | 3 |
TECHNICAL FIELD
[0001] The present invention relates to a ballpoint pen tip and particularly relates to a ballpoint pen tip which allows sufficient ink supply to a ball even if an ink with high viscosity in a resting state is used and further prevents the risk of an ink drop.
BACKGROUND ART
[0002] In conventional ballpoint pens, ballpoint pens for allowing an outflow of various kinds of inks have been disclosed in recent years. Among those ballpoint pens, a ballpoint pen using an ink containing metal particles or having pigment fine particles whose diameter is large particularly in an ink with a shear-thinning property tends to have poor ink outflow characteristics in comparison with a ballpoint pen using an ink of normal colors such as black, red and blue. Therefore, as a measure taken against the above problems, a prior art is disclosed in Patent Document 1. The prior art is to ensure an ink flow rate by expanding the width of a plurality of ink grooves formed at equal intervals around an ink guide hole positioned in an axial center of a ballpoint pen tip.
[0003] Meanwhile, in recent years, as a measure taken against an ink drop in retractable ballpoint pens and a measure taken against a faint written trace in writing caused by vibration and impact to a penholder, a spring has been often inserted in a ballpoint pen tip to constantly bias a writing ball forward. Such a spring is usually formed by turning a tip-end part of a helical spring into a straight rod shape so that the tip is used to press a rear end of the writing ball. Such a spring has been regarded as inappropriate for use in such a case as, for example, the invention according to Patent Document 1 because the width of ink grooves is so wide that the rod part may stuck in the ink grooves.
[0004] Therefore, if such a spring is employed in a ballpoint pen tip, as shown in the invention according to Patent Document 2, it is necessary to create ink grooves up to the halfway of an ink guide hole and restrict a tip-end part of the spring by an inner diameter of the rear end part of the ink guide hole in order to prevent the spring from being stuck in the ink grooves.
CITATION LIST
Patent Documents
[0005] Patent Document 1: JP 2002-52884 A
[0006] Patent Document 2: JP 000-158869 A
SUMMARY OF INVENTION
Technical Problem
[0007] However, the shape of the ballpoint pen tip according to Patent Document 2 makes it impossible to obtain a sufficient ink flow rate with the use of an ink with high viscosity. It is because such a shape allows an ink coming from the rear of a ballpoint pen tip to flow to a tip-end by passing through only an ink guide hole in which a tip-end part of the spring is present, whereby an effective sectional area of the ink guide hole is diminished by a wire diameter of the spring. Therefore, it was extremely difficult to manufacture a ballpoint pen tip which requires an ink flow rate while installing a spring therein to bias a wiring ball forward.
[0008] Accordingly, the present invention has an object to provide a ballpoint pen tip which neither causes, even if an ink with poor outflow characteristics is used, a faint written trace and an ink drop, nor impairs ink outflow characteristics.
Means to Solve the Problem
[0009] In the light of the above problems, the present invention relates to a ballpoint pen tip that comprises a writing ball and a holder holding the writing ball at its tip-end, wherein:
[0010] a tapered portion is formed to be tapered in a tip-end part of an outer periphery of the holder,
[0011] a narrowed portion is formed to hold the writing ball by a tip-end of the tapered portion being deformed plastically inward,
[0012] a ball house is formed as an inner space of the holder at the tapered portion in which the writing ball is inserted,
[0013] a back hole is formed as an inner space of the holder extending forward from a rear end of the holder to a vicinity of the ball house,
[0014] an ink guide hole is formed as inner space of the holder connecting the back hole and the ball house,
[0015] ink grooves are formed as grooves penetrating from the ball house to a tip-end part of the back hole in a radial manner at a plurality of positions around the ink guide hole with equal intervals,
[0016] an elastic member that biases the writing ball forward is inserted in the back hole,
[0017] a biasing portion that is a tip-end part of the elastic member and extends forward, passes through the ink guide hole, contacts a rear-end of the writing ball and biases it forward, and
[0018] inward protrusions that protrude inward are formed at positions in contact with rear-ends of the ink grooves in the tip-end part of the back hole;
[0019] when an inner diameter of the ink guide hole is A, an inner diameter of the tip-end part of the back hole is B, a diameter of a circle circumscribing the ink grooves is C, and a diameter of a circle inscribing the inward protrusions is D, the relationships of A<B<C and D<B are satisfied.
[0020] The “holder” refers to a main body part excluding the “writing ball” from the ballpoint pen tip and can be formed by, for example, curving a “columnar member” made of metal such as stainless steel.
[0021] A portion formed to be tapered at the tip-end of the holder is referred to as the “tapered portion.” For example, if the holder is formed by the metallic columnar member, the tapered portion is to be formed by the curving process. The “tip-end” here naturally refers to a writing point side of a ballpoint pen tip and an opposite side thereof is a “rear end.” Note that the rear end side of the holder, though its shape is not particularly limited, can be curved to reduce an outer diameter thereof and formed into a portion which is directly inserted into an ink storage tube or is inserted into a joint or the like interposed between the rear end and the ink storage tube.
[0022] The “ball house” refers to a space formed from the tip-end side in an inner circumferential area of the tapered portion, in which the writing ball is inserted. If the holder is made of the metallic columnar member, the ball house is formed by the curving process from the tip-end. The writing ball inserted in the ball house is held by the “narrowed portion,” which is a tip edge of the tapered portion that is narrowed inward, so as not to come off. An inner diameter of the ball house is preferably formed larger than a diameter of the writing ball.
[0023] The “back hole” is a center hole formed from the rear end of the holder to the vicinity of the ball house without reaching the ball house. If the holder is formed by the metallic columnar member, the back hole is formed by the curving process. Moreover, an inner diameter of the back hole is preferably reduced in a stepwise manner as approaching the ball house from the rear end of the holder.
[0024] The “ink guide hole” is a center hole connecting the back hole and the ball house with a smaller diameter than the back hole.
[0025] The “ink grooves” refer to grooves that are distributed at equal intervals around the ink guide hole with respect to the axial center and run along the axial direction. If the holder is formed by the metallic columnar member, the ink grooves are formed by the curving process using a broaching tool from a bottom surface of the ball house. Note that the ink grooves penetrate up to the tip-end part of the back hole. Therefore, ink guided to the tip-end of the back hole reaches the ball house via the ink grooves and the ink guide hole. The diameter (C) of the circle circumscribing the ink grooves is preferably formed less than the inner diameter of the ball house for processing stability. Furthermore, the diameter (C) of the circle circumscribing the ink grooves is preferably made larger than the diameter of the writing ball. Thus, it is possible to prevent the writing ball from blocking the ink grooves resulting from abrasion of the bottom surface of the ball house due to rotation of the writing ball in writing over a long distance. This can also contribute to the stability of ink outflow characteristics.
[0026] The “elastic member” is preferably a spring which can be configured without blocking the ink guide hole as much as possible, but it is not particularly limited as long as being a member such as rubber rod and damper which constantly presses the writing ball forward in a resting state. Note that, in retractable ballpoint pens whose writing point is constantly exposed to the external air, the elastic member is a necessary component in order to prevent an ink drop when a writing point is left in a downward direction. Of course, there is no problem to use such an elastic member in capped ballpoint pens in which a writing point is sealed by fitting a cap when not in use. Moreover, if an elastic member or particularly a spring is used in writing instruments which use an ink with a shear-thinning property, internal movement of the spring during writing generates a shearing force of ink, whereby achieving improvement of ink outflow characteristics.
[0027] The “biasing portion” formed at the tip of the elastic member penetrates the ink guide hole from the back hole so as to contact the rear end of the writing ball that is positioned in the ball house. Then, elasticity of the elastic member constantly bias the writing ball forward. The biasing portion can be formed into a rod shape or formed by reducing a diameter of the spring in its tip-end part.
[0028] The “inward protrusions” are protrusions formed to protrude inward in the tip-end part of the back hole and in positions in contact with rear ends of the ink grooves. Since the inward protrusions are arranged to correspond to the plurality of the ink grooves respectively, they are distributed in equal intervals with respect to the axial center in the same manner as the ink grooves. Inner circumferential surfaces of the inward protrusions are finished by the curving process or other processes as needed so as to have the inner diameter (D) which is less than the inner diameter (B) of the tip-end part of the back hole.
[0029] That is, the ink grooves have a penetration structure in an area of the ink guide hole which is an area before ink reaches the writing ball and exposed to a highest fluid resistance. The inner diameter (B) of the tip-end part of the back hole is set to be less than the diameter (C) of the circle circumscribing the ink grooves and to be more than the inner diameter (A) of the ink guide hole. The ink grooves are further processed up to the tip-end part of the back hole. Then, deformed parts generated in curving the ink grooves such as, for example, metal parts deformed as a result of having been curved and pushed to the rear end the ink grooves in curving the ink grooves, are used to form the inner protrusions.
[0030] According to the structure described above, when a tip-end of the biasing portion of the elastic member tilts to a direction where the ink groove exists, it contacts the inner peripheral surface of the inner protrusion before reaching the ink groove. Then, further movement to the direction of the ink grooves beyond the inner protrusions is prevented. Therefore, even if the ink grooves are designed to have a larger width than a diameter of the biasing portion of the elastic member, there is a structure to prevent the elastic member from being stuck in the ink grooves while allowing improvement of outflow characteristics of an ink with high static viscosity.
[0031] The size of the writing ball is not specifically defined in the form of the ballpoint pen tip but a remarkable effect can be exhibited especially with a relatively small ball diameter of 0.5 mm or less.
[0032] Note that no problem will arise with ink outflow characteristics if the number of the ink grooves is two or more, but three the ink grooves distributed widely at even intervals are particularly preferable.
Advantageous Effects of Invention
[0033] In the present invention as structured above, if the ink grooves are formed to have a width which is larger than a diameter of the biasing portion of the elastic member, a tip of the biasing portion which tilts toward the ink grooves contacts the inner protrusions prior to be stuck in the ink grooves. Therefore, the biasing portion of the elastic member is prevented from being stuck in the ink grooves. Moreover, owing to a small diameter difference between the tip-end part of the back hole and the ink guide hole, even if the ink grooves are processed to have a broad width for better ink outflow characteristics, deformation of the ink guide hole can be suppressed and the ink guide hole can be made shorter. Furthermore, a passage which threads its way through the inner protrusions and the grooves is formed to realize comprehensive reduction of an ink outflow resistance. Therefore, it is possible to provide a ballpoint pen tip which is capable of avoiding a faint written trace and an ink drop without impairing ink outflow characteristics even if an ink with poor ink outflow characteristics is used, as well as being capable of preventing defective writing caused by ink evaporation and blurring due to vibration applied to a pen body.
BRIEF DESCRIPTION OF DRAWINGS
[0034] [ FIG. 1 ] A front view (A) and a front cross sectional view (B) of a ballpoint pen tip according to the present invention.
[0035] [ FIG. 2 ] A cross sectional view showing a tip-end part of a holder.
[0036] [ FIG. 3 ] A cross sectional view along I-I shown in FIG. 2 .
[0037] [ FIG. 4 ] A cross sectional view along II-II shown in FIG. 2 .
[0038] [ FIG. 5 ] A cross sectional view along shown in FIG. 2 .
[0039] [ FIG. 6 ] A cross sectional view along IV-IV shown in FIG. 2 .
[0040] [ FIG. 7 ] An illustration showing a ballpoint pen tip according to another embodiment in light of the cross sectional view of FIG. 5 .
[0041] [ FIG. 8 ] A partial cross sectional view showing a state of the holder and an elastic member of the ball point pen tip according to the present invention, in which the writing ball is omitted.
[0042] [ FIG. 9 ] A front cross sectional view of a ballpoint pen refill on which the ballpoint pen tip according to the present invention is mounted (A) and a front cross sectional view of a ballpoint pen in which the ballpoint pen refill is mounted (B).
DESCRIPTION OF EMBODIMENTS
[0043] Embodiments of the present invention will be explained with reference to the drawings.
[0044] A ballpoint pen tip 20 according to the present embodiment is composed of, as shown in FIG. 1 , a holder 21 , a writing ball 35 held on a tip-end of the holder, and an elastic member 40 stored inside the holder.
[0045] The holder 21 is formed by curving a columnar member made of stainless steel. Its tip-end part is, as shown in FIG. 1(A) , is tapered and curved into a substantially conical shape to create a tapered portion 22 . On the other hand, a rear end part of the holder is formed as an inserted portion 24 whose outer diameter is reduced. This part is inserted into a joint 17 to be described later.
[0046] Furthermore, a tip part of the writing ball 35 , which is held inside the tapered portion 22 , is exposed from a tip edge of the tapered portion and a tip edge of the tapered portion 22 is pressed inward and subjected to diameter contraction deformation to create a narrowed portion 23 .
[0047] Next, with reference to FIGS. 1 to 8 , a manufacturing process of the ballpoint pen tip 20 according to the present invention will be explained.
[0048] First, a tip-end side of a columnar member made of stainless steel is curved and tapered to create the tapered portion 22 . Next, the inserted portion 24 is created by a curving process so as to reduce an outer diameter in the vicinity of a rear end of the holder 21 (see FIG. 1(A) ).
[0049] Then, from the rear end of the holder 21 to a middle part of the tapered portion 22 , a back hole 28 is bored by reducing a diameter thereof in several steps (see FIG. 1(B) and FIG. 2 ). Next, an ink guide hole 30 is penetrated from the tip-end of the holder 21 to the back hole 28 , followed by curving a ball house 26 from the tip-end of the holder 21 using a drill whose diameter is slightly larger than an outer diameter of the writing ball 35 (see FIG. 2 ). Subsequently, ink grooves 31 are created around the ink guide hole 30 from a bottom surface 27 of the ball house 26 by using a broaching tool (see FIGS. 3 and 8 ). As shown in FIG. 3 which shows a cross section along I-I in FIG. 2 and FIG. 4 which shows a cross section along II-II in FIG. 2 , the ink grooves 31 here are so provided that three ink grooves 31 are radially distributed at equal intervals around the ink guide hole 30 . The ink grooves 31 are penetrated up to a tip-end part 29 of the back hole 28 (see FIG. 2 ). Inward protrusions 32 are formed by smoothly curving the inner circumferences of portions protruding inward that are pressed and pushed rearward when the ink grooves 31 are formed, by using a drill(see FIG. 2 ). Here, as shown in FIGS. 3 and 5 which shows a cross section along III-III in FIG. 2 , when the inward protrusions 32 are seen from the tip-end, they are visible behind the ink grooves 31 . Moreover, as shown in FIG. 6 which shows a cross section along IV-IV in FIG. 2 , the inward protrusions 32 are formed to protrude inward from the tip-end part 29 of the back hole 28 .
[0050] Here, an inner diameter of the ink guide hole 30 is referred to as “A,” an inner diameter of the tip-end part 29 of the back hole 28 “B,” a diameter of a circle circumscribing the ink grooves 31 “C” and an inner diameter of an inner peripheral surface of the inward protrusions 32 “D.” Then, the relationship D<A<C is fulfilled as shown in FIGS. 3 and 5 , and D<B as shown in FIG. 6 . Furthermore, in FIGS. 5 and 6 , it is understood that the relationships A<B and B<C are obviously fulfilled from the comparison with D which is the same size in both figures. Therefore, from these figures, it is concluded that the relationships A<B<C and D<B are fulfilled.
[0051] Note that a case where A is larger than D as shown in FIG. 5 is an example and, for example, as shown in FIG. 7 which shows another embodiment, A may be smaller than D. When A is smaller than D, however, if a dimensional difference is too much, ink outflow becomes difficult and, therefore, it is preferable that A is nearly equal to B.
[0052] Then, the writing ball 35 which is made of cemented carbide is inserted into the ball house 26 , followed by pressing and deforming the tip of the tapered portion 22 inward by a narrowing tool to create the narrowed portion 23 (See FIGS. 1(A) and (B)).
[0053] On the other hand, the elastic member 40 formed by a spring is inserted in the back hole 28 . A tip part of the elastic member 40 is formed into a straight rod shape and this part is referred to as a biasing portion 41 . A tip of the biasing portion 41 passes thorough the ink guide hole 30 and is brought in contact with a rear end of the writing ball 35 so as to press it forward. Note that a rear end of the holder 21 is partially deformed inward and this part serves as a fixing portion 25 to prevent the elastic member 40 from slipping off (see FIG. 1(B) ).
[0054] In the ballpoint pen tip 20 , as shown in FIG. 8 , if the biasing portion 41 at the tip of the elastic member 40 is made eccentric toward the ink groove 31 , it contacts the inward protrusion 32 without contacting the ink groove 31 . Accordingly, even if the ink grooves 31 are designed to wider than a diameter of the biasing portion 41 , the biasing portion 41 is not stuck in the ink grooves 31 .
[0055] The ballpoint pen tip 20 is, as shown in FIG. 9(A) , mounted on an ink storage tube 16 , which stores an ink 18 , via the joint 17 so as to provide a ballpoint pen refill 15 . Note that an ink following body 19 of a grease form for preventing backflow from a tail end of the ink 18 is filled at a rear end of the ink 18 and a float 19 a whose gravity is equalized is stored therein in order to enhance its followability. The ballpoint pen refill 15 is accommodated inside a shaft tube 11 of a ballpoint pen 10 which is provided with a cap 12 as shown in FIG. 9(B) .
[0056] The following inks can be used for the ballpoint pen refill 15 as shown in FIG. 9(A) .
[0057] For instance, an ink for ballpoint pen containing at least an aluminum powder pigment, water and a thickener can be used.
[0058] A preferable aluminum powder pigment is characterized with an average particle diameter falling in a range of 0.5 to 5.0 μm under the consideration of stability and clogging resistance or other aspects of an ink for use in writing instruments. Moreover, a rust prevention process is preferably applied to the surface of an aluminum powder pigment in order to prevent oxidization in the water system. An aluminum powder pigment may be mixed with mixed components without processing or may also be used in a paste form by wetting with a hydrocarbon solvent such as mineral turpentine in advance. When it is used in a paste form, a commercial aluminum paste which is water dispersible can be used. Preferably used commercial products include 1500 MA which is a product manufactured by Toyo Aluminium K.K., WB1130 which is a product of the same, AW-808 as s trade name manufactured by Asahi Kasei Metals Corp., F500SIW as a trade name manufactured by Showa Aluminum Powder K.K., STAPAHydrolac-W8n. and STAPAHydrolac-WH8n.1. as trade names manufactured by ECKART. An aluminum powder pigment is arranged on the surface of a paint film to play a role of providing metallic luster of a metallic color.
[0059] Water is used as a main solvent and total pH of an ink is preferably set to about 7.
[0060] A thickener, which is combined in the present invention and used for suppressing precipitation of an aluminum powder pigment and providing appropriate fluidity as an ink for writing instrument, preferably provides a shear-thinning property. Concrete examples of the thickeners include: seed polysaccharides such as guar gum, locust bean gum, galactomannan, pectin and derivatives thereof, psyllium seed gum and tamarind gum, all of which are the examples as natural polysaccharides; xanthan gum, rheozan gum, rhamsan gum, welan gum and gellan gum, all of which are the examples derived from microorganisms; carrageenan and alginic acid and derivatives thereof, all of which are the examples as seaweed polysaccharides; resin polysaccharides such as tragacanth gum and cellulose or derivatives thereof; and polyacrylic acid and crosslinked copolymer thereof, polyvinyl alcohol, polyvinylpyrrolidone and derivatives thereof, and polyvinyl methyl ether and derivatives thereof, all of which are the examples as synthetic polymers.
[0061] In addition to the above examples, it is possible to appropriately add agents as needed such as water-soluble organic solvents, sequestering agents, pH adjusting agents, dispersion aids, fixing agents, surfactants, antiseptics, antibacterial agents, rust preventive agents, coloring pigments, coloring dyes, emulsions and latexes.
[0062] Moreover, by combination use of, as a coloring pigment other than the aluminum paste, known pigments which have been used for alcohol-based ink and glycol-based ink and dyes dissolved by the above solvents, a gold color or various kinds of other metallic colors can be exhibited.
[0063] In addition, as another example, a thermochromic ink may also be used, by which the color of the written traces can be changed with thermoplastic elastomer. The thermochromic ink is preferably a reversible thermochromic ink. The reversible thermochromic ink can be composed of individual use or concomitant use of various types of inks such as a thermal color extinction type whose color is extinguished by heating from a colored state, a color storage type whose colored state and a decolored state are interchangeably stored in a specific temperature range and a thermal coloring type whose color is developed by heating from a decolored state and returns to the decolored state by cooling from the colored state. An irreversible metachromasy ink may also be used. Moreover, a preferably used coloring material contained in the reversible thermochromic ink is a conventionally known reversible thermochromic microcapsule pigment in which a reversible thermochromic composition including at least three essential components of (i) an electron-donating coloring organic compound, (ii) an electron-accepting compound and (iii) a reaction medium determining the occurrence temperature of the color reaction of both of the compounds is encapsulated in microcapsules. The reversible thermochromic microcapsule pigment preferably has an average particle diameter falling in a range of 0.5 to 5.0 μm. If the average particle diameter is more than 0.5 μm, the outflow characteristics from a ballpoint pen tip and a capillary gap of a porous pen body are reduced. If the average particle diameter is less than 0.5 μm, it becomes difficult for the color development to exhibit high density. It is possible to blend the reversible thermochromic microcapsule pigment with a concentration of 2 to 50 wt. % (preferably 3 to 40 wt. %, or more preferably 4 to 30 wt. %) with respect to the total amount of the ink composition. If it is less than 2 wt. %, density of coloring will be insufficient. If it is more than 50 wt. %, ink outflow characteristics are reduced and result in hindrance of writability.
[0064] Furthermore, an eraser-erasable ink which allows erasure of written traces with erasers may also be used. The eraser-erasable ink needs to contain at least water, 3 to 30 wt. % of non-thermoplastic colored resin particles having an average particle diameter of 0.5 to 5.0 μm with respect to the total amount of the ink composition, and 0.1 to 10 wt. % of non-colored particles. The colored resin particles for use in the water-base ink according to the present invention are made of resin particles that are colored and non-thermoplastic with an average particle diameter of 0.5 to 5.0 μm such as, for example, colored resin particles in which a coloring agent made of a pigment is dispersed in resin particles, colored resin particles in which the surface of resin particles is coated with a coloring agent made of a pigment, and colored resin particles in which resin particles are dyed with a coloring agent made of a dye. In the present embodiment, colored resin particles may have either a hollow particle structure or a solid particle structure as long as being non-thermoplastic and satisfying the above average particle diameter. The shape of the colored resin particles may be, but not particularly limited to, spherical, polygon, flat, fibrous and other shapes. However, in light of demonstrating excellent eraser erasability, writability and chronic stability as an ink, it is preferable to use particles having intermolecular crosslinking such that a glass transition point is 150° C. or more near a pyrolysis temperature and further a melt flow index value is less than 0.1 without having an adhesion property and the particles are preferably colored resin fine particles of a spherical form with an average particle diameter of 0.5 to 5.0 μm.
[0065] An ink to be used is not particularly limited and any other inks can be used other than the aforementioned inks.
EXAMPLES
[0066] Examples of the present invention will be explained in comparison with comparative examples as follows. Each of the Examples according to the present invention and the Comparative Examples used the ink 18 composed as shown in a table 1 below and was filled in the ink storage tube 16 of the ballpoint pen refill 15 as shown in FIG. 9(A) .
[0000]
TABLE 1
Content
Component
(wt. %)
Aluminum paste:
8
“AW-808” (trade name, manufactured by Asahi
Kasei Metals Corp.)
Yellow pigment toner:
1
Acrylic resin dispersed aqueous toner
containing 15 wt. % of “Pigment Yellow” (trade
name, manufactured by Sanyo Color Works, Ltd.)
Emulsion:
5
“Joncryl J-450” (trade name, manufactured by
BASF Japan Ltd.)
Thickener:
9
2 wt. % aqueous solution of “Reozan” (trade
name, manufactured by Sansho Co., Ltd.)
pH adjusting agent: Triethanolamine
0.5
Lubricant:
0.2
“Phosphanol RS-610” (trade name, manufactured
by Toho Chemical Industry Co., Ltd.)
Rust preventive agent: Benzotriazole
0.2
Antiseptic:
0.2
“Proxel XL-2” (trade name, manufactured by
Arch Chemicals, Inc.)
Solvent: Propylene glycol
20
Solvent: Glycerine
5
Ion exchange water
The rest
[0067] The ballpoint pen tips 20 according to the Examples of the present invention and the Comparative Examples were formed with processing dimensions as described in the following Tables 2 to 4 and mounted on the ballpoint pen refill 15 as shown in FIG. 9(A) .
[0068] That is, in each of Example 1 and Comparative Examples 1-1 and 1-2 was used a writing ball 35 with a diameter of 0.38 mm. Moreover, in each of Example 2 and Comparative Examples 2-1 and 2-2 was used a writing ball 35 with a diameter of 0.50 mm. Furthermore, in each of Example 3 and Comparative Examples 3-1 and 3-2 was used a writing ball 35 with a diameter of 0.70 mm. Note that, other than the dimensions of the parts described in the Tables, identical processing dimensions and configurations were employed.
[0000]
TABLE 2
Comparative
Comparative
Example 1
Example 1-1
Example 1-2
Ball diameter (mm)
0.38
0.38
0.38
Inner diameter of ink
0.25
0.25
0.25
guide hole (A) (mm)
Inner diameter of tip-
0.33
0.60
0.60
end part of back hole
(B) (mm)
Inner diameter of ball
0.41
0.41
0.41
house (mm)
Diameter of circle
0.38
0.38
0.38
circumscribing ink
grooves (c) (mm)
Width of ink groove
0.15
0.15
0.15
(mm)
Presence/absence of
Yes
Yes
No
elastic member
Diameter of circle
0.23
0.23
No
inscribing inward
protrusion (D) (mm)
Wire diameter of
0.12
0.12
—
elastic member (mm)
Ink outflow rate
172
130
180
(mg/100 m)
[0000]
TABLE 3
Comparative
Comparative
Example 1
Example 1-1
Example 1-2
Ball diameter (mm)
0.50
0.50
0.50
Inner diameter of ink
0.30
0.30
0.30
guide hole (A) (mm)
Inner diameter of tip-
0.40
0.60
0.60
end part of back hole
(B) (mm)
Inner diameter of ball
0.53
0.53
0.53
house (mm)
Diameter of circle
0.50
0.50
0.50
circumscribing ink
grooves (c) (mm)
Width of ink groove
0.15
0.15
0.15
(mm)
Presence/absence of
Yes
Yes
No
elastic member
Diameter of circle
0.28
0.28
No
inscribing inward
protrusion (D) (mm)
Wire diameter of
0.12
0.12
—
elastic member (mm)
Ink outflow rate
272
251
287
(mg/100 m)
[0000]
TABLE 4
Comparative
Comparative
Example 1
Example 1-1
Example 1-2
Ball diameter (mm)
0.70
0.70
0.70
Inner diameter of ink
0.42
0.42
0.42
guide hole (A) (mm)
Inner diameter of tip-
0.55
0.80
0.80
end part of back hole
(B) (mm)
Inner diameter of ball
0.73
0.73
0.73
house (mm)
Diameter of circle
0.70
0.70
0.70
circumscribing ink
grooves (c) (mm)
Width of ink groove
0.22
0.22
0.22
(mm)
Presence/absence of
Yes
Yes
No
elastic member
Diameter of circle
0.40
0.40
No
inscribing inward
protrusion (D) (mm)
Wire diameter of
0.12
0.12
—
elastic member (mm)
Ink outflow rate
502
396
471
(mg/100 m)
[0069] Note that Comparative Examples 1-2, 2-2 and 3-2 did not have the elastic member 40 and their ink grooves 31 completely penetrated to the back hole 28 without forming the inward protrusions 32 . This structure is expressed as “No” in the Tables.
[0070] Moreover, regarding the inner diameter B of the tip-end part of each back hole, B is less than C in each of Examples whereas B is more than C in each of Comparative Examples.
[0071] The ballpoint pen refill 15 , on which each of the ballpoint pen tips 20 according to Examples and Comparative Examples was mounted, was mounted on the ballpoint pen 10 as shown in FIG. 9(B) and a writing test was carried out as shown below.
[0072] That is, an ink outflow rate for the initial 100 m was measured by a writing tester according to the JIS standard S6039 in writing on a writing paper according to the ISO standard (14145-1) under such conditions that a writing load was 0.98N, a writing speed was 4.5 m/min and a writing angle was 60 degrees with the presence of pen rotation, in addition to further determine the quality of a written trace by visual observation.
[0073] The results were as shown in the above Tables 2 to 4, wherein ink outflow rates shown in Examples 1, 2 and 3 provided with the inward protrusions 32 were more than those of Comparative Examples 1-1, 2-1 and 3-1, and were not so much different from those of Comparative Examples 1-2, 2-2 and 3-2 in which the elastic members 40 were not provided and therefore did not prevent an ink outflow, respectively. Note that a faint written trace was observed in each of Comparative Examples 1-1, 2-1 and 3-1 and an ink drop was also observed in each of Comparative Examples 1-2, 2-2 and 3-2, whereas excellent quality was shown in each of Examples 1, 2 and 3 that neither faint written trace nor an ink drop was observed.
[0074] That is, the elastic member 40 kept an appropriate position in each of Examples 1, 2 and 3, whereby a faint written trace as observed in each of Comparative Examples 1-1, 2-1 and 3-1 did not occur and an ink drop was prevented while maintaining an equivalent ink flow rate to each of Comparative Examples 1-2, 2-2 and 3-2.
INDUSTRIAL APPLICABILITY
[0075] The present invention can be used for a ballpoint pen which employs an ink with a high shear-thinning property and an ink with poor fluidity due to inclusion of particles whose diameter is relatively large such as metal particles and pigment fine particles. | A ballpoint pen tip in which ink grooves are formed around an ink guide hole at equally distributed places, the ink guide hole connecting a ball house and a back hole of a holder for holding the writing ball, and the ink grooves radially penetrate through from the ball house side to the front end portion of the back hole. Inward protrusions are formed at positions which are respectively in contact with the rear ends of the ink grooves. If the inner diameter of the ink guide hole is A, the inner diameter of the front end portion of the back hole is B, the diameter of the circle circumscribing the ink grooves is C, and the diameter of the circle inscribing the inward protrusions is D, their relationships are A<B<C, and D<B. | 1 |
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 relates to a method for treating paper filters contaminated by oil, rust particles and other undesirable contaminants. In a more particular aspect, this invention concerns itself with a method for recovering halogenated vacuum pump oils, such as chlorotrifluoroethylene, from contaminated paper filters which are used in oil purification processes.
At the present time, a number of oil purification processes utilize a vacuum technique to affect purification of oils. Generally, the vacuum pump used to create the necessary vacuum uses a halogenated vacuum pump oil which flows through a series of paper filters. After a period of time, the paper filters become clogged with contaminants from the pump oil and are no longer effective.
As a result, the filters were disposed of even though they contained substantial amounts of oil trapped by the filters' fibers. Disposing of the paper filters, however, constituted a wasteful and expensive practice since large amounts of the vacuum pump oil were discarded along with the filters.
It became extremely important, therefore, that a system be developed that would eliminate the waste involved in discarding paper filters and provide a means for lowering the costs involved in oil purification procedures. The need for such a system that is safe, reliable, inexpensive and ecologically acceptable becomes of paramount importance when one considers the considerable cost involved in using vacuum pump halocarbon oils which are relatively expensive. As a result of this need, a considerable research effort was undertaken in an attempt to overcome this problem and provide a means for recovering the vacuum pump oil in a non-contaminated condition for subsequent reuse in a vacuum pump.
As a result of that research effort, it was found that the problem of removing vacuum pump oil from paper filters, along with the simultaneous problem of eliminating contaminants from the vacuum pump oil itself, could be accomplished by first submerging the oil-saturated paper filters into an extraction bath containing a mixture of trichlorotrifluoroethane and water followed by vacuum distilling the extractive to recover the halocarbon pump oil in reasonably pure and uncontaminated form.
SUMMARY OF THE INVENTION
The present invention concerns itself with a novel method for recovering halocarbon vacuum pump oils from oil-contaminated paper filters. The process utilizes a trichlorotrifluoroethane (TCTFE) and water extraction bath followed by vacuum distilling the resulting extractives. In essence, the oil-saturated paper filters, which are normally discarded after use, are placed in a conventional extraction vessel and submerged in a bath of the extraction mixture. The extraction mixture is then continuously pumped in a countercurrent flow through the filter papers to extract the halocarbon pump oil and other contaminants from the paper filters. After a sufficient period of time has elapsed, the pump is shut off and an extracting solution of the recovered pump oil and (TCTFE) rests at the bottom of the extraction vessel with water floating on top of the extractive mixture. The entire extractive solution is then removed from the extraction vessel and placed in a separator vessel to remove the water constituent. The remaining portion of the extractive is then filtered to remove particulate material and then heated to boiling to remove substantially all of the (TCTFE) leaving a residue containing the recovered pump oil and a small amount of (TCTFE). The resulting solution is then vacuum distilled to remove the residual (TCTFE) from the recovered pump oil resulting in a purified halocarbon vacuum pump oil of about 99 percent purity. The recovered vacuum pump oil is then ready for reuse in a vacuum pump system.
Accordingly, the primary object of this invention is to provide a method for recovering a vacuum pump halocarbon oil from an oil saturated paper filter.
Another object of this invention is to recover a vacuum pump halocarbon oil from paper filters which were heretofore discarded after being utilized in oil purification processes.
Still another object of this invention is to provide a method for recovering a substantially contaminant-free vacuum pump halocarbon oil from paper filters for subsequent reuse in vacuum pump systems.
The above and still other objects and advantages of the present invention will become more readily apparent upon consideration of the following detailed description thereof when viewed in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 represents, in schematic form, an extraction vessel and associated equipment found to be suitable for use in the treatment of oil saturated filters in accordance with the recovery process of the invention.
FIG. 2 represents in schematic form and partly broken away, a separatory vessel for use in the oil recovery process of this invention; and
FIGS. 3 and 4 represent, in schematic form, distillation systems for use in the process of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Pursuant to the above-identified objects, the present invention concerns itself with a process for recovering halogenated vacuum pump oil from paper filters. Paper filters are presently being used in various oil recovery and oil purification processes as well as in vacuum pumps. After a period of operation, the paper filters become saturated with the pump oil and contaminated with dirt and fine metal fibers. Vacuum pumps generally utilize halogenated oils such as chlorotrifluoroethylene oils which are relatively expensive. Heretofore, no method was used to recover the vacuum pump oil from the filters and they were discarded after being removed from the vacuum pump system. As a result, considerable amounts of oil were lost resulting in substantial financial losses.
However, in accordance with the general concept of this invention, the problems associated with discarding the vacuum pump oils were overcome by a process in which the halocarbon vacuum pump oil is recovered from the paper filters by submerging the oil-saturated paper filters in a bath containing a trichlorotrifluoroethane (TCTFE) extraction mixture. After a period of time, depending on the degree of oil saturation, the oil is extracted from the paper filters and the resulting extractive solution comprises a mixture of oil and (TCTFE) . The extractive is then distilled to remove the (TCTFE) component. The end result is a product that is about 99 percent pure vacuum pump oil ready for re-use in a vacuum pump system. This enables the vacuum pump system to operate in a much more economical manner.
In carrying out the process of this invention, the filters, or filtering elements, are removed from either an oil filtering process or from a vacuum pump system. The filtering elements generally used in such processes are fabricated from paper and/or cellulose such as the Velcon filters identified as M/N CA-62202 and M/N F0718PLO-5 manufactured by Velcon Filters, Inc., San Jose, Calif. or the Fluitron filters manufactured by the Fluitron, Fluitec Corporation of Cookeville, Tenn. and identified as M/N C-6022-8P1 and M/N D061365-1052.
After removal from the oil filtering system, the halocarbon oil saturated filters are placed in an extraction vessel 10 of the type illustrated in FIG. 1. The vessel 10 comprises a tank 12 containing a solvent bath of (TCTFE) solvent 14. Oil saturated paper filters 16 are submerged in the bath 14 and then held in place in the vessel 12 by means of a top seal or lid 18 and a bottom seal 20. The solvent 14 is fed into the tank 12 through valve 22 from a source not shown. The solvent 14 dissolves the halogenated pump oil which saturates the filters and extracts it from the filter media.
The oil-saturated filters 16 are also laden with rust particles and other undesirable contaminants. The rust particles are predominantly Fe 2 O 3 (Ferric Oxide). In order to remove the rust and avoid contaminating the extracted oil from the recovery process of this invention, two liters of water are added to the (TCTFE) solvent 14 thereby forming an aqueous phase together with the (TCTFE) solvent phase. Since the rust is more soluble in water, part of the rust is extracted to the aqueous phase of the solvent 14.
The process of recovering oil from the filters 16 is continued by opening valve 24 to feed compressed air from a source not shown to regulator 26. This pressurizes the vessel 12 to about 5-PSIG to make sure that pump 28 does not cavitate. Valves 30 and 32 are opened and pump 28 is started. A Viking positive displacement pump that pumps 2 gallons per minute at 10 feet of head has been found suitable for this purpose. When the pump runs: a solution containing (TCTFE), water, rust particles and dissolved oil is pumped out of the bottom 40 of the extraction vessel 12 through valve 30, strainer 34, pump 28, valve 32 and conduit 36 and into the interior portion of filters 16. The (TCTFE) then dissolves more oil as it passes through the filter material 16 back into the bottom 40 of extraction vessel 12. The strainer 34 serves the purpose of preventing large particles from clogging pump 28.
The pump 28 is run continuously for about 4 hours. The fluid is run at room temperature; but, if desired, it could be heated by conventional heating means, not shown. Elevating the temperature would permit the (TCTFE) to dissolve more oil. At the present time, the process of this invention, when run at room temperature, extracts about 42 percent of the oil from filter elements 16. After about four hours of operation, the pump 28 is turned off. Solution 46, which lies at the bottom 40 of extraction vessel 12, now comprises a (TCTFE) and halocarbon oil mixture 48 with water 50 floating on its surface. At this point, separation of the mixture 48 and water 50 is desireable since the water phase 50 contains undesireable contaminants while the mixture 48 contains the desired recovered oil end product. Separation of solution 46 into its component factions 48 and 50 is accomplished by opening valve 42 and permitting solution 46 to flow into a conventional separator apparatus, such as separatory funnel 44, shown in FIG. 2 of the drawings. The extraction vessel 12 is drained of solution 46 which pours into separatory funnel 44. At this point, vessel 12 can be vented by opening valve 23. Once the solution 46 is positioned in separating funnel 44, the (TCTFE) and halocarbon oil mixture 48 falls to the bottom of funnel 44 while the aqueous phase 50 rises to the top with rust contaminants lying near the aqueous-organic interface 51. Mixture 48 is now ready for further processing while the aqueous portion 50 can be disposed of.
After the (TCTFE)-halocarbon oil mixture 48 has been separated from aqueous phase 50, it is desireable to remove any remaining particulate matter, such as the rust particles located at interface 51. A conventional filter may be utilized and a simple paper filter and funnel have been found satisfactory. The filter paper characteristics are a matter of choice, but 10 μm paper gives a very clean (TCTFE)-oil mixture 48. The mixture 48 is filtered at this point because the viscosity of the mixture is lower than the viscosity of the oil itself which allows for quicker filtration. Also, cleaning the solution 48 at this point keeps the other apparatus and vessels free from particulate contaminants. The fraction 48 is now ready for distillation.
The mixture 48 is placed in a distillation apparatus 52 as shown in FIG. 3. The apparatus 52 comprises a vessel 54 which can be heated by conventional heating means not shown. The mixture 48 is placed in vessel 54 along with boiling stones to facilitate boiling. Vessel 54 is heated until the mixture 48 starts to boil but should not exceed a temperature of about 50° C. A discharge conduit 56 is attached from vessel 54 to a catch tank 58 which in turn is vented to the atmosphere by means of condenser 60. The vapors resulting from heating mixture 48 in vessel 54 travel through conduit 56 into the catch tank 58.
The vapors in tank 58 cannot escape from the catch tank because cooling water at room temperature enters tank 58 through conduit 62 and valve 68 and causes the vapors to condense and drip back into the catch tank 58. During this process, valves 64 and 68 remain open. The oil-trichlorotrifluoroethane mixture 48 is distilled until boiling ceases. At this point, mostly oil is left in the heated vessel 54 while most of the (TCTFE) solvent remains in the catch tank 58. The solvent in the catch tank 58 is clean and can be reused as a solvent. To drain vessel 58, valve 66 is opened. The oil, with a small amount of residual solvent, contained in vessel 54 is now ready for vacuum distillation.
As shown in FIG. 4, the heated vessel 54, containing oil and a small amount of residual solvent, is attached to the inlet of a small vacuum pump 72 by means of conduit 74 and valve 70. The vacuum pump 72 has a capacity of about 60 liters/minute. The pump 72 is started and valve 70 is opened which brings the oil and residual solvent solution under vacuum and allows more of the residual solvent to evaporate from the mixture, yielding a more pure end product. The residual solvent vapors are drawn through the pump 72 and discharged. The oil solution can be heated at this point to offset any heat lost when the residual solvent evaporates. The final solution at about 50° C. and under vacuum for about 5 hours will only contain approximately 1.2 percent trichlorotrifluoroethane by weight. The remaining oil solution in vessel 54 is now ready to be removed and put back into the system it came from for reuse.
Although the present invention has been described by reference to a specific embodiment thereof, it should be understood that by those skilled in the art that the invention is capable of a variety of alternative embodiments and that all such embodiments, as are encompassed within the scope of the appended claims, are intended to be included herein. | A novel treatment method for recovering halogenated vacuum pump oils such as chlorotrifluoroethylene, from contaminated filter papers. The process utilizes a trichlorotrifluoroethane (TCTFE) solvent and water mixture to extract the oil followed by vacuum distilling the resulting extractive. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to hand tool devices, and is more particularly concerned with an adjusting device for hand-held tools, for example wrenches and the like, for applying torque to fixtures or work pieces, such as nuts and bolts.
BACKGROUND OF THE INVENTION
[0002] In my U.S. Pat. No. 6,973,857 I describe such a hand tool device which incorporates fluid operable contact members which is moveable into alternate clamping positions in relation to a work piece by the actuation of a button. The contact members are carried by pistons sliding within opposed cylinders having at their full bore ends resiliently loaded ball valves. When it is desired to effect clamping action by one of the contact members in relation to a work piece, the button is depressed and in so doing the valves are unseated since being physically pushed by the stem of the button thus allowing fluid to eventually flow between the cylinders. By manually pushing the other contact member, fluid flow occurs such that the piston of the contact member associated with the work piece is forced along its cylinder to extend the contact member into the desired clamping position. Release of the button allows the valves to reseat and to lock the contact members in position.
[0003] Whilst the hand tool device of this prior art functions adequately well, it requires two-handed operation and manual effort in addition to the fluid, e.g. hydraulic, force applied to the contact member.
[0004] Accordingly, there is a need for an improved adjusting device for hand-held tools.
SUMMARY OF THE INVENTION
[0005] It is therefore a general object of the present invention to provide an improved adjusting device for hand-held tools.
[0006] An advantage of the present invention is that the adjusting device obviates the need for dual-handed operation.
[0007] Another advantage of the present invention is that the adjusting device enables the user to apply added clamping pressure single-handedly to a contact member in contact with a work piece.
[0008] A further advantage of the present invention is that the adjusting device facilitates release of the clamping pressure when desired to disengage the contact member from the work piece.
[0009] Yet a further advantage of the present invention is that the adjusting device provides a simple and effective means of switching the clamping action from one end to another of a hand tool device with the use of one actuating member.
[0010] Still a further advantage of the present invention is that the piston of the adjusting device can be used to displace a pivotable and/or slidable contact member for clamping or holding a work piece therewith, such as in pliers and the like, or an open-face wrench or any other type of hand tools.
[0011] According to an aspect of the present invention, there is provided an adjusting device for a hand-held tool, comprising: a body defining at least one fluid-filled cylinder internally thereof; a piston movable within said cylinder and carrying a contact member extending exteriorly from the cylinder for contact in use with a work piece to be retained by the tool; a fluid reservoir in communication with said cylinder; a valve interposed between said reservoir and the cylinder for the control of fluid to and from the cylinder; and an actuating member associated with the fluid reservoir for initiating fluid flow across the valve, the actuating member being so adapted whereby upon continued actuation during extension of the contact member the force acting upon the work piece through the agency of the contact member increases.
[0012] The valve is preferably resiliently biased to a closed position on a seating provided for this within the cylinder.
[0013] The actuating member may be in the form of a plunger moveable within the reservoir with a button as simple pressure pad thereon.
[0014] The plunger may conveniently be resiliently biased fluidly away from the valve.
[0015] The valve is advantageously a ball valve normally biased into a closed position by an open-coiled compression spring.
[0016] In one embodiment of the present invention the body of the device defines a single cylinder with the valve being interposed between the reservoir and the cylinder. The actuating member comprises a resiliently-biased plunger operable within the reservoir and carrying a stem contactable with the valve to selectively actuate the valve.
[0017] In said one embodiment the stem of the plunger is grooved for registration with the valve and the plunger is rotatable within the reservoir, rotation of the stem in use causing the valve to open to release pressure fluid from the cylinder into the reservoir thereby withdrawing the contact member. The plunger conveniently includes an externally protruding grip for rotation thereof by a user. A lever may be pivoted to the body of the device and is operable upon the actuating member to operate the same.
[0018] In another embodiment of the present invention the body of the device is elongate and defines first and second fluid-filled cylinders internally thereof, the cylinders being in opposition between ends of the body. A piston is moveable within each cylinder and each carries a contact member extending exteriorly from the respective cylinder for contact in use with a work piece. A resiliently biased valve is interposed between said reservoir and a respective cylinder for the control of fluid to and from the respective cylinder. A switching element is coupled to the actuating member to direct in use fluid flow from the reservoir to a respective cylinder. The actuating member comprises a resiliently-biased plunger operable within the reservoir. Each valve is conveniently in the form of a ball valve and is provided with a main spring and a secondary spring, the main spring being disposed within a respective cylinder and the secondary spring being located in opposition thereto, each said secondary spring being stronger than the corresponding main spring.
[0019] The switching element may be in the form of an apertured disc mounted on the actuating member in such manner as to selectively register with the reservoir to permit or prevent fluid flow across the disc to a selected cylinder.
[0020] In yet another embodiment of the present invention the valve is resiliently biased into an opened position, and the actuating member comprises a resiliently biased plunger. The valve is conveniently a ball valve provided with a main spring and a secondary spring, the main spring being disposed within the cylinder, and the secondary spring being located in opposition thereto and being stronger than the main spring.
[0021] In a further embodiment of the present invention again the body is of elongate form defining first and second fluid-filled cylinders internally thereof, the cylinders being in opposition between ends of the body. A piston is moveable within each cylinder and each piston carries a contact member extending exteriorly from the respective cylinder for contact in use with a work piece to be retained by the tool. The device comprises two reservoirs in communication with the respective cylinders, a resiliently biased valve being interposed between a respective reservoir and the corresponding cylinder for the control of fluid therebetween,and an actuating member associated with each reservoir for initiating fluid flow across the corresponding valve. Each actuating member comprises a resiliently-biased plunger operable within the corresponding reservoir. The actuating members are so adapted that upon actuation of one of said actuating members to initiate fluid flow across a respective valve into one cylinder to pressurize the same, depressurization of the other cylinder occurs. Each actuating member is preferably in the form of a plunger moveable within the reservoir and carries a stem for initiating actuation of the valve associated with said other cylinder.
[0022] Conveniently, in use, the movement of the actuating member causes an increase in fluid pressure in its respective reservoir thereby to open said valve of the respective cylinder to extend the corresponding piston and its respective contact member and simultaneously to effect contact of the stem with the other said valve to release fluid from the other said cylinder thus retracting the other said piston and its contact member.
[0023] The fluid used in all the embodiments is conveniently hydraulic oil.
[0024] Other objects and advantages of the present invention will become apparent from a careful reading of the detailed description provided herein, with appropriate reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Further aspects and advantages of the present invention will become better understood with reference to the description in association with the following Figures, in which similar references used in different Figures denote similar components, wherein:
[0026] FIG. 1 is an end view of an adjusting device for a hand-held tool in accordance with a first embodiment of the present invention;
[0027] FIG. 2 is a sectional view taken along line 2 - 2 of FIG. 1 ;
[0028] FIG. 3 is a plan view of a second embodiment;
[0029] FIG. 3 a is an end view of the device of FIG. 3 ;
[0030] FIG. 4 is a sectional view taken along line 4 - 4 of FIG. 3 a;
[0031] FIG. 5 is an end view of a third embodiment;
[0032] FIG. 6 is a sectional view taken along line 6 - 6 of FIG. 5 ;
[0033] FIG. 6 a is a partially broken enlarged sectional view taken along line 6 a - 6 a of FIG. 6 ;
[0034] FIG. 7 is an end view of a fourth embodiment;
[0035] FIG. 8 is a sectional view taken along line 8 - 8 of FIG. 7 ;
[0036] FIG. 8 a is a sectional view taken along line 8 a - 8 a of FIG. 8 ;
[0037] FIG. 9 is an end view of a modified fourth embodiment; and
[0038] FIG. 10 is a sectional view taken along line 10 - 10 of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] With reference to the annexed drawings the preferred embodiments of the present invention will be herein described for indicative purpose and by no means as of limitation.
[0040] Reference is now made to FIGS. 1 and 2 . The adjusting hand tool device is shown generally at 1 and comprises a double-ended elongate body 2 defining therewithin two typically axially aligned (they could be angled without departing from the scope of the present invention) opposed cylinders 4 , 6 within each of which is accommodated a respective piston 8 , 10 . The cylinders are typically filled with hydraulic oil. The piston 8 , 10 each carry a contact member 12 , 14 for contact with a work piece 3 (shown in dotted lines in FIG. 3 ), the members 12 , 14 extending exteriorly of the body 2 as shown which has at each end a typically fixed ring 16 , 18 for locating the work piece 3 in use.
[0041] Intermediate the cylinders 4 , 6 is a control block 20 in which are formed two reservoirs 22 , 24 each having an actuating member such as a spring-loaded plunger 26 , 28 (with conical coil springs being shown) or the like respectively slidable therewithin in close fitting manner (sealed). Each plunger 26 , 28 has a button-like head 27 , 29 . The plungers 26 , 28 respectively carry stems 30 , 32 which sealably slide within guide channels 34 , 36 formed in the block to prevent fluid communication between the two reservoirs 22 , 24 (including the corresponding channels 34 , 36 ).
[0042] A ball valve 40 , 42 is seated within the end of a respective cylinder 4 , 6 and is resiliently loaded as by a spring 44 , 46 extending between the respective piston 8 , 10 and the valve 40 , 42 .
[0043] In operation of the first embodiment, one end ring 16 is located over a work piece 3 by a user and the relatively lower plunger 28 (as shown in the drawing) is depressed by the user the oil from the reservoir 24 to become pressurized and in so doing the ball valve 42 is lifted off its seating against the action of the spring 46 thus allowing the oil to enter the cylinder 6 to extend the contact member 14 into the ring space. At the same time the stem 32 of the plunger 28 contacts the opposite ball valve 40 to lift it from its seating thus allowing egress of oil from the cylinder 4 and releasing the contact member 12 . At the same time the oil escaping from the cylinder 4 pushes the plunger 26 to a starting position within the respective reservoir 22 . Furthermore, release of manual pressure from the plunger 28 allows the valve 42 to become reseated under the action of the spring 46 , thus locking the contact member 14 onto the work piece. When the tool is to be released from its clamping position, the plunger 26 is actuated whereby its stem 30 contacts the valve 42 to push it off its seating to allow oil flow from the cylinder 6 . At the same time oil is forced from the reservoir 22 into the guide channel 36 to release the valve 40 to allow oil flow into the cylinder 4 .
[0044] Operation of the contact member 12 is the same mutatis mutandis as for the contact member 14 .
[0045] It will be well understood that whilst a user continues to apply pressure to a plunger, the corresponding contact member continues to be increasingly pressurized.
[0046] Referring now to FIGS. 3 , 3 a and 4 , a second embodiment of adjusting hand tool device is shown and this embodiment differs from the first embodiment by providing a differently formed control block 20 , which again defines separate reservoirs 22 , 24 with respective plungers 26 , 28 that are not provided with any stems. The reservoirs 22 , 24 have channels 34 , 36 each leading separately to the cylinders 4 , 6 via the valves 40 , 42 . In this embodiment there is provided for each ball valve a secondary spring 50 , 52 accommodated in respective channels 34 , 36 opposed to the main springs 44 , 46 . All other features of this embodiment correspond to those of the first embodiment and are not described specifically again.
[0047] In this second embodiment, when it is desired to apply clamping pressure to a work piece 3 registering within one of the rings 16 , 18 the appropriate plunger 26 , 28 is operated to push oil from the reservoir 22 , 24 into the fluid-filled cylinder 4 , 6 and initiate displacement of the contact member 12 , 14 . Once the member 12 , 14 contacts the work piece, the user stops depressing the plunger 26 , 28 and starts rotating the tool around the work piece to pressurize the oil in the respective reservoir 22 , 24 . With the increasing pressure within the relevant cylinder, the ball valve reseats under the action of the oil pressure to lock the oil within the cylinder. However, once pressure on the work piece is removed the secondary spring 50 , 52 , which is of greater strength than the main spring 44 , 46 , overcomes the resistance of the main spring and lifts the valve 40 , 42 off its seating to allow back flow of the oil into the reservoir 22 , 24 .
[0048] In this second embodiment, the contact members and their respective active components operate independently of each other.
[0049] Referring now to FIGS. 5 , 6 and 6 a, a third embodiment of an adjusting hand tool device comprises similar features to those shown in FIGS. 3 , 3 a and 4 with the exception of the control block 20 which houses a single reservoir 20 with its associated spring-loaded plunger 26 which carries a stem 30 of hexagonal cross section (any other non-circular shape could obviously be considered without departing from the scope of the present invention) as can be seen more distinctly in FIG. 6 a, and is rotatably moveable within the generally cylindrical guide bore 34 ′. A selector element in the form of a disc 60 sealably engages on the stem 30 and is provided with blanking zone 62 and a cut-out 64 which latter is shown in FIGS. 6 and 6 a registering with a bore 66 extending from the reservoir 22 and opening into the end of the cylinder 4 , a similar bore 68 , shown as being blocked by the disc 60 , also extends from the reservoir 22 to open into the end of the cylinder 6 . The ball valves 40 , 42 are spring-loaded on opposite sides as with the previous embodiment, with the secondary springs 50 , 52 located within the respective bore 66 , 68 .
[0050] In operation of this embodiment with the orientation of the disc 60 as depicted, downward pressure of the plunger 26 causes oil to flow from the reservoir 20 into the bore 66 and thence past valve 40 into the cylinder 4 to extend the piston 8 and thus the contact member 12 into a clamping mode. As with the previous embodiment as the pressure on the contact member reduces upon rerleasing the work piece 3 so does the oil pressure inside the cylinder 4 and the secondary spring 50 causes the valve 40 to unseat and allow retraction of the piston 8 and the contact member 12 . The backflow of oil resets the plunger 26 . When it is desired to use the other contact member 14 , the plunger 26 is rotated, using an externally protruding and generally diametrically extending grip 31 , to bring the cut-out 64 into registration with bore 68 leading to the cylinder 6 while sealably blocking the bore 66 . The actuation of the plunger 26 is now capable of pressurizing the cylinder 6 to operate the piston 10 and the contact member 14 carried thereby.
[0051] Referring now to FIGS. 7 , 8 , and 8 a, the adjusting hand tool device of this fourth embodiment has but a single cylinder 6 formed within the body 2 and has a single reservoir 20 with the spring-loaded plunger 26 slidably operable therewithin. The plunger carries a stem 30 moveable within the associated guide channel 34 , the stem 30 having a groove 70 formed therein for clearing the ball valve 42 which partly extends into the channel 34 as shown and to allow the oil to flow between the reservoir 22 and the cylinder 6 via the channel 34 . When it is required to operate the hand tool device, the plunger 26 , with the groove 70 in register with the valve 42 , is depressed to expel oil from the reservoir 20 into the groove 70 and past the valve 42 into the cylinder 6 to extend the contact member 14 into the ring 18 . Continuing pressure on the plunger 26 increases pressure on the piston. Release of the plunger allows the pressurized oil in the cylinder 6 and the spring 46 to reseat the valve 42 and lock the tool device in its clamping mode. When it is desired to release the device, the plunger is rotated using the grip 31 thus causing the stem 30 , the walls of the groove 70 , to move the ball valve 42 off its seat to allow backflow of oil into the reservoir 22 .
[0052] Turning now to FIGS. 9 and 10 , there is shown a modified version of the fourth embodiment in which a lever 80 is hinged at 82 to the body 2 to provide a pivot, the lever having a protuberance 84 for contacting the grip 31 of the button-like head 27 of the plunger 26 . The provision of the lever 80 affords greater pressure to be applied to the plunger 26 . Release of the pressure in the cylinder is again effected by rotating the plunger to move the valve off its seating.
[0053] It is to be understood that with all embodiments of the present invention continued operation of the plunger(s) causes increased clamping pressure on the contact member.
[0054] While specific embodiments of the adjusting device for hand-held tools of the present invention has been described, those skilled in the art will recognize many alterations that could be made within the spirit of the invention. The description provided herein is provided only for purposes of illustration, and not for purposes of limitation. | A hand tool device incorporates a fluid operated mechanism actuable by a plunger pressurizing a reservoir to force fluid past a valve to a fluid filled cylinder accommodating a piston carrying a contact member for clamping a work piece in the manner of a wrench. Continued operation of the plunger increases the pressure applied to the work piece. | 1 |
TECHNICAL FIELD
The present invention relates to certain improvements in switching and power control circuitry for brushes driven by electric motors mounted on floor maintenance apparatus.
A wide variety of machines are available for use in maintenance of surfaces such as floors, parking lots, and streets. These maintenance machines generally include, among other types of equipment, sweeping machines and scrubbing machines. The present invention may be utilized on any such equipment to vary the speed of the sweeping brushes, scrubbing brushes or other tools. A floor maintenance machine equipped with this invention may be capable of more effective cleaning on a greater variety of floor surfaces than is possible with a single speed brush. The invention may also be coupled with floor maintenance apparatus having a variable speed of travel in order to permit more rapid coverage of the floor area since the brush speed may keep pace with the increased travel speed.
BACKGROUND OF THE INVENTION
Historically, floor maintenance apparatus with electrically powered brushes have had brushes limited to a single speed.
BRIEF SUMMARY OF THE INVENTION
The present apparatus is designed for use in floor maintenance apparatus having electrically driven brushes. Briefly, the floor maintenance apparatus may have a single pole, double throw (SPDT) switch mounted on its control panel. The switch, when operated in one direction, actuates relay coils which close relay contacts thereby arranging the two brush motors in series with each other and with the batteries. Throwing the switch the other direction actuates other relay coils which in effect rearrange the circuitry such that the brush motors are connected in parallel across the batteries. This permits the brush motors to operate at higher voltage and thus have increased power and speed.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a walk behind floor maintenance vehicle with electrically driven brushes;
FIG. 2 is a schematic diagram of the present improved control circuitry;
FIG. 3 is a schematic diagram of a second preferred embodiment of the improved control circuitry.
DETAILED DESCRIPTION OF THE INVENTION
A walk behind floor maintenance machine 10 of the present invention is disclosed in FIG. 1 having a battery compartment 14, switch controls 15, drive wheels 16 and a pair of brushes 12 and 12a.
Circuitry for one embodiment of the present improved control circuit is illustrated in FIG. 2 and includes two brush motors M1 and M2, one of which drives each of the brushes 12 and 12a shown in FIG. 1 respectively. The motors should be chosen with similar current and power characteristics although identical matching is not necessary. Batteries B1 and B2 may be storage type batteries consisting of several six or twelve volt batteries connected in series. Other voltages, however, are acceptable. For example, battery B1 may be 18 volts and battery B2 may be 18 volts.
Switching is provided for with mechanical relays. Solid state switching devices could of course be employed or switching could be accomplished directly with ganged heavy duty mechanical switches capable of handling the current.
Relay coils L1, L2, L3 and L4 provide mechanical switching for the circuit arrangement of the motors and should be chosen so that they will operate satisfactorily on the voltage of batteries B1 and B2. The relay contacts K1, K2, K3 and K4 associated with the relay coils L1 through L4, respectively, are capable of carrying the current load drawn by motors M1 and M2. These relay contacts are all of the normally-open type.
Switch SW1 consists of a single pole double throw (SPDT) switch with a neutral position for "Off". Switch SW1 may be mechanically connected to switch controls 15 of the vehicle in FIG. 1. It may be desirable to use a slow acting manual switch for SW1 in order to prevent the possibility of a direct short occuring should all relay contacts be closed simultaneously. This could occur if SW1 is operated quickly and the contacts in the newly-completed circuit close before the now-opened circuit contacts have yet to physically open. Fuses F1, F2, F3 and F4 are large enough to handle the current requirements of the circuit in which they are placed yet sufficiently limiting to protect the circuit. Fuse F4 protects wiring against this possible short circuit. Motors M1 and M2 consist of any type of DC motor capable of sufficient power output to rotate the sweeping brushes at appropriate speeds when they are in contact with the floor surface.
CIRCUIT LAYOUT
The circuit in FIG. 2 includes a battery B1 whose positive conductor is connected to bus line 101 and whose negative conductor is connected by bus line 102 to the positive terminal of battery B2. Bus line 102 is also connected to bus line 103. The negative terminal of battery B2 is connected to bus line 100. Bus line 101 is tapped by conductor 108, which is connected to one side of fuse F3. The other side of fuse F3 is connected to the common pole PC of switch SW1. Pole PA of switch SW1 is connected to the parallel combination of relay coils L1 and L3, which is in turn connected to bus line 100 through conductor 114. The other pole PB of switch SW1 is connected to the parallel combination of relay coils L2 and L4 which are connected to bus conductor 100 by conductor 114.
Bus line 101 is tapped by conductor 106 which is connected to one side of relay contact K3. The other side of relay contact K3 is connected to conductor 116 and one side of motor M2. The other side of motor M2 is connected to bus line 100 through fuse F2 and conductor 112. Bus line 101 also is tapped by conductor 104 which is connected to motor M1 through fuse F1. The other side of motor M1 is connected to the parallel combination of relay contacts K1 and K2. The other side of relay contact K1 is connected to bus conductor 100 through conductor 110 and the other side of the relay contact K2 is connected to conductor 103 through fuse F4. Relay contact K4 is connected between conductor 116 to conductor 103.
OPERATION OF THE INVENTION
The improved brush control circuitry may be used in conjunction with a variety of types of floor maintenance equipment including walk behind and riding type floor sweepers. A typical walk behind type vehicle 10 is shown in FIG. 1. Levers 15 in this embodiment may include a speed or direction control lever and a brush speed control lever. The brush speed lever may be connected to switch SW1 such that when the lever is pushed forward switch SW1 is closed from pole PC to PA, hereinafter referred to as the "first position", and when the lever is pulled backward, the circuit is complete from pole PC to PB, hereinafter referred to as the "second position".
When switch SW1 is in the first position, current flows from the batteries through bus line 101, conductor 108, through fuse F3, through switch SW1 and into relay coils L1 and L3. The current then returns to the batteries B1 and B2 through connector 114 and bus line 100. When relay coils L1 and L3 are energized, their corresponding contacts K1 and K3, respectively, are closed. This action completes two independent circuits, one for supplying current to each motor M1 and M2. In the first such circuit current from bus line 101 is tapped at conductor 104 which then travels across fuse F1, through motor M1, across relay contact K1 which is now closed, into conductor 110 and back to the batteries by bus line 100. In the second such circuit bus line 101 is tapped by conductor 106. Current flows into conductor 106, then across relay contact K3, through motor M2, through fuse F2, and into conductor 112, and in turn back to the batteries by bus line 100. This provides the full voltage of batteries B1 and B2 to each motor. Relay coils L2 and L4 are energized when switch SW1 is operated such that the circuit is completed with pole PC to PB. This will close the corresponding relay contacts K2 and K4. Now current will flow from batteries B1 and B2 into bus line 101, through at conductor 104, through fuse F1, into motor M1 through contact K2, through contact K4 into motor M2 and returning to the batteries through the fuse F2, conductor 112 and bus line 100. Conductor 103 carries a current when SW1 is in the second position under some circumstances. If motors M1 and M2 are not electrically identical or if different loads are applied to the brushes when they turn, a current may appear in 103, its direction dependent upon which motor draws more current. In such a case the circuit will appear to have two loops, one with motor M1 and battery B1 and the other with motor M2 and battery B2 with a conductor 103 common to both. The purpose of this configuration is to prevent the unequal operation of the brushes caused by unequal draw of the two motors. Thus motors M1 and M2 are now in series with batteries B1 and B2 and will be receiving approximately half voltage of batteries B1 and B2. It would also be possible to use unequal battery voltages for B1 and B2 or employ a switch to connect conductor 103 to different taps on the cells of the batteries in order to produce unequal speeds in motors M1 and M2.
SECOND PREFERRED EMBODIMENT
A second preferred embodiment of this invention is shown in FIG. 3 of the drawings. This alternative circuitry provides the same results as that of FIG. 2 with the advantage that there is no possibility of a direct short which could occur in the circuitry in FIG. 2 if all relay contacts happen to be closed at the same moment. This potential problem was described in the Detailed Description of the Invention supra.
This second preferred embodiment contains a power supply consisting of batteries B3 and B4, two brush motors M3 and M4, three relay coils L5-L7 with corresponding relay contacts K5a, K5b, K6a, K6b and K7 respectively, a single-pole-double-throw manual switch SW2 with a neutral position for "Off", three fuses F5, F6 and F7, and a diode D1. Relay coil L5 has corresponding relay contacts K5a which is normally open and K5b which is normally closed. Relay coil L6 has corresponding relay contacts K6a which is normally closed and K6b which is normally open. Relay coil L7 has a corresponding relay contact K7.
The above-mentioned components are connected as follows: the positive terminal of battery B3 is connected to the bus line 201 and its negative terminal is connected to the positive terminal of battery B4 via conductor 202. The negative terminal of battery B4 is connected to bus line 200. Bus line 201 is tapped by conductors 204 and 208. Conductor 204 is connected to one side of relay contact K7, the other side of K7 being connected to one side of fuse F5 and one side of relay contact K6a. The other side of fuse F5 is connected to one side of motor M3, the other side of M3 being connected to one side of relay contacts K5a, K5b and K6b. The other side of relay contact K5a is connected to conductor 202, the other side of contact K5b is connected to bus line 200, the other side of K6b is connected to the other side of K6a and one side of motor M4. The remaining side of M4 is connected to fuse F6 which in turn is connected to bus line 200 by conductor 212. Conductor 208 is connected to one side of fuse F7. The other side of fuse F7 is connected to the common pole C of switch SW2. One pole of SW2 denoted A is connected to the cathode side of diode D1 and one side of relay coil L7. The remaining pole of SW2 denoted B is connected to the anode side of diode D1 and one side of relay coils L5 and L6. Note that normally-open contacts of either L5 or L6 could be substituted for D1 and work as described without potential reversed polarity problems with D1. The remaining sides of relay coils L5, L6 and L7 are connected in parallel and in turn to bus line 200 by conductor 214.
This second preferred embodiment operates as follows: when switch SW2 is closed from pole C to pole A the current flows from battery B3 into bus line 201 and conductor 208 through fuse F7 across switch SW2 through relay coil L7 and back to the battery via conductor 214 and bus line 200. With this circuit complete L7 is energized and relay contact K7 is now closed. Current may now also flow from bus line 201 through relay contact K7 and contact K6a which is normally closed through motor M4, fuse F6 and back to the battery through conductor 212 and bus line 200. Current will also flow from relay contact K7 through fuse F5, motor M3 and normally-closed relay contact K5b into bus line 200 and back to the batteries. Thus, in this configuration motors M3 and M4 are essentially in parallel with each other and in series with batteries B3 and B4.
With switch SW2 closed from pole C to pole B, all three relay coils L5, L6 and L7 would be energized. Notice that L7 is energized with current supplied through diode D1. With all three coils energized all relay contacts would be operated. Thus, current would flow from bus line 201 across relay contact K7 and fuse F5 through motor M3 into relay contact K6b, through motor M4 and fuse F6 and returning to battery B4 through conductor 212 and bus line 200. Notice that the motors M3 and M4 are now connected in series with each other and with batteries B3 and B4.
Should the current requirement of one of the two motors be unequal as a result of unequal specifications of the motors or unequal force applied to the armatures, current may flow across relay contact K5a. The direction of this current is dependent upon which motor is drawing the greater current. The purpose of this relay contact is analogous with that of conductor 103 of FIG. 2. With such a conductor in place neither motor M3 or M4 will be stalled by unequal current requirements when the motors are in series. | An improvement for floor maintenance equipment employing electrically driven scrubbing or polishing brushes including means for varying the speed of the brush motors. Two brush speeds are provided by switching apparatus which change the interconnection of the brush motors from series to parallel and from parallel to series. This results in a substantial change in motor speed and power. | 0 |
FIELD OF THE ART
The present invention relates to open-end spinning machines, and more specifically, to fibrous sliver condensers to be used in such machines.
This invention may be most advantageously used for mechanopneumatic spinning machines where the main working element is a spinning chamber to which separated fiber is fed.
BACKGROUND OF THE INVENTION
It is known that one of the factors affecting quality of spinning, in particular the evenness, is uniform feeding of separated fiber to the spinning chamber. Such uniform feeding may be achieved, e.g., by uniformly distributing fiber over the cross-section of sliver when it is fed to a separating apparatus (carding arrangement or a drawing apparatus).
Slit-shaped condensers of various designs are used for uniformly distributing fiber over the sliver.
Thus known in the art are condensers installed upstream a drawing apparatus (cf. U.S. Pat. No. 3,947,923, Cl. 19-288, Apr. 6, 1976). The condenser is shaped as a triangle having inside thereof members forming a vertical slit enabling the movement of sliver (roving) downwards when moving along thicker portions. The movement of roving is limited by means of a bridge. The sliver can take any arbitrary position within the condenser.
Such movement of sliver is that is its movement under gravity results, however, in that the sliver tends to gather into a bunch, thickening in the middle of the condenser, whereby the sliver is not uniformly fed to the drawing apparatus, and the drawing quality is inadequate.
More uniform distribution of fiber in sliver may be ensured by using a known condenser (cf. German Offenlegungsschrift No. 2359176, May 30, 1974). This condenser has a casing accommodating a passage for sliver which narrows in the direction of sliver movement. At the sliver outlet side, the passage terminates in a rectangular opening, and the passage is internally provided with opposite projections extending at an angle to the longitudinal axis of the passage.
The provision of the opposite projections enables uniform distribution of fiber over the sliver since such projections engage the sliver to press out surplus fiber (bunches) from the middle of the sliver to its lateral portions.
In case, however, the structure of a sliver is such that maximum quantity of fiber is at the edges thereof and minimum quantity is in the middle portion, the prior art projections fail to provide uniform distribution of fiber over the entire cross-section of sliver.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a sliver condenser which ensures uniform distribution of fiber over the entire cross-section of sliver.
An important object of the invention is to improve the quality of the yarn.
These and other objects are accomplished in a sliver condenser having a casing provided with a passage which narrows in the direction of sliver flow and terminates in a rectangular opening, the passage being internally provided with opposite projections extending at an angle to the longitudinal axis of the passage, according to the invention, each projection extends over the entire length of the passage on either side of its longitudinal axis and the opposite projections cross one another.
The provision of the projections extending over the entire length of the passage and intercrossing of the projections provides uniform density of fiber over the entire cross-section of sliver since one fin displaces surplus quantity of fiber toward one edge of the sliver and the other fin which extends in the opposite direction, displaces the surplus quantity of fiber toward the other edge of the sliver.
For a simpler manufacture, each projection is made in the form of a step.
To maintain intact the sliver structure in the middle portion thereof, as well as to avoid breaking of formed flow of fiber at the sliver outlet from the condenser passage, the projections inside the passage are preferably arranged in such a manner that the distance therebetween on the side of the sliver outlet from the passage is equal to the maximum cross-sectional dimension of the outlet opening of the passage.
To improve the degree of action on thicker portions of sliver in the inlet and working zones, the projections are preferably arranged inside the passage in such a manner that the distance therebetween on the side of sliver entrance to the passage is from 0.4 to 1.0 of the maximum cross-sectional dimension of the passage. The distance 2a, equal to 0.4, in selected in case of processing an ordinary sliver in the condenser, that is a sliver having a lenticular cross-sectional shape. In such application, the main mass of fiber is in the middle of the sliver, and most intense action of the projections eliminating thicker portions which are displaced toward the edges, occurs in the central part of the sliver.
The distance 2a equal to 1.0 is used in applications where the condenser is used for a sliver having enlarged edge portions, that is an intense action of the projections for eliminating thicker portions at the edges and displacing them to the middle, occurs at the sliver edges.
The condenser according to the invention is preferably used in a drawing apparatus having a feeder device comprising a sliver clamping line arranged at an angle to the flat side of sliver. In such case, the distance as measured on the side of the inter opening of the passage between the surface provided with the projections is greater than the maximum dimension of the outlet opening of the passage.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention may be had from the following specific embodiments described with reference to the accompanying drawings, in which:
FIG. 1 shows the condenser according to the invention as seen from the inlet opening of the passage;
FIG. 2 is a sectional view taken along the line II--II in FIG. 1;
FIG. 3 is a sectional view taken along the line III--III in FIG. 1;
FIG. 4 is a sectional view taken along the line IV--IV in FIG. 3;
FIG. 5 is another embodiment of the condenser according to the invention;
FIG. 6 is a sectional view taken along the line VI--VI in FIG. 5;
FIG. 7 is a sectional view taken along the line VII--VII in FIG. 5;
FIG. 8 is a transverse section of the condenser;
FIG. 9 is the condenser according to the invention used in a drawing apparatus.
DETAILED DESCRIPTION OF THE INVENTION
The sliver condenser according to the invention has a casing 1 (FIG. 1) having inside thereof a passage 2 (FIG. 2) which narrows in the direction of sliver flow and terminates in a rectangular opening 3 (FIG. 1). The passage 2 is defined by a pair of walls 4 and 5 of which the walls 5 are wider than the walls 4.
The passage 2 is internally provided with opposite projections 6 which are made on the wider walls 5. The projections extend at an angle "α" to the longitudinal axis 7 of the passage 2 and cross one another, that is they extend in the opposite directions as can be seen in FIGS. 1, 3 and 4. Such arrangement of the projections enables elimination of fiber bunches by drawing fiber apart in the sliver in opposite directions, thereby ensuring evening of the sliver over the entire cross-section.
The projections 6 (FIG. 2) are arranged within the passage 2 in such a manner that the distance 2a therebetween (a is the distance from one projection to the longitudinal axis 7 of the passage) on the side of entrance of sliver to the passage 2 is from 0.4 to 1.0 of the maximum cross-sectional dimension of the inlet opening 8 of the passage.
The distance 2a is equal to 0.4 of the maximum dimension in an application where an ordinary sliver that is, a sliver of a lenticular cross-sectional shape is fed to the sliver condenser, and the distance 2a is equal to 1.0 maximum dimension in an application where a sliver with enlarged edges is fed to the sliver condenser.
FIGS. 5 and 7 show an embodiment of the sliver condenser in which each of the opposite projections thereof is formed as a step 9. The steps also extend at an angle "α" to the longitudinal axis 7 of the passage 2 (FIG. 6) and are arranged within the passage in such a manner that the distance "b" therebetween on the side of the sliver outlet from the passage 2 is equal to the maximum cross-sectional dimension of the outlet opening 3 of the passage.
The sliver condenser functions in the following manner.
A sliver 10 (FIG. 8) is inserted into the sliver condenser on the side of the inlet opening 8 of the passage 2, passes along this narrowing passage and leaves in the condenser state through the rectangular slit-shaped opening 3. When passing through the passage, the enlarged portions "c" of the sliver 10 are engaged by the projections 6,9 and are displaced thereby in opposite directions as shown by arrows "A" in the drawings.
This ensures a uniform distribution of fiber over the entire cross-section of the sliver at the outlet of the sliver condenser, thus contributing to a high degree of separation of fiber, hence, improved quality of the resultant yarn.
It is well known that sliver in cans or spools takes a flat shape under pressure.
On the other hand, known in the art are separating and drawing apparatus having a sliver clamping line 11 in their feed pairs of rolls as shown in FIG. 9 which extends at an angle to the flat side of the sliver 10.
In such a case, the sliver is fed to the clamp with its narrow side and its distributed along the line of clamp in the form of a bunch of an arbitrary configuration.
For a better separation of fiber, hence for improving quality of yarn, the flat side of the sliver is preferably oriented along the clamp line. This is achieved by using the sliver condenser according to the invention.
As shown in FIG. 9, the sliver 10 is fed to the entrance portion of the sliver condenser in such a manner that its edges are between the walls having the steps 6, 9 with a dimension "d". When the sliver moves, the steps act more strongly on its edges to turn the sliver in such a manner that its flat part is oriented along the maximum dimension "b" of the outlet opening, that is along the clamp line of the fiber by the feed pair of rolls. In order that the sliver cannot be damaged at the edges due to an abrupt narrowing, the distance "d" between the walls on which the projections are provided is preferably greater than the maximum cross-sectional dimension "b" of the outlet opening of the sliver condenser. | The invention relates to sliver condensers and may be most advantageously used in mechanopneumatic spinning machines. The sliver condenser has a casing provided with a passage which narrows in the direction of sliver flow. Opposite projections are internally provided over the entire length of the passage to extend at an angle to the longitudinal axis of the passage, the projections crossing one another. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to the manufacture of a long elongate composite element, comprising long reinforcement fibers, embedded in a matrix of cured resin.
It is becoming more and more common to use composite materials for manufacturing structural components or load-bearing components or reinforcement elements, owing to the ever better performance which may be achieved with composite materials. Composite materials often allow considerable weight savings to be made while achieving equivalent mechanical performance. Moreover, in applications where the composite material is subject to considerable stress, it is very important to be able to benefit fully from the reinforcing action of the fibers. This requires absolute mastery of the manufacture of composite elements.
The role of the resin is to connect the fibers firmly to one another and to transmit stresses to the fibers. It is very important for the fibers to be totally impregnated and distributed homogeneously and in accordance with the desired level of reinforcement over the entire cross section of the composite element.
One of the known methods of manufacturing composite components with good mechanical qualities is known as “pultrusion”. This entails continuously unwinding the reinforcing fibers and dipping them in a resin bath to ensure that the fibers are impregnated with the resin. Then, all the fibers and impregnating resin are drawn through a heated die, in order to effect at least partial polymerization of the resin. In this way, it is possible continuously to draw products with a cross section dictated by the shape of the die. Unfortunately, pultrusion does not readily lend itself to high speed operation, as impregnation tends to be slow and difficult. Furthermore, the kinetics of the heat transfer phenomenon considerably limits the rate of manufacture.
Another known possibility consists in disposing the reinforcement fibers as desired in a mold, producing a vacuum and finally impregnating the fibers with the resin. The vacuum allows very effective impregnation. This method lends itself well to the manufacture of components of moderate finite dimensions, as a mold is used which corresponds to the shape and dimensions of the manufactured component. However, when it comes to the continuous manufacture of long components, it is not easy to impregnate the fibers correctly. And the more it is wished to accelerate production rates, the more difficult it becomes to ensure perfect impregnation of the fibers with the resin.
Furthermore, the increasing commercial popularity of composite materials also depends on their cost price. It is therefore very important to be able to propose technological means capable of high manufacturing rates under the most competitive economic conditions possible.
SUMMARY OF THE INVENTION
One object of the invention is to achieve the fullest possible impregnation of the fibers in a manner which is compatible with very high manufacturing rates. Another object is to arrive at this result in a manner which is compatible with continuous manufacture.
A process for the continuous preparation of a long elongate composite element, containing reinforcement fibers embedded in a matrix based on a composition comprising a curable resin. The reinforcement fibers are formed into an arrangement which is conveyed so as to subject it, successively and in a feed direction, to the following, operations: degassing the arrangement of fibers by the action of a vacuum in a first processing chamber; impregnating said arrangement of fibers with said composition in a second processing chamber separate from said first processing chamber, to obtain a pre-preg containing the fibers and the composition while keeping said arrangement substantially out of contact with the atmosphere; passing said pre-preg through a die having a cross section of predetermined area and shape, to provide said pre-preg with a predetermined shape; and downstream of the die, stabilizing the shape of the pre-preg by at least partial polymerization of the pre-preg resin.
It should be noted that the fibers are called “long” because the length is not limited by constraints resulting from the production process, which latter may be described as continuous. According to a significant aspect of the present invention and in contrast to conventional pultrusion, the sizing die does not play any role in polymerization of the resin.
Preferably, the stabilization stage continues until said composition forms a solid medium (stage known as the gelling stage or therebeyond), so that the product is sufficiently cohesive to be capable of subsequent handling, for example to be capable of undergoing other treatments or of being used as an intermediate product incorporated into an end product, with the mechanical stresses which that entails, without the risk of “wringing” of the fibers, during which the amount of resin in the preform would diminish in an uncontrolled manner. The aim of stabilization is thus preferably to achieve a minimum level of polymerization allowing the prevention of any outflow of resin upon subsequent treatment thereof (in effect, treatment of the composite or of the item into which it is incorporated) under the action of heat, or even of pressure. The aim of stabilization is also preferably to achieve a minimum level of polymerization allowing the stabilized pre-preg to be provided with resistance to buckling of its fibers under subsequent bending stress.
Said composition advantageously comprises a resin curable by ionizing radiation and the stabilization stage is performed by means of a suitable treatment, for example by ionizing radiation. As suitable ionizing radiation, it is proposed to use ultraviolet-visible radiation in the spectrum ranging from 300 nm to 450 nm or a beam of accelerated electrons. Initiating polymerization by ionizing radiation not only allows the achievement of a stabilized impregnated state but also allows the process of polymerization to be stopped by ceasing emission of said radiation. In effect, the aim of stabilization is also not to exceed a maximum level of polymerization, allowing subsequent adhesion of the stabilized pre-preg, for example to itself or to rubber.
It is possible to select a composition comprising a resin curable by a peroxide, the stabilization stage being performed by means of a heat supply, for example by the action of microwaves. It is also possible to select a composition comprising a resin curable by ionizing radiation, stabilization stage polymerization being initiated and controlled by means of an ionizing treatment. The latter variant is of more particular relevance, since it opens up the way to various methods of liquefying the resin, so as to facilitate impregnation of the arrangement of fibers.
Thus, according to another aspect, the invention proposes a process for the continuous preparation of a long elongate composite element comprising reinforcement fibers embedded in a matrix based on a composition comprising a resin curable by ionizing radiation, comprising the following stages:
arranging reinforcement fibers and conveying this arrangement so as to subject it, successively and in the feed direction, to the following operations, while keeping said arrangement out of contact with the atmosphere; impregnating said arrangement of fibers with said composition to obtain a pre-preg containing the fibers and the composition; passing said pre-preg through a die having a cross section of predetermined area and shape, to provide said pre-preg with a predetermined shape; downstream of the die, stabilizing the shape of the pre-preg by at least partial polymerization of the pre-preg resin, said at least partial polymerization being initiated and controlled by ionizing radiation.
It is of course also possible to improve the efficacy of the impregnation by degassing the arrangement of fibers prior to impregnation by the action of a vacuum.
As suitable ionizing radiation, it is proposed to use radiation in the spectrum ranging from 300 nm to 450 nm designated hereinafter, as is conventional, as the ultraviolet-visible spectrum. It should be noted in passing that the degree of desired polymerization is achieved for example by adjusting the time of exposure to the ultraviolet-visible radiation (conveying speed, length of polymerization device).
In a particular embodiment, it is proposed experimentally to control the degree of polymerization by means of an analysis of the Shore D hardness of the composition. The Shore hardness values given below are measured using a Shore D hardness tester as described by French standard NF T 46-052. If the aim is to achieve Shore D hardness values of the order of 90 to 95 for the final composite, exposure to ionizing radiation is preferably stopped for example once the Shore D hardness of the stabilized pre-preg composition is greater than 45 and before the Shore D hardness of the stabilized pre-preg composition exceeds 65. More generally, it is proposed that the stage of exposure to ionizing radiation be stopped once the index D comprising the Shore D hardness of the stabilized pre-preg composition divided by the Shore D hardness of the final composite composition has reached a value of the order of 0.5 and before said index D has reached a value of the order of 0.7.
It is also possible experimentally to control the degree of polymerization by means of an analysis of the glass transition temperature T g of the composition. A rule of good practice is proposed, according to which, on the basis of the index T=T gf −T gpr , with T gpr being the glass transition temperature of the stabilized pre-preg composition and T gf being the glass transition temperature of the final composite composition, exposure to ionizing radiation is stopped once the index T has fallen below 120° C. and before said index T has fallen below 30° C. For example, where the glass transition temperature T g of the final composite composition is of the order of 160° C., exposure to ionizing radiation is stopped once the glass transition temperature T g of the stabilized pre-preg composition has reached a value of the order of 40° C. and before the glass transition temperature T g of the stabilized pre-preg composition has reached a value of the order of 130° C.
The stabilization stage is preferably performed in an inert atmosphere. Afterwards, various options are possible. It is possible to envisage continuing the stabilization stage until the resin is completely polymerized. After the stabilization stage, it is also possible to subject the stabilized pre-preg to heat treatment, during which the temperature thereof is raised, preferably to a temperature higher than the final glass transition temperature T g of the composition. By way of example, a suitable treatment temperature is of the order of 150° C. at least. The final properties of the material are not due solely or even principally to stabilization. They are also to a considerable extent the result of the additional heat treatment.
Due to the fact that control of the degree of polymerization, during the initiation stage of polymerization of the resin, is not performed thermally, it is possible to adjust the viscosity of the composition during the stage of fiber impregnation by a moderate increase in the temperature of said composition. For example, it is possible to raise the temperature to approximately 80° C., without any substantial effect on the stability of the resin. This allows much better impregnation of the fibers. There is thus available an impregnation phase control parameter which is independent of the parameters of the subsequent stages of the process.
As far as suitable resins are concerned, it should be mentioned by way of example that the resin may be selected from the group comprising vinyl ester resins and unsaturated polyester resins, or indeed be an epoxy resin.
As far as the reinforcement fibers are concerned, it should be mentioned that these may be selected from among organic fibers, such as high-tenacity polyacrylic fibers or oxidized polyacrylonitrile fibers, high-tenacity polyvinyl alcohol fibers, aromatic polyamide fibers or polyamide-imide fibers or polyimide fibers, chlorofibers, high-tenacity polyester fibers or aromatic polyester fibers, high-tenacity polyethylene fibers, high-tenacity polypropylene fibers, cellulose or rayon or high-tenacity viscose fibers, polyphenylene benzobisoxazole fibers or polyethylene naphthenate fibers, or they may be selected from among inorganic fibers such as glass fibers, carbon fibers, silica fibers or ceramic (alumina, aluminosilicate, borosilicoaluminate) fibers. The process preferably uses unidirectional fibers parallel to said at least one preferential reinforcement direction, disposed substantially in parallel during impregnation with said composition.
The composition preferably comprises a polymerization photoinitiator and the radiation is within the ultraviolet-visible spectrum. In this case, a glass fiber is preferably used. Partial polymerization of the composition is performed by exposure for a suitable period to ultraviolet-visible radiation (Philips UV tube TLK 40W/03). The pre-preg has proven to be sufficiently radiation-transparent for polymerization to be thoroughly homogeneous.
As a variant of or in addition to that which has been stated above in relation to the viscosity of the composition, it is also possible to adjust said viscosity by a monomer copolymerizable with the resin added to the composition and of which the proportion may be varied. For example, the monomer whose proportion may be varied is styrene. A suitable photoinitiator is the oxide of bis(2,4,6-trimethylbenzoyl)phenyl phosphine (photoinitiator Irgacure 819).
According to another particular aspect, the invention relates to a process of firmly connecting a composite material to rubber. To this end, a layer of resorcinol/formaldehyde latex (RFL) adhesive is preferably applied to the surface of the elongate composite element. In a particular application, said layer of RFL adhesive may be dried without reaching a temperature above 100° C., that is to say without high temperature heat treatment, before it receives said layer of rubber. During final molding, for example after incorporation of the elongate composite element into a rubber matrix as a reinforcement, a good connection is achieved between the elongate composite element and the rubber. The use of a non-polymerized RFL adhesive renders it unnecessary to have recourse to special elastomers for adhesion of the rubber to the composite material.
The invention also proposes an installation for manufacturing an elongate composite element in undefined lengths but of predetermined final cross section, said composite element containing reinforcement fibers forming a predetermined total fiber cross section smaller than said final cross section, said fibers being embedded in a matrix based on a composition containing a curable resin, the installation comprising:
a vacuum chamber; rigid-walled inlet tubing, having an inlet orifice and a downstream orifice opening into the vacuum chamber, the tubing having a minimum cross section greater than the total fiber cross section, the length of the tubing measured between the inlet orifice and the downstream orifice being very considerable in relation to said minimum cross section; an impregnation chamber; rigid-walled transfer tubing between the vacuum chamber and the impregnation chamber, having an inlet orifice communicating with the vacuum chamber and a downstream orifice opening into the impregnation chamber, the transfer tubing having a minimum cross section greater than the total fiber cross section, the length of the transfer tubing measured between the inlet orifice and the downstream orifice being very considerable in relation to said minimum cross section; a sizing die for the elongate composite element, downstream of the sizing die, means of at least prepolymerizing the resin.
The invention allows effective and continuous impregnation of the arrangement of fibers, in particular by prior vacuum treatment. Previously, use of a vacuum created tightness problems, such that it was used in practice only for the manufacture of components by means of a mold, that is to say one after the other and not continuously. Vacuum treatment was typically performed by means of a sealed chamber, into which the group of fibers to be impregnated had been previously introduced.
The use of rigid-walled tubing, for both the inlet orifice into the vacuum chamber and the outlet orifice from the vacuum chamber and for transfer from the vacuum chamber to the impregnation chamber, has proved compatible with high rates of passage of the fibers through the orifices without fiber breakage while allowing satisfactory levels of tightness. It is sufficient, if necessary experimentally, to determine the largest passage cross section, taking into account the total cross section of the fibers to be treated, which still allows sufficient tightness to be achieved, taking account of the speed of feed of the fibers and the length of the tubing. A large length promotes tightness.
Advantageously, at least one of the tubings has a cross section which does not increase, but rather preferably converges, as it travels from the inlet orifice towards the downstream orifice. This offers a good compromise between minimum friction of the fibers against the walls and good tightness. Of course, the tightness of the tubing in question is only relative. From the perspective of dynamic operation, this means that the leakage of air towards the vacuum chamber is low relative to the air evacuation capacity of the vacuum pump used. In practice, resin leakage towards the vacuum chamber is zero, given the viscosity of the resin, the pressure differential between the vacuum chamber and the impregnation chamber, the cross section and length of the passage between the vacuum chamber and the impregnation chamber and given the rate of feed of the fibers, which creates the effect of the resin returning towards the impregnation chamber.
Two examples of implementation of the process according to the invention will now be described with reference to the attached drawings, which illustrate schematically various variant embodiments of a treatment installation according to the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a first embodiment of an apparatus according to the invention;
FIG. 2 is an enlarged view of part of the apparatus according to the first embodiment of the invention;
FIG. 3 is a schematic representation of a another part of the apparatus according to the first embodiment of the invention;
FIG. 4 is a sectional view of a second embodiment of an apparatus according to the invention;
FIG. 5 is another sectional view, through a section plane perpendicular to the section plane of FIG. 4 , of the same second embodiment of an apparatus according to the invention;
FIG. 6 is an enlarged view of part of the apparatus according to the second embodiment of the invention;
FIG. 7 is a schematic representation of another part of the second embodiment of an apparatus according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention lends itself to a wide range of shapes for the cross section of the composite material produced, comprising suitable fibers embedded in the selected resin. FIGS. 1 to 3 illustrate an installation which is more particularly suited to manufacture of an elongate composite element of round cross section. FIG. 1 shows the fibers P 1 being continuously unwound from a reel. In general, the reinforcement fibers are supplied in rovings, that is to say in groups of fibers wound in parallel on a reel (for example, fibers, also known as filaments, are used which are sold under the name PPG 2001-300 TEX).
For example, the composite material exits in the form of a filament P 4 of round cross section of any size, drawn by a winding device comprising a roller 140 and a receiving reel 141 . The traction exerted by the roller 140 is what allows feed of the fibers in parallel along the installation.
FIG. 1 reveals in succession a vacuum chamber 110 , an impregnation chamber 120 and a stabilization chamber 130 . The fibers P 1 are introduced into the vacuum chamber 110 via rigid-walled inlet tubing 112 . The vacuum chamber is connected to a vacuum pump (not shown) via the orifice 115 . The function of the inlet tubing 112 is to ensure continuous tightness at high speed. Although the theoretical passage cross section of the inlet tubing 112 is far greater than the total combined cross section of all the fibers drawn by the roller 140 , it has been noted that sufficient tightness was reached for pressure levels of the order of 0.1 bar (absolute pressure), while the cross section of the inlet tubing 112 is of the order of twice the combined cross section of the fibers to be impregnated. The “combined cross section” is the sum of the individual cross section of each of the fibers. The length of the inlet tubing l 1 is preferably more than 30 times the minimum dimension d 1 of the smallest cross section of the inlet tubing.
Another possible function of the inlet tubing 112 is to prepare the arrangement of fibers in accordance with the shape of the composite to be manufactured. For example, a hollow needle 112 A (of circular cross section, see FIG. 2 ), is used.
It is desirable for the size of the cross section of the tubing not to be determined independently of the length of the tubing. The greater is the length of the inlet tubing l 1 , the easier it is to ensure dynamic vacuum tightness. In practice, sufficient tightness is deemed to have been reached when the leakage rate of the air which, in spite of everything, may pass from the atmosphere towards the inside of the vacuum chamber is very much less than the capacity of the vacuum pump. The greater is the length of the inlet tubing, the more tolerable is a large minimum inlet tubing cross section relative to the cross section of the fibers unwound through the installation.
As explained above with regard to the inlet tubing, the transfer tubing may also be a hollow needle of circular cross section (see 119 A in FIG. 2 ).
This is followed by the impregnation chamber 120 , which, in the example described here, is a tight enclosure supplied with resin via an external tank 121 by means of a pipe. A metering pump 123 is preferably inserted into said pipe. It is thus possible to know very precisely the amount of impregnation resin used. The tight impregnation chamber 120 is totally filled with resin. The fibers pass from the vacuum chamber to the impregnation chamber via the transfer tubing 119 of the length l 2 . The arrangement of fibers P 2 advancing through the inside of the transfer tubing 119 has undergone vacuum treatment. The arrangement of fibers is thus in a state in which its propensity to absorb resin is very considerable.
The role of the transfer tubing 119 is also to ensure tightness between the vacuum and the resin filling the impregnation chamber. As far as the transfer tubing is concerned, it has been noted it is sufficient for the length l 2 to be more than 40 times the minimum dimension d 2 of the minimum cross section, with a tubing cross section of the order of twice the combined cross section of the fibers to be impregnated.
Downstream of the impregnation chamber is a sizing die 129 . The role of the sizing die is to shape the pre-preg P 3 before polymerization of the resin is begun. In addition to shaping, it is suitable for ensuring considerable dimensional precision of the end product. For example, the sizing die is of circular cross section (see 129 A in FIG. 2 ), the length l 3 of the die being more than 50 times the smallest dimension d 3 of the minimum cross section.
The sizing die 129 or 129 B may play a part in metering of the proportion of fiber relative to resin. The proportion of fiber relative to resin depends on the minimum passage cross section through the sizing die relative to the total cross section of the fibers being unwound in parallel through the installation. It will be seen that it is also possible to control metering by means of a positive displacement pump.
The pre-preg sizing die 129 or 129 B is followed by a stabilization chamber 130 . The impregnating resin is relatively fluid at ambient temperature and has no mechanical stability of its own. It is therefore necessary to convert it into the solid phase, so as to be able to handle the elongate composite element, if only for storage. Polymerization of the resin may be initiated by one of the known methods, for example thermal initiation, or, as in this example of implementation, by ionizing radiation, for example ultraviolet radiation.
Thus, the stabilization chamber of the installation comprises a device allowing exposure of the composition containing said fibers to ionizing radiation, to initiate polymerization of the resin and obtain a stabilized pre-preg in which said composition is substantially in the solid phase.
Said stabilization chamber advantageously comprises a tight tube 132 , which comprises a wall which is at least partially transparent to said ionizing radiation. The pre-preg stabilization stage proceeds when the pre-preg P 3 is completely out of contact with any support (see FIG. 3 ). A radiation source is disposed outside the tight tube 132 , in such a way as to be able to expose said composition of the pre-preg P 3 to UV radiation in the absence of oxygen. Irradiation tubes 131 , for example Philips TLK 40W/03 UV tubes which provide radiation in the ultraviolet-visible spectrum, are shown positioned around the tight tube 132 .
The installation is very well suited to high treatment rates. The higher is the rate, the more expedient it is for the length of the various treatment zones, i.e. the length L V of the vacuum chamber 110 , the length L I of the impregnation chamber 120 and the length L S of the stabilization chamber to be considerable.
FIGS. 4 to 7 show an installation producing a tape R 4 with a cross section 0.2 mm by 5 mm. The Figures show inlet tubing 212 , a vacuum chamber 210 , transfer tubing 219 , an impregnation chamber 220 , a resin tank 221 and a metering pump 223 , a sizing die 229 and a stabilization chamber 230 . The sizing die is of rectangular cross section, the length of the die being more than 100 times the minimum dimension of the minimum cross section. FIG. 6 shows a sizing die 229 B of rectangular cross section, which may vary between the inlet 229 BI and the outlet 229 BO. The upstream orifice of said die has a cross section of 10 mm×0.5 mm, for example. The intermediate cross sections may be of varying proportions, while their surface area diminishes at least in part of the sizing die. In the example selected, the outlet cross section does not correspond exactly to the cross section of the tape produced, i.e., by way of reminder, 5 mm×0.2 mm. The dimensions of the downstream orifice of the sizing die may be slightly greater (for example 5.3 mm×0.25 mm).
The inlet tubing also has the function of ensuring initial shaping of the composite to be produced. It has also to distribute as homogeneously as possible the entirety of the fibers over the entirety of the passage cross section provided by the inlet tubing. It is proposed to ensure homogeneous distribution by multiplying the number of guides within the inlet tubing. For example, the latter is formed by an arrangement of hollow needles 212 B, of circular cross section and disposed in parallel (see FIG. 6 ).
In the second variant, the pre-preg stabilization stage proceeds when the pre-preg is in constant contact with a support (without relative slip). The fibers P 1 are introduced into the vacuum chamber 210 via rigid-walled inlet tubing 212 . The vacuum chamber is connected to a vacuum pump (not shown). Apart from the stabilization chamber, the installation is very similar and there is therefore no point in going over these aspects in detail again.
The stabilization chamber 230 comprises a mobile rim 232 , at the periphery of which there is formed a support surface 233 (see FIG. 7 ) partially defining said predetermined final cross section of the elongate composite element. For example, to produce a tape of rectangular cross section, a groove is preferably formed in the periphery of the rim 232 , the faces of said groove forming the support surface. The support surface 233 is capable of rotating. The pre-preg is thus supported without slip during stabilization treatment. The stabilization chamber 230 includes the vacuum chamber 210 and the impregnation chamber 220 . Through this arrangement, it is easy to install the pre-preg leaving the sizing orifice 229 on a support, while protecting it from oxidation. An inert (nitrogen) atmosphere may be provided, for example. Irradiation tubes 231 , for example Philips TLK 40W/03 UV tubes which provide radiation in the ultraviolet-visible spectrum, are shown positioned around the rim 232 . Thus, the stabilization chamber of the installation comprises a device allowing exposure of the composition containing said fibers in a thin layer to ionizing radiation, to initiate polymerization of the resin and obtain a stabilized pre-preg in which said composition is substantially in the solid phase.
The above-described installations offer the possibility of manufacturing long reinforcements of any cross section, either in the finished composite state (complete polymerization of the resin) or in the stabilized pre-preg state (i.e. polymerization of the resin is not complete but has proceeded to a sufficient degree for at least the outer surfaces of the product to be in the solid phase, making handling of the product possible to a reasonable degree without destroying it). It is possible to produce tapes of rectangular cross section, as explained above. It is also possible to produce filaments, for example of round cross section, which may for example serve as monofilament-type reinforcements for rubber tires.
The above-described installations allow very fast rates of manufacture, while attaining and maintaining relatively high levels of vacuum in the vacuum chamber, guaranteeing very good impregnation of the fibers by the resin. This is achieved with a negligible fiber breakage rate. The cross sections of the inlet and transfer tubing are all substantially larger than the total cross section of the fibers. There is very little friction between the fibers and the walls but, despite that, sufficient tightness is achieved between the atmosphere and the various chambers and between the chambers themselves. Changing the dimensions and/or cross sections of the products produced is very simple, as it is merely necessary to replace the inlet and transfer tubing and the sizing die. These elements have thus been designed so as to be easily exchanged.
The process according to the invention allows treatment conditions to be maintained from inlet of the fibers until the pre-preg is produced, without either the fibers or the assembly formed by the fibers and the impregnation composition coming into contact with the ambient atmosphere until the pre-preg has become sufficiently stable. For example, one or more enclosures allow said arrangement to be kept isolated from the atmosphere, dynamically speaking. This allows the treatment parameters to be maintained in a controlled manner. Furthermore, the use of separate treatment enclosures for degassing and impregnation, if both operations are provided, has the advantage of allowing mutually independent control of said operations.
Finally, there are several simple ways of influencing the proportion of fibers relative to the resin. The role of substantially determining the final shape of the elongate composite element is preferably reserved for the passage cross section. Although the passage cross section is not unrelated to the proportion of fibers, influencing the proportion of fibers relative to the resin is preferably achieved using a positive displacement metering pump. By varying the rate of resin injection into the impregnation chamber, it is possible, at a constant conveying speed for the fibers unwound in parallel, to vary somewhat the proportion of resin relative to the fibers by forcing the resin to exit to a greater or lesser extent via the sizing die. The invention provides the possibility of manufacturing a composite or stabilized pre-preg in very small cross sections, virtually without lower limit.
The surface area of the combined cross section of the fibers of said arrangement is preferably less than 80% of the surface area of the cross section of said die, in order not to crush the fibers and in order to treat correctly the assembly comprising the fibers and the impregnating resin. The proposed process in particular allows preparation of a pre-preg in which the surface area of the combined cross section of the fibers of said arrangement and the surface area of the resin cross section are substantially the same. The installation according to the invention is preferably such that the surface area of the cross section of the inlet tubing and the surface area of the cross section of the sizing die differ advantageously by less than 20%.
All conventional reinforcement fibers may be used in such an installation, in particular glass or carbon fibers. In the example described, glass fibers are used. Of course, the resin used may also comprise a certain number of additives, which may or may not participate in the gelling and polymerization reactions, such as thermoplastic resins, plasticizers, anti-shrinkage agents, internal mold release agents, colorants etc. This elongate composite element manufacturing process allows the achievement of very high fiber contents by volume, of up to 50%. | An apparatus for manufacturing an elongate composite element in undefined lengths, the composite element containing reinforcement fibers embedded in a matrix based on a composition containing a curable resin, including a vacuum chamber, rigid-walled inlet tubing, an impregnation chamber, rigid-walled transfer tubing between the vacuum chamber and the impregnation chamber, a sizing die and, downstream of the sizing die, irradiation tubes providing radiation in the ultraviolet-visible spectrum to prepolymerize the resin. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/801,254, filed Mar. 16, 2004, now U.S. Pat. No. 7,034,560 issued Apr. 25, 2006, which is a continuation of application Ser. No. 10/396,163 filed Mar. 25, 2003, now U.S. Pat. No. 6,801,048, issued Oct. 5, 2004, which is a continuation of application Ser. No. 09/797,368, filed Mar. 1, 2001, now U.S. Pat. No. 6,605,956, issued Aug. 12, 2003, which is a continuation of application Ser. No. 09/097,427, filed Jun. 15, 1998, now U.S. Pat. No. 6,240,535, issued May 29, 2001, which is a continuation-in-part of Ser. No. 08/718,173, filed Sep. 19, 1996, now U.S. Pat. No. 5,796,746, issued Aug. 18, 1998, which is a continuation-in-part of application Ser. No. 08/577,840, filed Dec. 22, 1995, now U.S. Pat. No. 5,825,697, issued Oct. 20, 1998, and Ser. No. 08/666,247, filed Jun. 20, 1996, now U.S. Pat. No. 5,764,574, issued Jun. 9, 1998.
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates in general to integrated circuit (IC) dice and, in particular, to devices and methods for testing dice in IC modules.
2. State of the Art
Integrated circuit (IC) dice are typically tested before they are packaged to determine if they have any failing circuitry. In general, one of the first steps in testing a die is to initiate a test mode in the die by applying control signals to selected bond pads on the die referred to as test bond pads. As an example, most Dynamic Random Access Memory (DRAM) dice manufactured by the Assignee of this invention, Micron Technology, Inc. of Boise, Id., are tested in a test mode initiated, in part, by applying a logic “0” signal to their Output Enable (OE) bond pad.
As shown in FIG. 1 , when multiple dice 10 are packaged together in an IC module 12 , their test bond pads 14 (e.g., their OE bond pads) are often interconnected with their reference voltage bond pads 16 to the reference voltage V SS through module terminals 18 to ensure that a test mode cannot be accidentally initiated in an end user's system. While this works well to prevent accidental initiation of a test mode in dice in an IC module in the field, unfortunately it also prevents intentional testing of the dice by an IC manufacturer after they are packaged in the IC module.
One conventional solution to this problem, described in U.S. Pat. Nos. 5,278,839 and 4,519,078, is to eliminate the need to initiate a test mode in the manner described above by incorporating self test circuitry into dice. Because the self test circuitry is controlled through address and control bond pads that generally are not fixed to the reference voltage V SS or supply voltage V CC , a test mode can be initiated with the self test circuitry after the dice are packaged in an IC module. However, self test circuitry is a cumbersome and expensive solution that does not address the need for a solution that is easily incorporated into existing dice and IC modules.
Because it would be advantageous to have the flexibility to test dice after they are packaged in an IC module, there is a need in the art for an improved device and method for initiating and performing such testing.
BRIEF SUMMARY OF THE INVENTION
An inventive integrated circuit (IC) module, such as a Multi-Chip Module (MCM), includes a terminal receiving a test mode initiate signal, such as a supply voltage V CC , and an IC die having a bond pad and a function circuit. A switching apparatus, such as a fuse, is connected with the bond pad between the terminal and the function circuit to conduct the test mode initiate signal to the function circuit, and an impedance apparatus, such as a resistor, connected between the function circuit and an operational mode signal, such as a reference voltage V SS , supports a difference in voltages between the test mode initiate signal at the function circuit and the operation mode signal. The function circuit responds to the test mode initiate signal by initiating a test mode in the die. The switching circuit also selectively isolates the function circuit from the die, and the impedance apparatus then conducts the operational mode signal to the function circuit. The function circuit responds to the operational mode signal by entering an operational mode. Thus, a test mode can be initiated in the die after it is packaged in the IC module by providing the test mode initiate signal at the terminal, and the test mode can then be disabled and the die fixed in the operational mode by selectively isolating the function circuit from the terminal with the switching apparatus, thereby ensuring that the test mode is not accidentally initiated by an end user in the field.
In one version of this inventive IC module, the switching apparatus and the impedance apparatus are both incorporated in the die, and in other versions one or both of the switching apparatus and impedance apparatus are incorporated in a substrate of the IC module. In another version, the IC module itself is incorporated into an electronic system, such as a computer system. In still other versions, the operational mode signal is provided by an operational mode signal circuit on the die, or is provided by external circuitry through another terminal in the IC module. Finally, in a modified version of this inventive IC module, the test mode initiate signal is generated on the die by a test mode initiate signal circuit responsive to external circuitry rather than being provided by external circuitry.
In another embodiment of this invention, an IC module includes one or more terminals receiving a test mode initiate signal and an operational mode signal. One or more IC dice in the IC module each have one or more function circuits and a plurality of bond pads, and a first subset of the bond pads is coupled to the function circuits while a second subset of the bond pads is adapted to receive signals other than the test mode initiate signal in the test mode. A dedicated conduction circuit coupled between the terminals and the first subset bond pads and isolated from the second subset bond pads conducts the test mode initiate and operational mode signals to the function circuits. When the function circuits receive the test mode initiate signal, they initiate a test mode, and when the function circuits receive the operational mode signal, they enter an operational mode. Thus, a test mode can be initiated in the dice after they are packaged in the IC module by providing the test mode initiate signal at the terminals, and an operational mode can be initiated by providing the operational mode signal at the terminals. In one version of this IC module, the IC module is incorporated into an electronic system. In other versions, the terminals comprise a first terminal receiving the test mode initiate signal and a second terminal receiving the operational mode signal, and the first and second terminals are coupled by an impedance element, such as a resistor, or by a link, such as a surface mount resistor or a jumper.
In a further embodiment of this invention, a method for initiating a test mode and an operational mode in dice in an IC module includes: receiving a test mode initiate signal at a terminal of the IC module; conducting the test mode initiate signal only to those bond pads on dice in the IC module adapted to receive the signal and from those bond pads to function circuits in the dice to initiate a test mode therein; discontinuing conduction of the test mode initiate signal to the function circuits; and conducting an operational mode initiate signal to each function circuit to initiate the operational mode therein.
In a still further embodiment, a method for testing one or more dice in an IC module includes: providing a test mode initiate signal to an externally accessible terminal of the IC module; conducting the test mode initiate signal exclusively to bond pads on the dice adapted to receive the signal to initiate a test mode in the dice; testing each die; receiving response signals from the dice; and evaluating the response signals to identify any failing elements in the dice.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is an isometric view of a conventional integrated circuit module;
FIG. 2 is an isometric, block and schematic view of an integrated circuit module including a switching circuit and an impedance circuit in accordance with this invention;
FIGS. 3A-C are schematic views of alternative versions of the switching circuit of FIG. 2 ;
FIGS. 4A-C are schematic views of alternative versions of the impedance circuit of FIG. 2 ;
FIG. 5 is a schematic and block view of an alternative version of the switching and impedance circuits of FIG. 2 ;
FIG. 6A is a block diagram of an electronic system in accordance with this invention;
FIG. 6B is a block diagram and circuit schematic of a switching circuit of the electronic system of FIG. 6A ;
FIG. 7 is an isometric and schematic view of another integrated circuit module in accordance with this invention;
FIGS. 8A and 8B are isometric and schematic views of alternative versions of the integrated circuit module of FIG. 7 ;
FIG. 9 is a block diagram of an integrated circuit die in accordance with this invention;
FIG. 10 is a block, schematic and isometric view of a test apparatus in accordance with this invention;
FIG. 11 is a block diagram of an alternative version of the test apparatus of FIG. 10 ;
FIGS. 12A and 12B are flow diagrams of a method for testing integrated circuit dice in an integrated circuit module in accordance with this invention; and
FIGS. 13A and 13B are flow diagrams showing the method of FIGS. 12A and 12B in more detail.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 2 , an inventive integrated circuit (IC) module 20 includes IC dice 22 having function circuits, such as input buffers 24 , selectively receiving a test mode initiate signal, such as a supply voltage V cc , through a module terminal 26 , a switching circuit 28 , and test mode enable bond pads 30 (e.g., Output Enable (OE) bond pads). It will be understood by those having skill in the field of this invention that the IC module 20 may be any electronic structure having at least one die accessed externally through terminals, including, for example, any Multi-Chip Module (MCM), such as a Single In-line Memory Module (SIMM), a Dual In-line Memory Module (DIMM), a Random Access Memory (RAM) card, a flash Read-Only-Memory (ROM) module or card, a Synchronous Dynamic RAM (SDRAM) module or card, and a Rambus RAM module or card. It will also be understood that the dice 22 may be any dice for purposes of this invention, including, for example, DRAM dice, Static Random Access Memory (SRAM) dice, Synchronous Graphics Random Access Memory (SGRAM) dice, ROM dice, and processor dice.
Also, it will be understood that the function circuits may be any circuitry on a die for initiating a test mode in the die, the test mode initiate signal may be any signal for initiating a test mode in a die, the module terminal 26 may be any terminal including, for example, an MCM pin (e.g., a SIMM, DIMM, RAM card, RAM module, ROM card, or ROM module pin), the switching circuit 28 may be, for example, a fuse or a transistor or any other device for selectively isolating the function circuits from the module terminal 26 , and the test mode enable bond pads 30 may be any bond pads connectable to a function circuit for enabling a test mode in a die. Further, it should be understood that although the switching circuit 28 is shown in FIG. 2 as being a single circuit coupled to the module terminal 26 , it may instead comprise a plurality of circuits, each one coupled to the module terminal 26 and one of the dice 22 .
In response to receiving the test mode initiate signal, the input buffers 24 initiate a test mode in the dice 22 . In this mode, various test signals may be provided to the dice 22 in a well known manner to test the circuitry thereon, and the dice 22 then output various response signals indicating the presence of any failing circuitry. While the test mode initiate signal, such as the supply voltage V CC , is being provided to the test mode enable bond pads 30 and the input buffers 24 , an impedance circuit 32 , such as, for example, a resistor, resistance-connected MOS transistor, or anti-fuse, supports a difference in voltages between the test mode initiate signal at the test mode enable bond pads 30 and an operational mode enable signal, such as a reference voltage V SS , at a reference terminal 34 , such as, for example, an MCM pin (e.g., a SIMM, DIMM, RAM card, RAM module, ROM card, or ROM module pin). It will be understood that although the impedance circuit 32 is shown in FIG. 2 as being a single circuit coupled to the reference terminal 34 , it may instead comprise a plurality of circuits, each one coupled to the reference terminal 34 and one of the dice 22 .
Once testing of the dice 22 is complete, the switching circuit 28 isolates the input buffers 24 from the module terminal 26 to disable the test mode, and the impedance circuit 32 conducts the operational mode signal, such as the reference voltage V SS , to the input buffers 24 . In response, the input buffers 24 initiate an operational mode in the dice 22 in which the dice 22 operate in accordance with their intended normal function. Thus, for example, if the dice 22 are DRAMs, they would perform normal memory operations in their operational mode.
Thus, the dice 22 in the IC module 20 are fully testable even after being packaged, and yet their test mode can be disabled as necessary so the IC module 20 can be used by end users in the field.
As will be described in more detail below with respect to FIGS. 6 and 9 , one or both of the switching circuit 28 and the impedance circuit 32 may be incorporated into the dice 22 instead of being provided on a substrate 36 of the IC module 20 as shown in FIG. 2 . Also, as will be described in more detail below with respect to FIG. 9 , one or both of the test mode initiate signal and the operational mode signal may be generated on the dice 22 rather than being provided by external circuitry.
As shown in FIGS. 3A , 3 B, and 3 C, the switching circuit 28 of FIG. 2 can be, for example, a fuse 38 that is blown once testing is complete, or an NMOS transistor 40 or PMOS transistor 42 that is de-activated once testing is complete. Also, as shown in FIGS. 4A , 4 B and 4 C, the impedance circuit 32 of FIG. 2 can be, for example, a resistor 44 , an anti-fuse 46 that is blown once testing is complete, or an NMOS transistor 48 that is activated once testing is complete. Further, as shown in FIG. 5 , the NMOS transistor 40 of FIG. 3B and the NMOS transistor 48 of FIG. 4C , for example, may be controlled by an anti-fuse isolate logic circuit 50 that outputs a high voltage during a test mode and is then programmed to output a low voltage once testing is complete. The high voltage during the test mode activates the NMOS transistor 40 and de-activates the NMOS transistor 48 through an inverter 52 , and the low voltage after programming de-activates the NMOS transistor 40 and activates the NMOS transistor 48 through the inverter 52 . Of course, a wide variety of other combinations are well within the scope of this invention.
As shown in FIG. 6A , in another embodiment, this invention comprises an electronic system 60 , such as a computer system, including an input device 62 , an output device 64 , a processor device 66 , such as a state machine, and a memory device, such as an IC module 68 . Although this embodiment will be described with respect to the memory device comprising the IC module 68 , it will be understood that the IC module 68 could comprise all or any portion of the input device 62 , the output device 64 , the processor device 66 , and the memory device. Also, although the electronic system 60 will be described with respect to a particular IC module 68 , it will be understood that this invention includes any of the inventive IC modules described herein as incorporated into an electronic system. Further, as discussed above, it will be understood that the IC module 68 may comprise any electronic structure having at least one die externally accessible through terminals, including, for example, an MCM, such as a SIMM, DIMM, RAM card, RAM module, ROM card, or ROM module.
The IC module 68 includes a terminal 70 , such as an MCM pin as discussed above, receiving a test mode initiate signal (e.g., the supply voltage V CC ) from the processor device 66 . The terminal 70 conducts the test mode initiate signal to a bond pad 72 of an IC die 74 . As discussed above, it will be understood that the IC die 74 may be any die, including, for example, a DRAM die, SRAM die, SGRAM die, processor die, flash ROM die, SDRAM die, or Rambus RAM die.
To initiate a test mode in the die 74 , a switching circuit 76 conducts the test mode initiate signal from the bond pad 72 to a function circuit 78 (e.g., an OE input buffer). In response, the function circuit 78 initiates a test mode in the die 74 as described above. While the test mode initiate signal is being conducted to the function circuit 78 , an impedance circuit 80 supports a difference in voltages between the test mode initiate signal at the function circuit 78 and an operational mode signal, such as a reference voltage V SS , supplied by an operational mode voltage circuit 82 .
It should be understood that the switching circuit 76 may, for example, comprise a fuse, a MOS transistor, or a flash memory cell, the function circuit 78 may comprise any circuit which enables or initiates a test mode in response to a test mode initiate signal, the impedance circuit 80 may, for example, comprise an anti-fuse, a MOS transistor, or a resistor, and the operational mode voltage circuit 82 may comprise any circuit for supplying an operational mode signal, such as a reference voltage V SS , on a die.
When testing is over, the switching circuit 76 isolates the function circuit 78 from the bond pad 72 to disable the test mode in the die 74 by, for example, blowing a fuse or de-activating a MOS transistor. The impedance circuit 80 then conducts the operational mode signal from the operational mode voltage circuit 82 to the function circuit 78 by, for example, blowing an anti-fuse or activating a MOS transistor. In response to the operational mode signal, the function circuit 78 initiates an operational mode in the die 74 as described above.
Thus, the die 74 is fully testable even after being packaged in the IC module 68 , and yet the test mode of the die 74 can be disabled as necessary so the IC module 68 can be used by end users in the field.
As shown in detail in FIG. 6B , the switching circuit 76 of FIG. 6A may include a flash memory cell 77 programmed to activate or deactivate an NMOS transistor 79 . The cell 77 may be programmed, for example, to conduct the test mode initiate signal during a test mode, and to isolate the bond pad 72 ( FIG. 6A ) from the function circuit 78 ( FIG. 6A ) during normal operations of the electronic system 60 ( FIG. 6A ).
As shown in FIG. 7 , an inventive IC module 84 includes dice 86 having function circuits, such as input buffers 88 , selectively receiving a test mode initiate signal, such as a supply voltage V cc , through a first terminal 90 , a dedicated conductor 92 , and test mode enable bond pads 94 (e.g., Output Enable (OE) bond pads). It will be understood by those having skill in the field of this invention that the IC module 84 may be any electronic structure having at least one die accessed externally through terminals, including, for example, an MCM, such as a SIMM, a DIMM, a RAM card, a RAM module, a ROM card, and a ROM module. It will also be understood that the dice 86 may be any dice for purposes of this invention, including, for example, DRAM dice, SRAM dice, SGRAM dice, flash ROM dice, SDRAM dice, Rambus RAM dice, and processor dice.
Also, it will be understood that the function circuits may be any circuitry on a die for initiating a test mode in the die, the test mode initiate signal may be any signal for initiating a test mode in a die, the first terminal 90 may be any terminal including, for example, an MCM pin, such as a SIMM, DIMM, RAM card, ROM card, RAM module, or ROM module pin, the dedicated conductor 92 may be, for example, any conductive structure or device connected exclusively to those bond pads 94 on the dice 86 adapted to receive the test mode initiate signal or unaffected by receipt of the test mode initiate signal, and the test mode enable bond pads 94 may be any bond pads connectable to a function circuit for enabling a test mode in
In response to receiving the test mode initiate signal, the input buffers 88 initiate a test mode in the dice 86 in a well known manner as described above. Once testing of the dice 86 is complete, an operational mode signal, such as a reference voltage V SS , is provided through the first terminal 90 and the dedicated conductor 92 to the input buffers 88 to initiate an operational mode in the dice 86 in the well known manner described above. A second terminal 96 provides the reference voltage V SS to other circuits in the dice 86 via a reference conductor 97 and reference voltage bond pads 98 .
Thus, the dice 86 in the IC module 84 are fully testable even after being packages, and yet the operational mode can be enabled as necessary so the IC module 84 can be used by end users in the field.
As shown in FIG. 8A in an isometric view of a portion of an alternative version of the IC module 84 of FIG. 7 , a conductive via 100 through a substrate 102 of the IC module 84 couples the first terminal 90 and dedicated conductor 92 to the second terminal 96 and the reference conductor 97 through an impedance element, such as a surface mount resistor 104 . Of course, the impedance element may, for example, comprise a resistance-connected MOS transistor rather than the surface mount resistor 104 .
During testing, a test mode initiate signal, such as the supply voltage V CC , may be supplied to the first terminal 90 to initiate a test mode as described above with respect to FIG. 7 . At the same time, an operational mode signal, such as the reference voltage V SS , may be supplied to the second terminal 96 without interfering with the test mode, because the surface mount resistor 104 supports a difference in voltages between the test mode initiate signal at the first terminal 90 and the operational mode signal at the second terminal 96 .
Once testing is complete, the operational mode signal, or no signal, may be supplied to the first terminal 90 . At the same time, the surface mount resistor 104 conducts the operational mode signal from the second terminal 96 to the dedicated conductor 92 , in order to initiate the operational mode as described above with respect to FIG. 7 .
As shown in FIG. 8B in an isometric view of a portion of another alternative version of the IC module 84 of FIG. 7 , a test mode initiate signal, such as the supply voltage V cc , may be supplied to the first terminal 90 during testing to initiate a test mode as described above with respect to FIG. 7 . At the same time, an operational mode signal, such as the reference voltage V ss , may be supplied to the second terminal 96 and the reference conductor 97 without interfering with the test mode, because a removable link 106 , such as a jumper or zero Ohm surface mount resistor, is not present during testing, thus isolating the second terminal 96 from the first terminal 90 .
Once testing is complete, the operational mode signal, or no signal, may be supplied to the first terminal 90 . At the same time, the link 106 is positioned to connect the second terminal to the dedicated conductor 92 through the conductive via 100 in the substrate 102 , thereby conducting the operational mode signal from the second terminal 96 to the dedicated conductor 92 in order to initiate the operational mode as described above with respect to FIG. 7 .
Although the first and second terminals 90 and 96 are shown in FIGS. 8A and 8B as being on opposing sides of the substrate 102 , it will be understood that the invention is not so limited.
As shown in FIG. 9 , in another embodiment, this invention comprises an IC die 108 . As discussed above, the IC die 108 may be any die including, for example, a DRAM die, SRAM die, SGRAM die, flash ROM die, SDRAM die, Rambus RAM die, or processor die. To initiate a test mode in the die 108 , a test mode enable signal directs a test mode voltage circuit 110 in the die 108 to generate a test mode voltage V TEST , such as 3.3 Volts. A switching circuit 112 then conducts the test mode voltage V TEST to a function circuit 114 (e.g., an OE input buffer). In response, the function circuit 114 initiates a test mode in the die 108 as described above. While the test mode voltage V TEST is being conducted to the function circuit 114 , an impedance circuit 116 supports a difference in voltages between the test mode voltage V TEST at the function circuit 114 and an operational mode voltage V OPER , such as 0.0 Volts, supplied by an operational mode voltage circuit 118 .
It should be understood that the switching circuit 112 may, for example, comprise a fuse or a MOS transistor, the function circuit 114 may comprise any circuit which enables or initiates a test mode in response to a test mode voltage V TEST , the impedance circuit 116 may, for example, comprise an anti-fuse, a MOS transistor, or a resistor, and the operational mode voltage circuit 118 may comprise any circuit for supplying an operational mode voltage V OPER on a die.
When testing is over, the switching circuit 112 isolates the function circuit 114 from the test mode voltage V TEST to disable the test mode in the die 108 by, for example, blowing a fuse or de-activating a MOS transistor. The impedance circuit 116 then conducts the operational mode voltage V OPER from the operational mode voltage circuit 118 to the function circuit 114 by, for example, blowing an anti-fuse or activating a MOS transistor. In response to the operational mode voltage V OPER , the function circuit 118 initiates an operational mode in the die 108 as described above.
Thus, the die 108 is fully testable even after being packaged, and yet the test mode of the die 108 can be disabled as necessary so the die 108 can be used by end users in the field.
As shown in FIG. 10 , a test apparatus 120 for testing an IC module 122 of this invention having an IC die 124 includes a test apparatus-to-module interface 126 having interface terminals 128 connectable to module terminals 130 on the IC module 122 . The module terminals 130 , in turn, are in communication with the die 124 including a redundancy circuit 132 . A test mode enable circuit 134 provides a test mode initiate signal to the die 124 through the interface 126 to initiate a test mode in the die 124 in the manner described above. A test signal circuit 136 then provides test signals to the die 124 through the interface 126 to test the die 124 in the test mode. A response signal circuit 138 receives response signals from the die 124 in the test mode in response to the test signals, and an evaluator circuit 140 then evaluates the response signals to identify any failing circuitry in the die 124 .
A repair enablement device 142 in the test apparatus 120 may provide repair control signals to the redundancy circuit 132 in the die 124 directing the redundancy circuit 132 to replace any failing circuitry identified by the evaluator circuit 140 with redundant elements 144 in the die 124 . The manner in which repair control signals may direct the redundancy circuit 132 to repair any failing circuitry in the die 124 is well known by those skilled in the art.
As shown in FIG. 11 in a block diagram of an alternative version of the test apparatus 120 described with respect to FIG. 10 , a processor 146 coupled to a memory device 148 and an input/output device 150 may provide the test mode initiate signal, the test signals, and the repair control signals, and may receive and evaluate the response signals, in the manner described above with respect to FIG. 10 . It should be understood that the memory device 148 may comprise any permanent or temporary electronic storage medium, including, for example, a DRAM, SRAM, SGRAM, disk, tape, memory card, memory module, or programmable logic array.
As shown in still another embodiment of this invention in FIGS. 12A and 12B , a method for testing any one of the above-described inventive IC dice or modules includes the steps of: 160 providing a test mode initiate signal to an externally accessible terminal of an IC module; 162 conducting the test mode initiate signal exclusively to bond pads on dice in the IC module adapted to receive the signal to initiate a test mode in the dice; 164 testing each of the dice in the test mode by providing test signals to each die through the externally accessible terminals of the IC module; 166 receiving response signals from each die through the terminals of the IC module in response to the test signals; 168 evaluating the response signals from each die to identify any failing elements in the dice of the IC module; 170 providing repair control signals to a redundant circuit in each die to direct each die to replace any identified failing elements with redundant elements; 172 re-testing each die by providing re-test signals to each die through the IC module's externally accessible terminals; 174 receiving response signals from each die through the IC module's terminals in response to the re-test signals; and 176 evaluating the response signals from each die to confirm the repair of any failing elements therein.
As shown in FIGS. 13A and 13B , the step 170 from FIGS. 12A and 12B of providing repair control signals to a redundant circuit in each die includes, for each identified failing element, the steps of: 180 determining an address associated with the failing element; 182 latching the failing element's address into the dice; 184 providing a programming mode enable signal, such as a super voltage Column Address Strobe (CAS) signal, to the dice to enable a programming mode therein; 186 applying a fuse address of a fusebank enable anti-fuse associated with a redundant element selected to replace the failing element to the IC module's terminals to identify the location of the anti-fuse; 188 coupling to the anti-fuse; 190 determining the anti-fuse's resistance; 192 applying a programming voltage, such as a voltage between 8 and 10 Volts, to the anti-fuse to blow the anti-fuse; 194 redetermining the anti-fuse's resistance to confirm it is blown; and, for each asserted address bit in each failing element's address: 198 applying a fuse address of an address bit anti-fuse associated with the redundant element selected to replace the failing element to the IC module's terminals to identify the location of the anti-fuse; 200 coupling to the anti-fuse; 202 determining the address bit anti-fuse's resistance; 204 applying a programming voltage, such as a voltage between 8 and 10 Volts, to the anti-fuse to blow the anti-fuse; and 206 redetermining the address bit anti-fuse's resistance to confirm it is programmed. As used herein, each “asserted” address bit in a failing element's address may be each “1” bit in the address or each “0” bit in the address.
It will be understood that any or all of the steps 160 - 206 in the embodiment of FIGS. 12A , 12 B, 13 A, and 13 B, or any portion thereof, may be implemented in hardware, software, or both, using a wide variety of well-known architectures, including, for example, a state machine and the embodiment of FIGS. 10 and 11 . It will also be understood that, although the embodiment of FIGS. 12A , 12 B, 13 A, and 13 B has been described with respect to anti-fuses, any programmable circuit or element will work for purposes of this invention. Also, it will be understood that the step 186 in FIG. 13A may include automatic selection of the location and type of redundant element (e.g., redundant row or column) to be used to replace the failing element. Finally, it will be understood that the steps 180 to 206 of FIGS. 13A and 13B may be automated by computer or performed manually.
This invention thus advantageously provides a device and method for testing and repairing IC dice already packaged in IC modules.
Although this invention has been described with reference to particular embodiments, the invention is not limited to these described embodiments. Rather, the invention is limited only by the appended claims, which include within their scope all equivalent devices and methods that operate according to the principles of the invention as described. | An IC module, such as a Multi-Chip Module (MCM), includes multiple IC dice, each having a test mode enable bond pad, such as an output enable pad. A fuse incorporated into the MCM's substrate connects each die's test mode enable bond pad to one of the MCM's no-connection (N/C) pins, and a resistor incorporated into the substrate connects the test mode enable bond pads to one of the MCM's ground pins. By applying a supply voltage to the test mode enable bond pads through the N/C pin, a test mode is initiated in the dice. Once testing is complete, the fuse may be blown, and a ground voltage applied to the test mode enable bond pads through the ground pins so the resistor disables the test mode in the dice and initiates an operational mode. As a result, dice packaged in IC modules may be tested after packaging. | 7 |
This application is a continuation of application Ser. No. 335,553, filed 12-29-81, now U.S. Pat. No. 4,436,956.
FIELD OF THE INVENTION
This invention relates to electronic filter circuits and, in particular, to active electronic filter circuits.
BACKGROUND OF THE INVENTION
In many applications involving the processing of electronic signals it is desirable to initially filter the signals to remove unwanted frequencies and spurious noise and to select a small, predetermined frequency range for further processing. Such a filtering operation is typically performed with a bandpass filter.
Many prior filter circuits have been designed in an attempt to produce a filter circuit which has dual characteristics of a high amount of signal attenuation for signals with frequencies outside the predetermined frequency range (designated as the "passband") and a low amount of signal attenuation for signals having frequencies inside the passband.
The filtering problem is further complicated because many electronic circuits process signals which have frequencies in several distinct ranges. One such electronic circuit is a modem, a device that allows electronic computers to communicate via ordinary telephone lines. The modem converts electronic digital signals produced by one computer into audio-frequency signals which are then transmitted over a telephone line. A corresponding modem at the other end of the telephone line receives the audio-frequency signals and reconverts them into digital signals which are then used by another computer.
In a typical prior art modem communication system, two different sets (four frequencies total) are used to provide full duplex operation. The audio-frequencies generated and received by each modem may be selected from either set depending on whether the modem originated the telephone connection or merely answered a telephone call placed by another modem. Typically, a modem must be able to receive a small band of audio-frequencies with an approximate center frequency or 1170 Hertz if it is in the "answer" mode and a center frequency of 2100 Hertz if it is in the "originating" mode. The width of the passband is typically 400 Hertz in both cases.
In order to filter signals in two separate ranges with widely spaced center frequencies, it is necessary to design two bandpass filters with substantially different characteristics. Therefore, a typical prior art solution to this problem has been to use two separate filter circuits which have many duplicated components. This solution, although straightforward, is not totally satisfactory when applied to a modem in which only one filter circuit is in use at any given time (depending on whether the modem is in the "answer" or "originate" mode). Obviously this prior art approach results in duplication of components and increased costs.
To avoid duplication of parts, other prior art attempts have been made to design a single bandpass filter having two separate passbands by utilizing an active filter circuit with multiple feedback loops and interchanging components in the filter networks to change the center frequency of the filter. These attempts have encountered problems, however, because the signal gain of such a switchable filter usually changes when the values of the components in the filter networks are changed.
It is therefore an object of the invention to provide a switchable bandpass filter having passbands with two separate center frequencies which utilizes a minimum number of components.
It is a further object of the invention to provide a switchable bandpass filter in which the overall signal gain remains constant even though the center frequency changes.
It is a still further object of the invention to produce increased sensitivity and selectivity of the bandpass filter circuitry.
SUMMARY OF THE INVENTION
The foregoing problems are solved and the foregoing objects are achieved in one illustrative embodiment of the invention in which a multi-section active filter circuit having switchable passive components is provided in which the gain of each of the filter section is low. Overall filter gain is achieved by a separate amplifier at the filter input. In order to change the center frequency of the filter, passive components in each filter stage are changed and gain compensation elements in each stage are changed simultaneously so that the gain of each filter stage remains constant even though the center frequency has changed.
More particularly, a six-pole Chebyshev filter is provided which uses three active filter sections incorporating operational amplifiers. The active sections are provided with sets of passive frequency-selection components which can be interchanged by means of electronic switches in order to change the center frequency of the filter. The components are chosen so that the gain of each section is low compared to the gain of prior art filter sections, and a separate amplifier is provided at the input of the first section to provide gain for the overall filter. In order to compensate for changes in signal level when the center frequency of the filter is changed, the feedback circuits of the operational amplifiers are also modified by means of electronic switches so that the signal gain of each filter stage remains relatively constant.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a block diagram of an electronic modem utilizing the inventive switchable bandpass filter.
FIG. 2 is a detailed electrical schematic of the modem circuitry shown in the block diagram of FIG. 1.
FIG. 3 is a schematic diagram of various electrical waveforms at selected points in the circuit of FIG. 2.
DETAILED DESCRIPTION
Referring to FIG. 1, modem circuitry containing the illustrative switchable bandpass filter is shown in block schematic form. The modem is connected to telephone line 100 via line interface 105, which contains "matching" circuitry that helps match the internal impedance of the modem circuitry to the impedance of the telephone line to prevent echoes and noise.
Digital information is passed between modems by means of audio-frequency signals in which information has been encoded by frequency-shift keying (FSK) techniques that are well-known. Specifically, in a typical FSK arrangement, if a modem is operating in the "answer" mode, it encodes an FSK "mark" (corresponding to a digital "1") as an audio signal with a frequency of 1270 Hertz. An FSK "space" (corresponding to a digital "0") is encoded as a signal with a frequency of 1070 Hertz. On the other hand, if the modem is operating in the "originate" mode a "mark" is encoded by a signal with a frequency of 2225 Hertz and a "space" is encoded by a signal with a frequency of 1025 Hertz.
Incoming information from interface 105 is provided to receive filter 116 which illustratively incorporates principles of the invention. Receive filter 116 is a bandpass filter which has a center frequency of approximately 2100 Hertz when the modem is operating in the "originate" mode and a center frequency of 1170 Hertz when the modem is operating in the "answer" mode. The bandwidth of the filter in both cases is approximately 400 Hertz. The narrow passband and widely-separated center frequencies insure that only signals which are within the FSK bandwidth are processed by the system and that outgoing signals produced by the modem itself do not interfere with incoming signals from other modems.
The output of receive filter 116 is a sinusoidal waveform with a frequency equal to that of the incoming coded signals. This output is provided to carrier-detect circuit 120 and limiter 125. Carrier-detect circuit 120 detects the presence of a signal having a frequency within the FSK passband and a magnitude greater than a predetermined minimum. Carrier-detect circuit 120 signals the presence of such a signal by generating a signal on carrier-detect line 160. The carrier-detect signal is used to inhibit the modem output when there are no FSK signals present to prevent erroneous noise pulses from being processed by the associated computer system.
Limiter circuit 125 converts the sine wave output of receive filter 116 into a square wave signal which is provided to the output processing circuitry and to modem integrated circuit (I.C.) chip 135. I.C. chip 135 is a prior art integrated circuit which decodes the FSK-encoded data in a well-known manner to produce an output signal on receive data lead 150 indicative of the digital information encoded in the FSK signals.
Certain computer circuitry can accept the digital signals produced by chip 135 and, accordingly, the information on lead 150 may by provided directly to the associated computer circuitry for further processing. Other computer circuits only receive data from the modem via an "audio cassette port". This port can receive data encoded by audio signals, but only in a format different from the FSK signal format. When the modem operates with the latter type of computer, the outputs of I.C. chip 135 and limiter 125 are combined by AND gate 130. In the composite output of AND gate 130 a "burst" of audio-frequency signals represents a "mark" and the absence of audio-frequency signal represents a "space".
Data which is to be transmitted on telephone line 100 is provided to the modem by a computer or other processing device, via lead 155, to level shifter 140. This data is usually in a standard format known as RS232-C and consists of digital information encoded by means of voltage levels (plus or minus 12 volts). Level shifter 140 converts the data from RS232 voltage levels to voltage levels used by I.C. chip 135 (generally 0 volts to 5 volts).
The information coded into the RS232 voltage levels is converted into FSK format by I.C. chip 135 (which generates a digitally synthesized sine wave of appropriate frequency) and provided to transmit filter 115. Filter 115 removes high-frequency harmonics from the digital sine wave generated by the I.C. chip to prevent feedback of the outgoing signal through receive filter 116. The FSK coded signal is provided to line interface circuit 105 for transmission over telephone line 100 to a remote modem.
Referring to FIG. 2, the electrical schematic of the illustrative modem circuitry is shown in detail. Incoming FSK data from a remote modem is provided to the circuitry from the telephone line shown in the upper left hand side of the Figure. The telephone line impedance is matched to the modem input circuit impedance by matching hybrid transformer, T1, which has a tapped secondary winding. A balancing network consisting of resistor R37 and capacitor C16 is connected the center tap of the transformer secondary winding in order to isolate transmitted signals from received signals. In order to reduce noise, the secondary winding is also terminated by resistors R26 and R28. In addition, a 22-volt metal-oxide varistor ZN1 is connected across the primary of the transformer to protect the modem from voltage spikes which may occur on the telephone line.
The FSK tones arriving over the telephone line are coupled by the secondary winding of transformer T1 to the input of amplifier U1 via resistor R25.
In accordance with the invention, amplifier U1 is used to provide gain for the receive filter circuitry. As will be discussed in detail hereinafter each section of the receive filter has been designed to have a signal gain which is much less than the signal gain of prior art units, and amplifier U1 provides most of the gain for the entire filter circuitry. The low gain in each of the filter sections makes its filter characteristics less sensitive to changes in the values of the electronic components which make up each section. Therefore, it is possible to mass produce the filter circuitry with standard components while insuring that the filter circuit will operate properly. Also, in accordance with the principles of this invention, the gain of each section is electronically adjusted during frequency shifts to insure that the overall gian of the filter remains constant. The adjustment may also be done with standard components due to the low gains of each section.
Amplifier U1 is connected in a well-known negative feedback arrangement (wherein resistor R14 provides negative feedback) and also provides some initial pre-filtering, via capacitor C31, to eliminate high-frequency noise generated by the I.C. chip U15. The output of amplifier U1 is provided to the inventive receive filter.
The receive filter utilized by the modem consists of three sections. Each section is "active" in that it includes an amplifier device in addition to various passive components. Devices U2 through U4 and comprise the three sections, and together, devices U2-U4 form a six-pole Chebyshev filter with one dB of ripple in the passband. The filter center frequency is switchable to accomodate the "answer" and "originate" modes of operation by means of transistors Q3-Q5.
Each stage of the circuit has the same basic configuration--only component values are different. Therefore, for the purposes of clarity, the operation of the filter will be described with respect to only one stage. The actual values of the components used in each filter stage can be computed via well-known Chebyshev filter theory and will not be discussed in detail herein.
Each filter section consists of an amplifier, such as amplifier U2 in the first filter section, and associated passive filter elements. Particularly, the first filter section has a feedback loop connected from the output of the amplifier to its negative input consisting of resistors R41 and R40 and capacitor C19 (resistor R41 may be shunted by FET switch Q7). The signal input to the filter stage is provided via resistor R22 which, together with resistor R23 and capacitor C20 acts as a passive filtering stage.
In order to control the center frequency of the first filter section, resistor R23 may be shunted by resistor R32 under control of transistor Q5. Advantageously, according to the invention, when transistor Q5 is operated to change the filter center frequency, FET switch Q7 is also turned off to place resistor R41 in series with resistor R40 maintaining the gain of the first stage constant. FET Q7 and transistor Q5 are, in turn, controlled by signals on lines 200 and 201, respectively. The signals on leads 200 and 201 are controlled by switches which are set depending on the operating mode of the modem.
In particular, lead 200 is connected by diode CR3 to switch S1B. Similarly lead 201 is connected, via diode CR6, to switch S1B. When the modem is in the "originate" mode, switch S1B is in its upward position and connects positive voltage source 205 to the cathode of diode CR3 and the anode of diode CR6, via lead 203. The positive voltage on lead 203 back-biases diode CR3 and forward-biases diode CR6.
Forward-biased diode CR6 places a positive voltage on lead 201 (which is normally held "low" by resistor R11). The positive voltage on lead 201 is supplied, via resistor R42, to the base of transistor Q5, turning it "on". Turned-on transistor Q5 connects the lower terminal of resistor R32 to ground, effectively connecting resistor R32 in parallel with resistor R23 to change the filter center frequency. However, the operation of transistor Q5 also changes the gain of the filter section. Illustratively, FET Q7 is simultaneously operated to maintain the signal gain constant.
Specifically, back-biased diode CR3 allows resistor R10 to maintain a "low" signal on lead 200 which signal, in turn, turns "off" FET Q7 and all other FET's in the receive filter). With FET Q7 "off", resistor R41 and R40 are connected in series, thus increasing the feedback resistance and the gain of the first stage feedback loop.
Similar to filter section U2, filter sections U3 and U4 are provided with switchable feedback networks consisting of FET switches Q2 and Q6, respectively, and transistor switches Q3 and Q4, respectively. Therefore, the characteristics of both of stages U3 and U4 of the illustrative receive filter can be changed in order to change the receive filter center frequency from approximately 2100 Hertz in the "originate" mode to 1170 Hertz in the "answer" mode while maintaining the overall filter gain approximately constant.
The filtered output signal generated by the receive filter is approximately a sine wave signal as shown in line D of FIG. 3. This signal is provided, via capacitor C23, to limiter circuit U5 and, by resistor R15, to the carrier-detect circuit consisting of devices U7, U8 and U9.
Specifically, the sine wave signal generated at the output of the receive filter is AC-coupled, via capacitor C23, to the inverting input of high-speed comparator U5. Capacitor C23 and resistor R33 are used to remove any DC offset which might be present at the output of the receive filter. The positive input of comparator U5 is connected to ground by resistors R36 and R34 and to the output of the comparator by resistor R35. When connected in this manner the comparator switches its output state when the input signal passes through zero. The output of the comparator is an "open collector" output which is actively pulled "low" by the internal comparator circuitry but is pulled "high" by resistor R45 connected to a positive voltage source. This arrangement allows the output of comparator U5 to be connected with the carrier detect circuit in a "wired-OR" configuration, as will be hereinafter explained.
The limited output produced by device U5 is shown in line E of FIG. 3. This output is provided to the receive input (pin 1) of I.C. chip U15. As will be hereinafter explained, I.C. chip U15 decodes the FSK-coded waveforms to produce DC levels which are provided to the computer.
The output of the receive filter is also provided, via resistor R15, to the carrier-detect circuit consisting of devices U6, U7 and U8. Amplifier U6, in conjunction with diodes CR7 and CR8 comprises an active rectifier circuit. When the signal at resistor R15 becomes negative, the output of amplifier U6 becomes positive, causing diode CR7 to conduct which, in turn, causes the input signal to be amplified and clipped. However, when the voltage at resistor R15 swings positive, diode CR8 conducts and bypasses gain resistor R16, causing the amplifier feedback to be effectively "shorted" producing only a small gain at the amplifier output. The output produced by the halfwave rectifier with a typical signal input from the receive filter is shown at line F in FIG. 3.
The rectified output of amplifier U6 is filtered by capacitor C30 and provided to the inverting input of threshold amplifier U8. The positive input of amplifier U8 is provided with a variable threshold voltage controlled by comparator U9.
The threshold voltage produced by comparator U9 is controlled by the signal level on lead 201. The threshold voltage may be varied depending on whether the modem circuit is operating in the "answer" or "originate" modes. In some embodiments of the invention, the variable threshold may not be necessary. In particular, if precision-trimmed resistors are used in the filter feedback sections, then the gain of the receive filter sections will remain relatively constant when the center frequency changes. However, if standard-value components must be used in the feedback loops of the filter elements, it may not be possible to exactly compensate for filter gain variations with FET switches Q5-Q7. The change in threshold then compensates for the slight change in gain of the receive filter which occurs when its center frequency is switched from the "answer" center frequency to the "originate" center frequency.
Specifically, for those embodiments which require additional compensation, the signal on lead 201 is provided to the inverting input of comparator U9. The positive input of comparator U9 is fixed at a predetermined voltage produced by dividing a positive reference voltage source by the divider consisting of resistors R56 and R57. Resistors R56 and R57 are chosen so that comparator U9 produces a "low" signal when switch S1B is in the "originate" position (and lead 201 has a "high" signal thereon) and a "high" signal when switch S1B is in the "answer" position (and lead 201 has a "low" signal thereon). A "low" signal at the output of comparator U9 causes resistors R50 and R59 to be connected in parallel. Therefore, the voltage provided to the positive input of comparator U8 is determined by the voltage divider consisting of resistor R60 and resistors R50 and R59 are parallel. On the other hand, when the switch S1B is in the "answer" position, comparator U9 provides a "high" signal on its output, which effectively places resistors R60 and R50 in parallel. The threshold voltage divider therefore consists of resistors R60 and R50 in parallel and resistor R59.
Device U8 is connected with feedback resistor R40 so that when the signal present in its negative input exceeds the variable threshold voltage applied to its positive input, its output becomes negative. The negative voltage at the output of device U8 is applied to the resistive voltage divider consisting of resistors R44 and R63. The reduced signal at the junction of resistors R44 and R63 is, in turn, connected to the base of transistor Q8. A negative signal turns "off" transistor Q8 to "release" the output of the limiter circuit, U5, and allow signals produced by the circuit to pass to the rest of the circuitry. If, on the other hand, the signal present at the negative input of device U8 is less than the threshold voltage, its output becomes positive, which positive voltage is applied via the resistive voltage divider to the base of transistor Q8. Transistor Q8, thereupon, turns "on", grounding the output of the limiter circuitry to effectively "mute" the apparatus.
Specifically, when no signal is present at the output of the receive filter, the active rectifier U9 produces substantially no voltage at its output. The absence of voltage at the negative output device U8 causes it to produce a high output, in turn, turning "on" transistor Q8 and muting the limiter circuitry. On the other hand, when a valid input signal is present at the output of the receive filter, the signal is rectified by active rectifier device U9, filtered by capacitor C30 and the resulting D.C. signal causes device U8 to produce a low signal on its output which, in turn, turns "off" transistor Q8 allowing the signals to pass to the remaining circuitry.
The output of device U8 is also provided to the computer (after being converted to RS232 levels by device U12) on pin J2-1 to inform the computer when incoming signals are being processed by the modem.
When it is not muted, the output of the limiter circuitry is provided from the output of device U5 to input pin 1 of I.C. chip U15. In accordance with principles well-known to those skilled in the art, chip U15 converts FSK-coded tones into digital logic levels for transmission to the associated computer apparatus. Digital signals are produced by I.C. chip U15 on output pin 7 and are provided to the upper input of RS232 driver U13. This driver device has its lower input coupled by resistor R65 to a positive voltage source and converts the logic levels produced by chip U15 into RS232 voltage levels (plus or minus 12 volts) which are slew-rate limited by capacitor C28 and provided to the computer via pin J2-2.
Alternatively, the modem may interface with the associated computer via a "cassette port" which accepts digital signals coded in tone bursts. In order to operate with this type of an interface, switch S2 is moved to the "cassette" or "B" position. The output of chip U15, on pin 7, is also provided to comparator U11. Comparator U11 is provided with resistors R47-R49 and R58 and is connected to act as an invertor for the output data from chip U15.
The output of device U11 is connected to the upper input of NAND gate U14. The lower input of NAND gate U14 is connected to the output of limiter circuit U5. Therefore, in response to the signals at its inputs, U14 generates tone bursts which have the frequency of the output signal from limiter U5 and are controlled by the output signal level on pin 7 of IC chip U15. In particular, when the output of chip U15 is "high", comparator U11 provides a "low" output to gate U14 which disables the gate and causes it to apply a "high" output, via resistor R51, switch S2A and pin J2-2 to the computer. When the output of IC chip U15 is "low", comparator U11 applies a "high" signal to gate U14 which enables the gate to pass the tone signals generated by limiter U5 to the computer, via resistor R51, switch S2A and pin J2-2.
Data to be transmitted over the telephone line from the computer is provided to the modem via pin J1-2. The signal at pin J1-2 is normally held "high" by resistor R43 and receives RS232 signals (plus or minus 12 volts) from the computer. The RS232 signals pass, via diode CR9 and resistor R54, to receiver amplifier U10. Resistors R54 and R55 provide a voltage divider to divide the incoming signal level down to a level suitable for amplifier U10.
Amplifier U10 is provided with resistors R52 and R53 as a threshold circuit to compare the input signal, via resistor R54, to a threshold established on its positive terminal. The threshold can be varied by means of switch S2B; when switch S2B is in the "RS232" position, resistors R61 and R62 establish a threshold of approximately 3 volts on the positive terminal of amplifier U10. The incoming RS232 signals (at plus or minus 12 volts) are then compared to the threshold in order to convert the RS232 signals into the logic levels used by chip U15. When switch S2B is in the "cassette" position, however, diode CR10 shunts resistor R62 to establish a 0.6 volt threshold level which is used as a comparison level for the audio frequency tone signals which are provided to the receiver amplifier U10, via resistor R54, from the computer. The output of amplifier U10 (which normally ranges from 0 to 5 volts) is provided to the incoming port of I.C. chip U15 at pin 11.
In response to an incoming signal at pin 11, I.C. chip U15 produces FSK-coded tones on its output pin 9. The tones consist of digitally-synthesized sine waves, as shown in line A of FIG. 3. The signal at pin 9 is provided, via capacitor C1, to variable resistor R1 which is used as a transmit level control. From there the signal is provided, via resistor R8, to the transmit filter consisting of amplifier device U6, capacitor C8 and resistors R27, R9 and R7. The transmit filter removes harmonics from the digital sine wave generated by I.C. chip U15 in order to prevent "singing" or feedback between the transmit and receive filters through transformer T1.
The center frequency of the transmit filter is also controlled by transistor Q1, which, when operated, places resistor R7 in parallel with resistor R9. Transistor Q1 is, in turn, controlled by resistor R6 and switch S1C. When switch S1C is in the "originate" position the base of transistor Q1 is grounded via switch S1C, causing transistor Q1 to be turned "off". Thus, the outgoing signal is divided by the voltage divider consisting of resistors R8 and R7. When, however, switch S1C is in the "answer" position, the base of transistor Q1 is connected to a positive voltage source. Transistor Q1 turns "on" connecting resistor R7 in parallel with resistor R9. Therefore, the outgoing signal is divided by the voltage divider consisting of resistor R8 and resistor R7 in parallel with resistor R9. The signal produced at the output of the transmit filter is shown in line B of FIG. 3. It consists of a sine wave with the higher harmonics removed and is provided via resistor R28 to transformer T1 and to the telephone line.
The following values are suitable for one illustrative embodiment of the invention. The invention, however, is not limited by these values and other suitable values may be used by those skilled in the art to produce the same result:
______________________________________CAPACITORSDevice Value Device Value______________________________________C1 0.1 mF C18 0.0047 mFC7 0.0047 mF C19 0.0047 mFC8 0.0047 mF C20 0.0047 mFC11 0.0047 mF C23 1.0 mFC12 0.0047 mF C28 330 pFC16 0.047 mF C30 3.3 mFC17 0.0047 mF C31 68 pF______________________________________DIODESDevice Code______________________________________CR1 1N4735CR2 1N4002CR3 1N4002CR4 1N4735CR5 1N4148CR10 1N4148______________________________________INTEGRATED CIRCUITSDevice Code______________________________________U1 MC4558, Wideband Op AmpU2 MC4558, Wideband Op AmpU3 MC4558, Wideband Op AmpU4 MC4558, Wideband Op AmpU5 MLM311P1, ComparatorU6 MC4558, Wideband Op AmpU7 MC4558, Wideband Op AmpU8 LM339, Quad ComparatorU9 LM339, QUAD ComparatorU10 LM339, QUAD ComparatorU11 LM339, QUAD ComparatorU12 75488, RS-232 DriverU13 75488, RS-232 DriverU14 75488, RS-232 DriverU15 MC14412AFP, CMOS, MODEM______________________________________RESISTORSDevice Value Device Value______________________________________R1 10K R33 1.0KR2 620 ohms R34 1.0KR3 180 ohms R35 1 MR6 9.1K R36 1.0KR7 2.26K R37 910 ohmsR8 8.06K R38 107KR9 13.7K R39 422KR10 100K R40 590 ohmsR11 10K R41 118KR12 32.4K R42 4.7KR13 287K R43 16KR14 360K R44 4.7KR15 10K R45 2KR16 39K R46 2.4 MR17 4.7K R47 2.4 MR18 1.3K R48 1.0KR19 52.3K R49 9.1KR20 1.18K R50 1.1KR21 2.74K R51 820 ohmsR22 73.2K R52 10KR23 1.65K R53 390KR24 15 M R54 1.0KR25 27K R55 10KR26 620 ohms R56 9.1KR27 165K R58 9.1KR28 620 ohms R59 820 ohmsR29 4.7K R60 9.1KR30 806 ohms R61 30KR31 33.2K R62 11KR32 806 ohms R63 1.1K R65 1.0K______________________________________
Although one illustrative embodiment has been described herein other modificatons and changes within the spirit and scope of this invention will be apparent to those skilled in the art. | A bandpass filter suitable for use in modem circuitry and other applications which require the filter's center frequency to be switched is disclosed. The filter circuit has the characteristic that although the center frequency is changed the overall gain of the filter remains constant. This characteristic results from using a plurality of filter sections which each have low individual gain and providing compensating gain at the input of the filter. In addition, compensating gain elements are used in each filter section so that when the center frequency of the filter is changed, the gain of each filter stage remains constant. | 7 |
TECHNICAL FIELD
This invention relates to an improved golf training aid, and more particularly to a putting aid that is collapsible for easy storage in a golf bag.
BACKGROUND ART
The objective of all putting aids is to help the golfer develop and retain a superior putting stroke. Essentially, a superior putting stroke is one in which the putter blade follows the initial portion of the intended path to the cup. For short and medium putts, this is accomplished by stroking the putter straight back and straight through the initial portion of the intended path, while keeping the face of the putter blade perpendicular to the stroke path. For longer putts, a more pronounced backstroke and throughstroke is required whereby the putter blade is carried slightly inside the line of the stroke path at the extremes of the stroke. For all putts, however, the vertical distboards were parallel. Moreover, for longer putts, it was necessary to reposition the boards to provide a larger distance therebetween to allow the putter blade to be brought slightly inside the line in the back and throughstrokes.
Accordingly, several putting aids have developed stemming from the "two-board" concept that are lightweight and collapsible, thus, providing an advancement in convenience and portability over the two-by-four approach. Representative of these putting aids, for example, is U.S. Pat. No. 2,169,407 which provides a lightweight and collapsible putting aid utilizing a pair of parallel guides between which a golfer strokes the golf ball. However, the previously developed devices that are collapsible generally do not collapse to a size and configuration convenient for storage in the side pocket of a golf bag, and are complicated and difficult to assemble. Moreover, such devices do not provide putting aids with which both short and long putts may be practiced without having to readjust the distance between the parallel guides.
Accordingly, there is a need for an improved putting aid that is collapsible to a size and configuration convenient for storage in the side pocket of a golf bag, that is easy to assemble, and that may be used for practicing both short and long putts without havng to readjust the distance between the putting guides.
DISCLOSURE OF THE INVENTION
In accordance with the present invention, a putting aid is provided that includes a pair of elongated, telescopically extendable rails and a pair of adjustable slide rails interposed between the distal ends of the extendable rails.
The putting aid of the present invention is easy to assemble, yet is collapsible for storage in a convenient, unitary and rigid configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more completely understood by reference to the following Detailed Description taken in conjunction with the accompanying Drawings in which:
FIG. 1 is a perspective view of the putting aid of the present invention in the extended operational position;
FIG. 2 is a top view of the present invention in the folded stowed position; and
FIG. 3 is a cross section view taken generally along sectional lines 3--3 of FIG. 2.
DETAILED DESCRIPTION
Referring simultaneously to FIGS. 1, 2 and 3, the putting aid of the present invention is illustrated and is generally identified by the numeral 10. Putting aid 10 includes a pair of elongated housing members 12 and 14. Slidably mounted within housing member 12 and exiting from end 12a of housing member 12 is an extension rail 16. Similarly, slidably mounted within housing member 14 and exiting from end 14a of housing member 14 is an extension rail 18. As is more clearly illustrated in FIG. 3, extension rails 16 and 18 are "U" shaped in cross section and are completely contained within housing members 12 and 14, respectively, in the folded stowed position of putting aid 10 as illustrated in FIG. 2.
Integrally connected to end 12b of housing member 12 is a swivel post 24 for pivotally supporting a slide rail 26. Slide rail 26 is movable between the extended operation position of putting aid 10 as illustrated in FIG. 1 to the folded stowed position illustrated in FIG. 2. Integrally interconnected to extension rail 18 is a swivel post 28 for pivotally supporting a slide rail 30. Slide rail 30 is movable in a manner similar to slide rail 26 between the extended operation position of putting aid 10 as illustrated in FIG. 1 to the folded stowed position as illustrated in FIG. 2.
Integrally interconnected to end 14b of housing member 14 is an end post 34 which includes a threaded aperture 36. Threaded aperture 36 receives a screw 38 which is carried by slide rail 26. Screw 38 is carried within an elongated slot 40 contained within slide rail 26.
Integrally interconnected to extension rail 16 is an end post 44 including a threaded aperture 46. Threaded aperture 46 receives a screw 48 which is carried by slide rail 30. Screw 48 is slidable within an elongated slot 50 within slide rail 30. It therefore can be seen that by positioning screws 38 and 48 within elongated slots 40 and 50 of slide rails 26 and 30, the spacing between housing members 12 and 14 in the extended operation position of putting aid 10 can be selectably changed. When the desired distance between housing members 12 and 14 is achieved, screws 38 and 48 are tightened to engage threaded apertures 36 and 46, respectively, such that a rectangular rigid structure is formed by slide rails 26 and 30 as ends and, extension rails 16 and 18 and housing members 12 and 14 as sides of putting aid 10.
Once putting aid 10 has been properly assembled by pivoting slide rails 26 and 30 perpendicularly to housing members 12 and 14 and extending extension rails 16 and 18 from housing members 12 and 14, the golfer adjusts the distance between housing members 12 and 14 so that there is sufficient space for the putter blade to pass therebetween with the putter blade oriented such that the face thereof is perpendicular to the interior walls 12c and 14c of housing members 12 and 14. In the preferred embodiment of the present putting aid 10, slide rails 26 and 30 are dimensioned such that the space between housing members 12 and 14 can be varied from approximately four inches to approximately seven inches to thereby accommodate a variety of putter blade sizes. The adjustment to accommodate varying sized putter blades is accomplished by loosening screws 38 and 48 within elongated slots 36 and 46 until the desired spacing is achieved. When this spacing is achieved, screws 38 and 48 are tightened such that slide rails 26 and 30 are rigidly attached to end posts 34 and 44, respectively.
To assist the golfer in adjusting putting aid 10 so that housing members 12 and 14 are parallel, indicia 60 shown in inches and indicia 62 shown in centimeters are contained on slide rails 26 and 30 adjacent elongated slots 40 and 50. Using indicia 60 or 62, slide rails 26 and 30 can be adjusted so that the positioning of screw 38 in elongated slot 40 will lie at the same position as screw 48 within elongated slot 50.
Putting aid 10 may be used in practicing both short and long putts without the necessity of readjusting the distance between housing members 12 and 14 because the distance between slide rails 26 and 30 is greater than the distance between housing members 12 and 14. This aspect of the present invention makes it possible for the golfer to bring the putter slightly inside the line of the initial portion of the intended path to the cup on the back and through stroke which is necessary for longer putts. However, at the same time, putting aid 10 requires the golfer to stroke the putter between the interior walls 12c and 14c of housing members 12 and 14 through the critical portion of both short and long putts.
As illustrated in FIGS. 2 and 3, puttting aid 10 collapses to a size and configuration convenient for storage in a golf bag. To collapse putting aid 10, screws 38 and 48 are loosened such that slide rail 26 disengages from end post 34 and slide rail 30 disengages from end post 44. Extension rail 16 is telescopically inserted into housing member 12 and extension rail 18 is telescopically inserted into housing member 14. Housing members 12 and 14 are then brought into contact along their interior side walls 12c and 14c (FIG. 1) to permit slide rails 26 and 30 to pivot about swivel posts 24 and 28, respectively, to achieve the position illustrated in FIG. 2. After rotation of slide rail 26 and 30, screw 48 is positioned at the end of elongated slot 50 to engage a threaded aperture 70 (FIG. 1) contained within housing member 12 and screw 38 is positioned at the end of elongated slot 40 of slide rail 26 to engage a threaded aperture 72 (FIG. 1) contained within housing member 14. Upon tightening screws 38 and 48, housing members 12 and 14 are rigidly held together to maintain putting aid 10 in the folded stowed position illustrated in FIG. 2.
In order to maintain extension rails 16 and 18 within housing members 12 and 14, respectively in the folded stowed position, end posts 34 and 44 include a locking boss 74 (FIG. 1) which is received by a recess 76 within swivel posts 24 and 28, respectively.
As illustrated in FIG. 2, end posts 34 and 44 include an aperture 78 for receiving a golf tee to thereby allow the user of putting aid 10 to secure putting aid 10 to the ground with the use of a pair of golf tees.
The present putting aid 10 is lightweight in construction and can be fabricated by injection molding of plastic to provide for a durable and maintenance free structure.
A further embodiment of the present putting aid 10 can include a second set of extension rails 16 and 18 slidably mounted within housing members 12 and 14, respectively, and exiting from ends 12b and 14b similiar to extension rails 16 and 18 shown in FIG. 1. In this further embodiment the length of putting aid 10 would be approximately twice that shown in FIG. 1 for use in assisting the golfer on longer putts.
It therefore can be seen that the present invention provides for a golf putting aid which is collapsible to a size and configuration convenient for storage in a golf bag as well as being easy to assemble for the practice of both short and long putts.
Whereas the present invention has been described with respect to specific embodiments thereof, it will be understood that various changes and modifications will be suggested to one skilled in the art and it is intended to encompass such changes and modifications as fall within the scope of the appended claims. | A golf training aid (10) is provided and includes a pair of telescopically extendable rails (16, 18) and a pair of adjustable slide rails (26, 30). Screws (38, 48) interconnect rails (16, 18) and rails (26, 30) in an operational position and folded storage position. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This U.S. National stage application claims priority under 35 U.S.C. §119(a) to German Patent Application No. 10 2008 035 772.3, filed in Germany on Jul. 31, 2008, the entire contents of which are hereby incorporated herein by reference.
BACKGROUND
1. Field of the Invention
The present invention relates to a mechanical particle filter comprising a membrane having a multiplicity of pores, and to a method for manufacturing such a particle filter.
2. Background Information
Particle filters of this type are used to filter particles, for example bacteria, from a fluid. The particles filtered out can be analyzed in order to ascertain the pollution of the fluid with specific particles.
US 2003/0150791 A1 discloses a particle filter of the type mentioned in the introduction, wherein the membrane is formed from a silicon-based material. In order to form the pores, a mask material is applied to the silicon and small spheres are pressed into said mask material and displace the mask material at points. Afterward, the locations of the silicon membrane that have been uncovered in this way are etched open to create pores. Finally, the mask material is removed.
By contrast, U.S. Pat. No. 5,753,014 discloses a method for manufacturing a membrane filter, wherein a mask can be lithographically applied with the aid of a photosensitive layer. After exposure, the pores of the membrane are produced by etching.
DE 10 2006 026 559 A1 discloses the porosification of a substrate, for example composed of silicon, proceeding from the surface thereof, such that it is pervaded by thin channels or holes. This process can be adapted for example by electrochemical etching with light irradiation. As soon as the desired membrane thickness has been reached, the porosification process is ended.
SUMMARY
The invention is based on the object of providing an, in particular mechanical, particle filter of the type mentioned in the introduction which has an improved mechanical and chemical stability in comparison with known particle filters. Moreover, the intention is to provide a method for manufacturing such an improved particle filter.
In order to achieve said object, a particle filter is proposed wherein at least one partial region of a surface of the membrane which is accessible for the medium to be filtered is produced from and/or coated with a carbon material having a diamond structure.
An advantageous manufacturing method for the particle filter is the subject matter of the alternative independent claim.
Advantageous configurations of the invention are the subject matter of the dependent claims.
The particle filter according to the invention has the advantage that the carbon material having a diamond structure is almost completely inert chemically. As a result, simple purification, that is to say removal of the particles accumulated by the filter, can be realized in a simple manner since the particles scarcely form stable bonds with the membrane. Furthermore, a carbon material having a diamond structure is very stable mechanically, such that, when the filter is used, a high differential pressure between the two sides of the membrane can be used. The flow rate through the filter is thereby increased.
The membrane can be produced completely from the carbon material. Since the carbon material is transparent on account of its diamond structure, a membrane constructed in this way makes it possible, by means of simple translumination of the membrane, to identify residual contaminants after purification or structural defects in the membrane in a simple manner.
The membrane can be produced completely from diamond.
The membrane is advantageously supported by a carrier, to which it is fixed. This further increases the loading capacity of the particle filter.
The carrier can be formed from a material which can be patterned by lithographic methods. This makes it possible to use the frame material during the manufacture of the membrane as a support and subsequently to remove it in a gentle manner from the porous region of the membrane.
In an advantageous configuration, the material of the carrier has a crystal structure which predetermines the direction of an anisotropic etching process. The form of the carrier can be determined reliably in such a material.
The carrier can be formed from silicon. Silicon has the advantage that it is available inexpensively, can be subjected to lithography in industrially known methods and is mechanically stable.
The silicon advantageously has a (110) orientation. By virtue of this orientation, sidewalls of the carrier which are almost completely planar and perpendicular to the surface of the membrane are achieved in the course of etching after the lithography.
In the method proposed for advantageous manufacture, firstly an etching mask is applied on one side of a carrier and patterned, then a layer composed of a carbon material having a diamond structure is applied on the other side, wherein an etching mask is applied to the layer composed of carbon material and is patterned, then the layer composed of carbon material is patterned by etching, and, finally, the carrier is patterned by etching.
Such a method has the advantage that it produces a membrane which has a high loading capacity and which is adapted to the carrier in such a way that it has no prestresses. Furthermore, the thickness of the layer composed of carbon material and also the arrangement and form of the pores can be defined in a simple manner.
In an advantageous configuration, the layer composed of carbon material is patterned by plasma etching. This method allows a reliable definition of the pore size and produces pore walls having low roughness.
The carrier can be patterned by wet-chemical anisotropic etching. This allows the excess carrier material to be removed, without the membrane being attacked.
The etching masks are advantageously removed after patterning. This avoids a situation in which the material of the etching masks comes into contact with the fluid to be filtered and possibly enters into chemical or physical interactions which can destroy the particle filter or influence the result of analyses.
The carrier and/or the membrane can finally be coated with a layer composed of carbon material having a diamond structure. The entire particle filter is thus reliably separated from the fluid to be filtered.
The layer composed of carbon material can be deposited by means of chemical vapor deposition in a methane-hydrogen atmosphere. This constitutes a particularly uniform and reliable deposition of diamond-like carbon.
BRIEF DESCRIPTION OF THE DRAWINGS
Details and further advantages of the particle filter according to the invention and of the method according to the invention will become apparent from the following description of a preferred exemplary embodiment. In the drawings, which only schematically illustrate the exemplary embodiment, specifically:
FIG. 1 illustrates a plan view of a particle filter;
FIG. 2 illustrates a cross section through a particle filter along the line II-II in FIG. 1 ;
FIG. 3 illustrates a cross section through a particle filter as in FIG. 2 during a production step;
FIG. 4 illustrates a section through a particle filter as in FIG. 2 with an alternative orientation of the lattice structure of the carrier, and
FIG. 5 shows a section as in FIG. 2 through a diamond-coated particle filter.
DETAILED DESCRIPTION OF EMBODIMENTS
The particle filter 214 shown in FIG. 1 and FIG. 2 has a membrane 312 and a carrier 314 . Pores 316 arranged in a grid are introduced into the membrane 312 . The pores 316 have a round or square cross section.
The carrier 314 supports the membrane 312 in an edge region 318 . A through-flow region 320 is provided in the region of the pores 316 .
The manufacture of the particle filter 214 will be described below with reference to the figures.
As shown in FIG. 3 , a silicon wafer 322 having a (110) crystal orientation is provided as the starting material.
The silicon 323 is thermally oxidized, such that, for example, SiO 2 324 having a thickness of approximately 500 nm is produced. The SiO 2 324 formed is subsequently removed from the front side 330 . The SiO 2 324 on the rear side 332 is patterned in order later as etching mask 326 .
On the front side, diamond 328 or DLC (diamond-like carbon) is deposited for example with a thickness of approximately 1 μm. A chromium layer is applied with a thickness of approximately 100 nm, for example, and patterned. It serves as an etching mask for the subsequent patterning of the diamond 328 .
The diamond 328 is preferably patterned by plasma etching and the chromium mask is subsequently removed. FIG. 3 shows the particle filter after this step.
The front side 330 is then protected in an etching holder and the silicon is etched wet-chemically anisotropically starting from the rear side 332 . By way of example, TMAH or potassium hydroxide is appropriate as etchant. In this case, the SiO 2 324 on the rear side 32 serves as an etching mask 326 . After the conclusion of the etching process, this layer is removed. The particle filter 214 then appears as in FIG. 2 .
Finally, the complete particle filter 214 can be coated with a diamond layer 334 , as a result of which an extremely stable particle filter 214 that is both chemically and mechanically resistant arises. Even the silicon is protected and the entire particle filter 214 is enveloped with diamond 328 . The only exception to this is possible outer areas that are uncovered when the particle filters 214 are sawn apart (separated). However, the outer areas are generally separated anyway by sealing rings from the fluid to be filtered.
If such outer areas are also intended to be protected, the individual chips or particle filters 214 can be coated with a diamond layer 334 after the separation of the wafer.
The diameter of the pores 316 decreases as a result of the additional diamond layer 334 . This should already be taken into account during the patterning of the chromium mask, particularly if a desired diameter of the pores of approximately 450 nm, for example, is intended to be obtained.
The particle filter 214 illustrated in FIG. 5 thus acquires a diamond layer 334 which protects it against chemical and mechanical influences.
Alternatively, the silicon can be completely removed, as a result of which individual thin filter membranes are obtained.
The use of silicon having a (110) orientation has the advantage that perpendicular walls arise during etching, as a result of which a high packing density of particle filters 214 on a silicon wafer 322 is achieved. This can also be obtained by dry etching of the silicon, although this process is more cost-intensive. In addition, it should be ensured in this case that the etching process is ended upon reaching the diamond 328 .
However, the silicon wafer 322 can also consist of silicon having a (100) orientation. During the wet-chemical anisotropic etching of such a silicon wafer 322 , however, oblique edges rather than perpendicular edges are produced, as a result of which the packing density is reduced.
As an alternative to thermally oxidized silicon (SiO 2 324 ), it is also possible to use other etching masks, for example differently deposited SiO 2 324 or Si 3 N 4 . A use of SOI wafers or the utilization of further methods is likewise conceivable. A particle filter 214 with use of SOI wafers having a (100) orientation is shown in FIG. 4 .
The particle filters 214 completed by such an alternative process can subsequently be provided with a diamond layer 334 , as a result of which a particle filter 214 completely protected by a diamond 328 once again arises. This method involves greater outlay in terms of processing, but affords the advantage that the diamond layer 334 does not have to be patterned.
Instead of silicon, it is also possible to use other materials as carrier for the membrane 312 composed of diamond 328 . In particular, hard metal, titanium or refractory metals such as, for example, W, Ta, Mo and the carbides thereof are appropriate in this case. SiC and Si 3 N 4 are likewise particularly suitable.
The diamond deposition takes place, in particular, by means of CVD (chemical vapor deposition) in a methane-hydrogen atmosphere. The energy required for the dissociation of the gases is advantageously made available by a hot filament. However, microwave plasma or impulse discharge excitation (arc jet) is also possible.
In order to detect the particles, the latter can be marked with fluorescent dyes. These dyes are excited by a laser and the emitted light is measured by a detector.
Since diamond is transparent, the use of the particle filters 214 described here enables the illumination and the detection to be effected from different sides. This is advantageous when detecting the particles.
The particle filters 214 comprising a membrane 312 composed of diamond 328 are particularly suitable in particular for determining and measuring viruses in media such as blood and saliva. Relatively fine pores 316 , for example having a diameter of 50 nm, are used for this purpose. Pores 316 having a very small diameter beyond the resolution limit of conventional exposure and patterning methods can be manufactured reproducibly by a finished particle filter, or one in which at least the diamond 328 has already been patterned, being coated with a further diamond layer 334 . Pores 316 are narrowed as a result.
Direct detection without fluorescence can be used, particularly in the case of spatially resolved illumination, in order to be able to identify structural defects in the particle filter 214 or inadequate purification. This information can furthermore be evaluated in such a way that a warning indication is issued or the particle filter 214 is exchanged.
In order to detect bacteria in drinking water, the hole diameter can be 450 nm. In this case, the membrane thickness is approximately 1 μm.
The pores 316 are intended to have a high verticality with respect to the surface of the membrane 312 .
The roughness of the perforation on the inner side of the pores 316 is rms<2 μm, preferably rms<100 nm, and particularly preferably <50 nm.
The grain size of the diamond layer is intended to be less than 1 μm, preferably less than 50 nm, and particularly preferably less than 20 nm.
The flexural bending stress of the diamond layer is intended to be more than 1 GPa, preferably more than 4 GPa, and particularly preferably more than 7 GPa. The modulus of elasticity is intended to be above 500 GPa, preferably above 700 GPa, and particularly preferably above 1000 GPa.
The particle filters 214 can be used not only for detection or analysis, but also for the targeted purification of media (filtering), for example for the purification of drinking water.
The particle filter 214 allows accumulation of bacteria in water or air through a micromechanical surface filter, for example in order to improve a detection limit of an analysis device. By virtue of the use of diamond 328 in the membrane 312 , the particle filter 214 has a high chemical and mechanical robustness. This brings about a high degree of recycling and hence a high degree of automation.
As is described in greater detail in DE 10 2006 026 559 A1, to which reference is expressly made for further details, the particle filter can be used in a detection method in which, in order to detect specific particles in media (e.g. bacteria in drinking water), the medium is pumped through thin filters. The particle filter 214 has pores 316 having a diameter adapted in such a way that the particles to be detected and all particles which are just as large or larger remain on the filter surface, i.e. are accumulated there.
As described here, diamond or a diamond-like material will be used as material for such a filter, in order to achieve very high mechanical and chemical stability.
The high mechanical stability makes it possible to generate a high differential pressure between the two sides of the membranes, as a result of which the flow rate through the filter can be increased. Alternatively or additionally, the pore density can be increased in order to increase the percentage proportion of the total area of the filter that is constituted by the pore area. This is of interest particularly with regard to a miniaturization of the overall system.
Both liquids and gases can be appropriate as media to be filtered. FIGS. 1 and 2 show a plan view and a cross section through the particle filter used as filter element. The pores are preferably round, but can also have some other form.
After the accumulation of the particles on the filter surface, they are detected directly or e.g. after marking with dyes. In particular, the particles, e.g. bacteria, viruses or toxins, can be specifically provided with fluorescent dyes, e.g. fluorescence-marked antibodies, in order to detect them after excitation with light having a suitable wavelength by means of a detector, e.g. photomultiplier or CCD camera. This principle can also be applied to other marking and detection methods.
In order to enable fully automatic operation in a detection system, the fluidic system and in particular the filter is cleaned after each sample examined. In this case, all previously added substances (sample to be examined, marking substances, auxiliary reagents, dirt and impurities) are removed by the use of aggressive chemicals such as e.g. acids, alkaline solutions or solvents for cleaning purposes. | A mechanical particle filter comprises a membrane having a plurality of pores. At least one partial region of the surface of the membrane, that is accessible for the medium to be filtered, includes a carbon material having a diamond structure. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a shift register circuit, and more particularly, to a shift register circuit having high driving ability.
2. Description of the Prior Art
Liquid crystal displays (LCDs) have advantages of a thin profile, low power consumption, and low radiation, and are broadly adopted for application in media players, mobile phones, personal digital assistants (PDAs), computer displays, and flat screen televisions. The operation of a liquid crystal display is featured by modulating the voltage drop across opposite sides of a liquid crystal layer for twisting the angles of liquid crystal molecules in the liquid crystal layer so that the transmittance of the liquid crystal layer can be controlled for illustrating images with the aid of light source provided by a backlight module. In general, the liquid crystal display comprises plural pixel units, a source driver, and a shift register circuit. The source driver is utilized for providing plural data signals to be written into the pixel units. The shift register circuit comprises a plurality of shift register stages and functions to generate plural gate signals for controlling the operations of writing the data signals into the pixel units. That is, the shift register circuit is a crucial device for providing a control of writing the data signals into the pixel units.
FIG. 1 is a schematic diagram showing a prior-art shift register circuit. As shown in FIG. 1 , the shift register circuit 100 comprises a plurality of shift register stages and, for ease of explanation, illustrates an (N−1) th shift register stage 111 , an Nth shift register stage 112 and an (N+1) th shift register stage 113 . Each shift register stage is employed to generate one corresponding gate signal furnished to one corresponding gate line according to a gate signal generated by one preceding shift register stage. For instance, the (N−1) th shift register stage 111 is utilized for generating a gate signal SGn−1 furnished to a gate line GLn−1 according to a gate signal SGn−2, the Nth shift register stage 112 is utilized for generating a gate signal SGn furnished to a gate line GLn according to the gate signal SGn−1, and the (N+1)th shift register stage 113 is utilized for generating a gate signal SGn+1 furnished to a gate line GLn+1 according to the gate signal SGn. In the operation of the Nth shift register stage 112 , the input transistor 181 of an input unit 180 comprises a first end for receiving the gate signal SGn−1, a gate end for receiving a control signal, and a second end for outputting a driving control voltage VQn. As the gate signal SGn−1 and the control signal are both at a high-level voltage, the second end of the input transistor 181 outputs the driving control voltage VQn which is lower than the high-level voltage by the threshold voltage of the input transistor 181 . Thereafter, the driving control voltage VQn is further pulled up to an active voltage by the rising edge of a system clock CK through coupling of the device capacitor of a pull-up transistor 191 in a pull-up unit 190 . The active voltage is then employed to drive the pull-up unit 190 for generating the gate signal SGn. However, the active voltage is lower than twice the high-level voltage by the threshold voltage of the input transistor 181 . That is, the output driving ability of the pull-up unit 190 is significantly lowered by the threshold voltage of the input transistor 181 in the operation of the Nth shift register stage 112 .
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention, a shift register circuit is disclosed for providing plural gate signals to plural gate lines. The shift register circuit comprises a plurality of shift register stages. And an Nth shift register stage of the shift register stages comprises an input unit, a pull-up unit, an energy-store unit, and a pull-down unit.
The input unit is electrically connected to an (N−1)th shift register stage of the shift register stages for receiving an (N−1)th gate signal of the gate signals, and is electrically connected to an (N−2)th shift register stage of the shift register stages for receiving an (N−2)th driving control voltage. The input unit is utilized for outputting an Nth driving control voltage according to the (N−1)th gate signal and the (N−2)th driving control voltage. The pull-up unit, electrically connected to the input unit and an Nth gate line of the gate lines, is utilized for pulling up an Nth gate signal of the gate signals according to the Nth driving control voltage and a system clock. The Nth gate line is employed to transmit the Nth gate signal. The energy-store unit, electrically connected to the pull-up unit and the input unit, is employed to perform a charging/discharging process based on the Nth driving control voltage. The pull-down unit is electrically connected to the input unit and the Nth gate line, and is electrically connected to an (N+2)th shift register stage of the shift register stages for receiving an (N+2)th gate signal of the gate signals. The pull-down unit is utilized for pulling down the Nth gate signal and the Nth driving control voltage according to the (N+2)th gate signal.
In accordance with another embodiment of the present invention, a shift register circuit is disclosed for providing plural gate signals to plural gate lines. The shift register circuit comprises a plurality of shift register stages. And an Nth shift register stage of the shift register stages comprises an input unit, a pull-up unit, a carry unit, an energy-store unit, and a pull-down unit.
The input unit is electrically connected to an (N−1)th shift register stage of the shift register stages for receiving an (N−1)th start pulse signal, and is electrically connected to an (N−2) th shift register stage of the shift register stages for receiving an (N−2)th driving control voltage. The input unit is utilized for outputting an Nth driving control voltage according to the (N−1)th start pulse signal and the (N−2)th driving control voltage. The pull-up unit, electrically connected to the input unit and an Nth gate line of the gate lines, is utilized for pulling up an Nth gate signal of the gate signals according to the Nth driving control voltage and a system clock. The Nth gate line is employed to transmit the Nth gate signal. The carry unit, electrically connected to the input unit, is utilized for outputting an Nth start pulse signal according to the Nth driving control voltage and the system clock. The energy-store unit, electrically connected to the pull-up unit and the input unit, is employed to perform a charging/discharging process based on the Nth driving control voltage. The pull-down unit is electrically connected to the input unit and the Nth gate line, and is electrically connected to an (N+2)th shift register stage of the shift register stages for receiving an (N+2)th gate signal of the gate signals. The pull-down unit is utilized for pulling down the Nth gate signal and the Nth driving control voltage according to the (N+2)th gate signal.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing a prior-art shift register circuit.
FIG. 2 is a schematic diagram showing a shift register circuit in accordance with a first embodiment of the present invention.
FIG. 3 is a schematic diagram showing related signal waveforms regarding the operation of the shift register circuit illustrated in FIG. 2 , having time along the abscissa.
FIG. 4 is a schematic diagram showing another embodiment of the Nth shift register stage of the shift register circuit illustrated in FIG. 2 .
FIG. 5 is a schematic diagram showing a shift register circuit in accordance with a second embodiment of the present invention.
DETAILED DESCRIPTION
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Here, it is to be noted that the present invention is not limited thereto.
FIG. 2 is a schematic diagram showing a shift register circuit in accordance with a first embodiment of the present invention. As shown in FIG. 2 , the shift register circuit 200 comprises a plurality of shift register stages and, for ease of explanation, illustrates an (N−2)th shift register stage 211 , an (N−1)th shift register stage 212 , an Nth shift register stage 213 , an (N+1)th shift register stage 214 and an (N+2)th shift register stage 215 . For the sake of brevity, only the internal structure of the Nth shift register stage 213 is exemplified in detail. The internal structures of other shift register stages are similar to the Nth shift register stage 213 and can be inferred by analogy. In the operation of the shift register circuit 200 , the Nth shift register stage 213 is utilized for performing a circuit operation with high driving ability to generate a gate signal SGn and a driving control voltage VQn according to a driving control voltage VQn−2 generated by the (N−2)th shift register stage 211 , a gate signal SGn−1 generated by the (N−1)th shift register stage 212 , a gate signal SGn+2 generated by the (N+2)th shift register stage 215 , a first system clock HC 1 , a first clock LC 1 , a second clock LC 2 having a phase opposite to the first clock LC 1 , and a power voltage Vss. The circuit functions of other shift register stages are similar to the Nth shift register stage 213 and can be inferred by analogy. Regarding the system clocks HC 1 -HC 4 shown in FIG. 2 , it is noted that the third system clock HC 3 has a phase opposite to the first system clock HC 1 , the second system clock HC 2 has a 90-degree phase difference relative to the first system clock HC 1 , and the fourth system clock HC 4 has a phase opposite to the second system clock HC 2 .
The Nth shift register stage 213 comprises an input unit 305 , a pull-up unit 310 , an energy-store unit 315 , a pull-down unit 325 , a first auxiliary pull-down unit 330 , a first control unit 340 , a second auxiliary pull-down unit 350 , and a second control unit 360 . The input unit 305 is electrically connected to the (N−1)th shift register stage 212 for receiving the gate signal SGn−1, and is further electrically connected to the (N−2)th shift register stage 211 for receiving the driving control voltage VQn−2. The input unit 305 is utilized for outputting the driving control voltage VQn according to the gate signal SGn−1 and the driving control voltage VQn−2. The pull-up unit 310 , electrically connected to the input unit 305 and the gate line GLn, is utilized for pulling up the gate signal SGn of the gate line GLn according to the driving control voltage VQn and the first system clock HC 1 . The gate line GLn is employed to transmit the gate signal SGn. The energy-store unit 315 , electrically connected to the input unit 305 and the pull-up unit 310 , functions to perform a charging/discharging process based on the driving control voltage VQn. The pull-down unit 325 is electrically connected to the input unit 305 and the gate line GLn, and is further electrically connected to the (N+2) th shift register stage 215 for receiving the gate signal SGn+2. The pull-down unit 325 is utilized for pulling down the gate signal SGn and the driving control voltage VQn according to the gate signal SGn+2.
The first control unit 340 , electrically connected to the input unit 305 , is utilized for generating a first control signal SCn 1 according to the driving control voltage VQn and the first clock LC 1 . The first auxiliary pull-down unit 330 , electrically connected to the first control unit 340 , the input unit 305 and the gate line GLn, is utilized for pulling down the gate signal SGn and the driving control voltage VQn according to the first control signal SCn 1 . The second control unit 360 , electrically connected to the input unit 305 , is utilized for generating a second control signal SCn 2 according to the driving control voltage VQn and the second clock LC 2 . The second auxiliary pull-down unit 350 , electrically connected to the second control unit 360 , the input unit 305 and the gate line GLn, is utilized for pulling down the gate signal SGn and the driving control voltage VQn according to the second control signal SCn 2 .
In the embodiment shown in FIG. 2 , the input unit 305 comprises a first transistor 306 , the pull-up unit 310 comprises a second transistor 311 , the energy-store unit 315 comprises a capacitor 316 , the pull-down unit 325 comprises a third transistor 326 and a fourth transistor 327 , the first auxiliary pull-down unit 330 comprises a ninth transistor 331 and a tenth transistor 332 , and the second auxiliary pull-down unit 350 comprises a fifteenth transistor 351 and a sixteenth transistor 352 . It is noted that each of the transistors aforementioned or to be mentioned may be a thin film transistor (TFT), a field effect transistor (FET) or other similar device having connection/disconnection switching functionality.
The first transistor 306 comprises a first end electrically connected to the (N−1)th shift register stage 212 for receiving the gate signal SGn−1, a gate end electrically connected to the (N−2)th shift register stage 211 for receiving the driving control voltage VQn−2, and a second end for outputting the driving control voltage VQn. The second transistor 311 comprises a first end for receiving the first system clock HC 1 , a gate end electrically connected to the second end of the first transistor 306 for receiving the driving control voltage VQn, and a second end electrically connected to the gate line GLn. The capacitor 316 is electrically connected between the gate and second ends of the second transistor 311 . The third transistor 326 comprises a first end electrically connected to the gate line GLn, a gate end electrically connected to the (N+2) th shift register stage 215 for receiving the gate signal SGn+2, and a second end for receiving the power voltage Vss. The fourth transistor 327 comprises a first end electrically connected to the second end of the first transistor 306 , a gate end electrically connected to the (N+2)th shift register stage 215 for receiving the gate signal SGn+2, and a second end for receiving the power voltage Vss.
The ninth transistor 331 comprises a first end electrically connected to the gate line GLn, a gate end electrically connected to the first control unit 340 for receiving the first control signal SCn 1 , and a second end for receiving the power voltage Vss. The tenth transistor 332 comprises a first end electrically connected to the second end of the first transistor 306 , a gate end electrically connected to the first control unit 340 for receiving the first control signal SCn 1 , and a second end electrically connected to the gate line GLn. The fifteenth transistor 351 comprises a first end electrically connected to the gate line GLn, a gate end electrically connected to the second control unit 360 for receiving the second control signal SCn 2 , and a second end for receiving the power voltage Vss. The sixteenth transistor 352 comprises a first end electrically connected to the second end of the first transistor 306 , a gate end electrically connected to the second control unit 360 for receiving the second control signal SCn 2 , and a second end electrically connected to the gate line GLn.
FIG. 3 is a schematic diagram showing related signal waveforms regarding the operation of the shift register circuit 200 illustrated in FIG. 2 , having time along the abscissa. The signal waveforms in FIG. 3 , from top to bottom, are the second system clock HC 2 , the third system clock HC 3 , the fourth system clock HC 4 , the first system clock HC 1 , the driving control voltage VQn− 2 , the gate signal SGn−1, the driving control voltage VQn, the gate signal SGn, and the gate signal SGn+2. As shown in FIG. 3 , during an interval T 1 , the (N−2) th shift register stage 211 employs the driving control voltage VQn−4 and the gate signal SGn−3 to pull the driving control voltage VQn−2 up to the high-level voltage VGH of system clock. During an interval T 2 , the (N−2) th shift register stage 211 employs the rising edge of the third system clock HC 3 to pull the driving control voltage VQn−2 further up to approximate 2VGH. During an interval T 3 , the (N−1) th shift register stage 212 outputs the gate signal SGn−1 having the high-level voltage VGH while the driving control voltage VQn−2 retains the voltage of approximate 2VGH. For that reason, the first transistor 306 of the Nth shift register stage 213 is capable of pulling the driving control voltage VQn up to the high-level voltage VGH according to the driving control voltage VQn−2 and the gate signal SGn−1 during the interval T 3 . It is noted that since the voltage at the gate end of the first transistor 306 approximates 2VGH during the interval T 3 , the driving control voltage VQn at the second end of the first transistor 306 is able to reach the high-level voltage VGH, i.e. without being lowered by the threshold voltage of the first transistor 306 . During an interval T 4 , the driving control voltage VQn is further boosted from VGH to approximate 2VGH by the rising edge of the first system clock HC 1 through coupling of the device capacitor of the second transistor 311 , and the second transistor 311 is then turned on for pulling the gate signal SGn up to the high-level voltage VGH.
During an interval T 5 , the (N+2)th shift register stage 215 outputs the gate signal SGn+2 having the high-level voltage VGH, and therefore the third transistor 326 and the fourth transistor 327 of the Nth shift register stage 213 are both turned on by the gate signal SGn+2 for pulling the gate signal SGn and the driving control voltage VQn down to the power voltage Vss. According to the above description regarding the operation of the Nth shift register stage 213 , the gate signal SGn is pulled up by the second transistor 311 having high output driving ability according to the driving control voltage VQn of approximate 2VGH, thereby enhancing pixel charging rate to improve display quality.
FIG. 4 is a schematic diagram showing another embodiment of the Nth shift register stage of the shift register circuit illustrated in FIG. 2 . As shown in FIG. 4 , the Nth shift register stage 413 is similar to the Nth shift register stage 213 shown in FIG. 2 , differing in that the first control unit 340 is replaced with a first control unit 440 , and the second control unit 360 is replaced with a second control unit 460 . In the embodiment shown in FIG. 4 , the first control unit 440 comprises a fifth transistor 341 , a sixth transistor 342 , a seventh transistor 343 and an eighth transistor 344 , and the second control unit 460 comprises an eleventh transistor 361 , a twelfth transistor 362 , a thirteenth transistor 363 and a fourteenth transistor 364 .
The fifth transistor 341 comprises a first end for receiving the first clock LC 1 , a second end for outputting the first control signal SCn 1 , and a gate end electrically connected to the seventh transistor 343 . The sixth transistor 342 comprises a first end electrically connected to the second end of the fifth transistor 341 , a gate end electrically connected to the second end of the first transistor 306 , and a second end for receiving the power voltage Vss. The seventh transistor 343 comprises a first end for receiving the first clock LC 1 , a gate end for receiving the first clock LC 1 , and a second end electrically connected to the gate end of the fifth transistor 341 . The eighth transistor 344 comprises a first end electrically connected to the second end of the seventh transistor 343 , a gate end electrically connected to the second end of the first transistor 306 , and a second end for receiving the power voltage Vss.
The eleventh transistor 361 comprises a first end for receiving the second clock LC 2 , a second end for outputting the second control signal SCn 2 , and a gate end electrically connected to the thirteenth transistor 363 . The twelfth transistor 362 comprises a first end electrically connected to the second end of the eleventh transistor 361 , a gate end electrically connected to the second end of the first transistor 306 , and a second end for receiving the power voltage Vss. The thirteenth transistor 363 comprises a first end for receiving the second clock LC 2 , a gate end for receiving the second clock LC 2 , and a second end electrically connected to the gate end of the eleventh transistor 361 . The fourteenth transistor 364 comprises a first end electrically connected to the second end of the thirteenth transistor 363 , a gate end electrically connected to the second end of the first transistor 306 , and a second end for receiving the power voltage Vss. The circuit operations regarding the fifth through eighth transistors 341 - 344 and the eleventh through fourteenth transistors 361 - 364 are well known to those skilled in the art and, for the sake of brevity, further discussion thereof is omitted. Other circuit functions of the Nth shift register stage 413 are similar to those of the Nth shift register stage 213 , and are not described again here.
FIG. 5 is a schematic diagram showing a shift register circuit in accordance with a second embodiment of the present invention. As shown in FIG. 5 , the shift register circuit 500 comprises a plurality of shift register stages and, for ease of explanation, illustrates an (N−2) th shift register stage 511 , an (N−1) th shift register stage 512 , an Nth shift register stage 513 , an (N+1)th shift register stage 514 and an (N+2)th shift register stage 515 . For the sake of brevity, only the internal structure of the Nth shift register stage 513 is exemplified in detail. The internal structures of other shift register stages are similar to the Nth shift register stage 513 and can be inferred by analogy. In the operation of the shift register circuit 500 , the Nth shift register stage 513 is utilized for performing a circuit operation with high driving ability to generate a gate signal SGn, a start pulse signal STn and a driving control voltage VQn according to a driving control voltage VQn−2 generated by the (N−2) th shift register stage 511 , a start pulse signal STn−1 generated by the (N−1) th shift register stage 512 , a gate signal SGn+2 generated by the (N+2) th shift register stage 515 , a first system clock HC 1 , a first clock LC 1 , a second clock LC 2 having a phase opposite to the first clock LC 1 , and a power voltage Vss. The circuit functions of other shift register stages are similar to the Nth shift register stage 513 and can be inferred by analogy. Regarding the system clocks HC 1 -HC 4 shown in FIG. 5 , it is noted that the third system clock HC 3 has a phase opposite to the first system clock HC 1 , the second system clock HC 2 has a 90-degree phase difference relative to the first system clock HC 1 , and the fourth system clock HC 4 has a phase opposite to the second system clock HC 2 .
As shown in FIG. 5 , the Nth shift register stage 513 is similar to the Nth shift register stage 213 shown in FIG. 2 , differing in that the input unit 305 is replaced with an input unit 505 , and a carry unit 520 is further added. The input unit 505 is electrically connected to the (N−1) th shift register stage 512 for receiving the start pulse signal STn−1, and is further electrically connected to the (N−2) th shift register stage 511 for receiving the driving control voltage VQn−2. The input unit 505 is utilized for outputting the driving control voltage VQn according to the start pulse signal STn−1 and the driving control voltage VQn−2. The carry unit 520 , electrically connected to the input unit 505 , is utilized for outputting the start pulse signal STn according to the driving control voltage VQn and the first system clock HC 1 .
In the embodiment shown in FIG. 5 , the input unit 505 comprises a first transistor 506 , and the carry unit 520 comprises a seventeenth transistor 521 . The first transistor 506 comprises a first end electrically connected to the (N−1) th shift register stage 512 for receiving the start pulse signal STn−1, a gate end electrically connected to the (N−2) th shift register stage 511 for receiving the driving control voltage VQn−2, and a second end for outputting the driving control voltage VQn. The seventeenth transistor 521 comprises a first end for receiving the first system clock HC 1 , a gate end electrically connected to the second end of the first transistor 506 for receiving the driving control voltage VQn, and a second end for outputting the start pulse signal STn. Since the waveform of the start pulse signal STn is substantially identical to that of the gate signal SGn, the circuit operation of the Nth shift register stage 513 is therefore similar to that of the Nth shift register stage 213 and, for the sake of brevity, further discussion thereof is not described again here.
To sum up, in the operation of the shift register circuit according to the present invention, while pulling up one gate signal by a corresponding pull-up unit, the corresponding pull-up unit is driven by a driving control voltage of approximate twice the high-level voltage of system clock so as to achieve high output driving ability, thereby enhancing pixel charging rate for improving display quality.
The present invention is by no means limited to the embodiments as described above by referring to the accompanying drawings, which may be modified and altered in a variety of different ways without departing from the scope of the present invention. Thus, it should be understood by those skilled in the art that various modifications, combinations, sub-combinations and alternations might occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof. | A shift register circuit includes plural shift register stages for providing plural gate signals. The Nth shift register stage of the shift register stages includes an input unit, a pull-up unit and a pull-down unit. The input unit is put in use for outputting an Nth driving control voltage according to an (N−1)th gate signal and an (N−2)th driving control voltage which are generated respectively by the (N−1) th shift register stage and the (N−2) th shift register stage of the shift register stages. The pull-up unit pulls up an Nth gate signal according to the Nth driving control voltage and a system clock. The pull-down unit pulls down the Nth gate signal and the Nth driving control voltage according to an (N+2)th gate signal generated by the (N+2)th shift register stage of the shift register stages. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on Japanese Patent Application No. 2005-56639 filed on Mar. 1, 2005, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an ultrasonic sensor.
BACKGROUND OF THE INVENTION
[0003] An ultrasonic sensor is mounted on an automotive vehicle, for example. The sensor detects a distance between the sensor, i.e., the vehicle and an obstruction when a driver parks the vehicle or when the driver turns the vehicle. The ultrasonic sensor is disclosed in, for example, JP-A-2001-16694. The sensor for detecting the obstruction includes a transmission device and a reception device, which transmits an ultrasonic wave and receives the ultrasonic wave. The sensor may include a transmitting/receiving device. When the transmission device transmits the ultrasonic wave, the ultrasonic wave hits the obstruction. The obstruction reflects the ultrasonic wave; and then, the reflected ultrasonic wave is received by the reception device. On the basis of the received ultrasonic wave by the reception device, an acoustic pressure of the ultrasonic wave, a time lag and/or a phase difference are detected so that a direction to the obstruction and a distance between the obstruction and the vehicle are calculated. Further, a concavity and a convexity of the obstruction can be detected.
[0004] The reception device of the ultrasonic wave is for example, an ultrasonic element having a vibrator formed of a piezoelectric thin film disposed on a membrane as a thin portion of a substrate. The ultrasonic element with a membrane structure is disclosed in, for example, JP-A-2003-284182. This element is formed by a micro machining method so that the element is called a MEMS (i.e., micro electro mechanical system) type ultrasonic element. JP-A-2003-284182 also discloses an ultrasonic array sensor including the MEMS type ultrasonic elements.
[0005] The MEMS type ultrasonic element 90 R is shown in FIG. 13A . In the element 90 R, a PZT ceramics thin film layer 2 as a ferroelectric substance is sandwiched by a pair of electrodes 3 a , 3 b . The element 90 R further includes a piezoelectric sensor having a predetermined resonance frequency for detecting the ultrasonic wave. When the element 90 R operates, a predetermined bias voltage is applied between two electrodes 3 a , 3 b so that the resonant frequency of the element 90 R is changed, i.e., controlled.
[0006] FIG. 13B explains a positioning measurement method by using the ultrasonic wave, which is disclosed in JP-A-2003-284182. An ultrasonic sensor 900 includes an ultrasonic wave source 40 as a transmission device of the ultrasonic wave and an ultrasonic array device A 90 R as a reception device of the ultrasonic wave. The ultrasonic array device A 90 R includes multiple MEMS type ultrasonic elements 90 R, which are arrayed. In the sensor 900 , the source 40 is adjacent to the sensing device A 90 R, and transmits the ultrasonic wave. The ultrasonic wave hits an object 51 , 52 as an obstacle; and then, the ultrasonic wave is reflected by the object 51 , 52 . Thus, the ultrasonic wave is returned to the sensor 900 . The returned ultrasonic wave is received by each sensing element 90 R in the sensing device A 90 R. On the basis of the received ultrasonic wave, the position of the object 51 , 52 including an orientation angle to the object 51 , 52 is determined. Specifically, on the basis of a transmission time of the ultrasonic wave in each incident direction of the sensing element 90 R, the distance between the sensing element 90 R and the object 51 , 52 in the incident direction is calculated. Thus, distribution of the distance in different incident directions is determined. Accordingly, the distance between the object 51 , 52 and the sensing element 90 R in a depth direction of the object 51 , 52 is determined. Here, the transmission time of the ultrasonic wave is a time from a transmission time when the ultrasonic wave is transmitted from the source 40 to a returning time when the ultrasonic wave is returned to the sensing element 90 R.
[0007] Here, the source 40 and the sensing device A 90 R are separated each other. Therefore, a manufacturing cost of each of the source 40 and the sensing device A 90 R is necessitated. Further, when the source 40 and the sensing device A 90 R are mounted on a bumper of the vehicle, mounting accuracy of each of the source 40 and the sensing device A 90 R affects detection accuracy of the direction and the distance of the object. Furthermore, the mounting distance between the source 40 and the sensing device A 90 R may be increased.
[0008] Further, in general, when an ultrasonic sensing device is directly mounted on the bumper of the vehicle, the sensing device cannot detect the distance to the object accurately by a water drop or a dust attached on a surface of the sensing element. Furthermore, attenuation of the ultrasonic wave transmitting through air depends on temperature and humidity of the air. These temperature and humidity are changeable in accordance with the environment around the vehicle. Thus, the detection accuracy of the object may depend on temperature change and humidity change. Specifically, the environmental temperature around the vehicle can be detected by an external temperature sensor or the like. However, there is no appropriate external humidity sensor mounted on the outside of the vehicle. Thus, the environmental humidity around the vehicle cannot be detected.
SUMMARY OF THE INVENTION
[0009] In view of the above-described problem, it is an object of the present invention to provide an ultrasonic sensor having a transmission device and a reception device of an ultrasonic wave.
[0010] An ultrasonic sensor for detecting an object includes: a substrate; a transmission device for transmitting an ultrasonic wave; a plurality of reception devices for receiving the ultrasonic wave; and a circuit for processing received ultrasonic waves, which are received by the reception devices after the ultrasonic wave transmitted from the transmission device is reflected by the object. The transmission device and the reception devices are integrated into the substrate.
[0011] The dimensions of the above sensor are minimized, compared with a conventional sensor. Further, a manufacturing cost of the sensor is reduced. Furthermore, a positioning relationship between the transmission device and the reception device is accurately determined; and therefore, detection accuracy of the sensor is not affected by mounting accuracy of the sensor.
[0012] Alternatively, the number of the reception devices may be equal to or larger than three so that the circuit is capable of detecting an operation failure. Further, each of the transmission device and the three reception devices has a surface for transmitting or receiving the ultrasonic wave, the surface being perpendicular to a ground. The three reception devices are composed of a first to a third reception devices. The first reception device is disposed above the third reception device, and disposed on a left side of the second reception device. The circuit is capable of calculating a horizontal plane distance between the object and the sensor in a horizontal plane parallel to the ground and a horizontal plane direction angle from the sensor to the object in the horizontal plane on the basis of the received ultrasonic waves received by the first and the second reception devices. The circuit is further capable of calculating a vertical plane distance between the object and the sensor in a vertical plane perpendicular to the ground and a vertical plane direction angle from the sensor to the object in the vertical plane on the basis of the received ultrasonic waves received by the first and the third reception devices. The circuit is capable of checking the horizontal and the vertical plane distances and the horizontal and the vertical plane direction angles on the basis of the received ultrasonic waves received by the second and the third reception devices so that the circuit is capable of detecting the operation failure.
[0013] Alternatively, the number of the reception devices may be equal to or larger than four. Further, each of the transmission device and the four reception devices has a surface for transmitting or receiving the ultrasonic wave, the surface being perpendicular to a ground. The four reception devices are composed of a first to a fourth reception devices. The first reception device is disposed above the third reception device, and disposed on a left side of the second reception device. The fourth reception device is disposed under the second reception device, and disposed on a right side of the third reception device. The circuit is capable of calculating a horizontal plane distance between the object and the sensor in a horizontal plane parallel to the ground and a horizontal plane direction angle from the sensor to the object in the horizontal plane on the basis of the received ultrasonic waves received by the first and the second reception devices, and further capable of calculating a vertical plane distance between the object and the sensor in a vertical plane perpendicular to the ground and a vertical plane direction angle from the sensor to the object in the vertical plane on the basis of the received ultrasonic waves received by the first and the third reception devices, so that a first data of the object is obtained. The circuit is capable of calculating the horizontal plane distance and the horizontal plane direction angle on the basis of the received ultrasonic waves received by the third and the fourth reception devices, and further capable of calculating the vertical plane distance and the vertical plane direction angle on the basis of the received ultrasonic waves receive by the second and the fourth reception devices, so that a second data of the object is obtained. The circuit is capable of checking the first data and the second data so that the circuit is capable of detecting the operation failure.
[0014] Alternatively, the transmission device may be capable of transmitting multiple ultrasonic waves having different frequencies so that the circuit is capable of compensating humidity. Further, the transmission device is capable of a first ultrasonic wave having a first frequency and a second ultrasonic wave having a second frequency. The number of the reception devices is equal to or larger than three. Each of the transmission device and the three reception devices has a surface for transmitting or receiving the ultrasonic wave, the surface being perpendicular to a ground. The three reception devices are composed of a first to a third reception devices. The first reception device is disposed above the third reception device, and disposed on a left side of the second reception device. The circuit is capable of calculating a horizontal plane distance between the object and the sensor in a horizontal plane parallel to the ground and a horizontal plane direction angle from the sensor to the object in the horizontal plane on the basis of the received ultrasonic waves having the first frequency received by the first and the second reception devices, and further capable of calculating a vertical plane distance between the object and the sensor in a vertical plane perpendicular to the ground and a vertical plane direction angle from the sensor to the object in the vertical plane on the basis of the received ultrasonic waves having the first frequency received by the first and the third reception devices. The circuit is capable of calculating a first attenuation loss between the transmitted ultrasonic wave and the received ultrasonic waves having the first frequency. The circuit is capable of calculating a second attenuation loss between the transmitted ultrasonic wave and the received ultrasonic waves having the second frequency. The circuit is capable of calculating the humidity of environment on the basis of the first and the second attenuation losses and a temperature obtained from an external temperature sensor.
[0015] Alternatively, each of the transmission device and the reception devices may be provided by an ultrasonic element. The ultrasonic element is disposed on a membrane of the substrate. The ultrasonic element includes a piezoelectric thin film and a pair of metallic electrodes so that a piezoelectric vibrator is provided. The piezoelectric thin film is sandwiched by the metallic electrodes. The piezoelectric vibrator is capable of resonating together with the membrane at a predetermined ultrasonic frequency. Further, the piezoelectric thin film of the transmission device includes a partial cutting pattern, which is disposed on a stress concentration region of a radial direction vibration of the membrane. Furthermore, the membrane is separated by the partial cutting pattern into four pieces. The membrane has a square planar shape, and each piece of the membrane has a square planar shape. The partial cutting pattern penetrates one of the metallic electrodes and the piezoelectric thin film.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings:
[0017] FIG. 1A is a top view showing an ultrasonic sensor according to a preferred embodiment of the present invention, and FIG. 1B is a schematic perspective view showing the sensor mounted on a circuit board;
[0018] FIG. 2A is a plan view showing an ultrasonic element in the sensor, and FIG. 2B is a cross sectional view showing the element taken along line IIB-IIB in FIG. 2A ;
[0019] FIG. 3 is a plan view showing another ultrasonic sensor, according to a modification of the embodiment;
[0020] FIG. 4A is a plan view showing an ultrasonic element according to a second modification of the embodiment, and FIG. 4B is a cross sectional view showing the element taken along line IVB-IVB in FIG. 4A ;
[0021] FIG. 5A is a plan view showing an ultrasonic element according to a third modification of the embodiment, and FIG. 5B is a cross sectional view showing the element taken along line VB-VB in FIG. 5A ;
[0022] FIG. 6A is a plan view showing an ultrasonic element according to a fourth modification of the embodiment, and FIG. 6B is a cross sectional view showing the element taken along line VIB-VIB in FIG. 6A , and FIG. 6C is a partially enlarged cross sectional view showing a part VIC of the element in FIG. 6B ;
[0023] FIG. 7A is a plan view showing an ultrasonic element according to a fifth modification of the embodiment, and FIG. 7B is a cross sectional view showing the element taken along line VIIB-VIIB in FIG. 7A ;
[0024] FIG. 8A is a plan view showing an ultrasonic element according to a sixth modification of the embodiment, FIG. 8B is a cross sectional view showing the element taken along line VIIIB-VIIIB in FIG. 8A , and FIG. 8C is a cross sectional view showing the element taken along line VIIIC-VIIIC in FIG. 8A ;
[0025] FIG. 9A is a schematic view explaining a reception ultrasonic wave in a X-Y plane received by reception devices, FIG. 9B is a schematic view explaining the reception ultrasonic wave in a Z plane received by the reception devices, and FIG. 9C is a timing chart showing signals from a transmission device and four reception devices;
[0026] FIG. 10 is a timing chart showing signals having two different frequencies from a transmission device and four reception devices, according to a seventh modification of the embodiment;
[0027] FIG. 11A is a top view showing an ultrasonic sensor according to an eighth modification of the embodiment, and FIG. 11B is a timing chart showing signals having two different frequencies from two transmission devices and four reception devices, according to the eighth modification;
[0028] FIG. 12 is a top view showing an ultrasonic sensor according to a ninth modification of the embodiment; and
[0029] FIG. 13A is a partially enlarged cross sectional view showing an ultrasonic element according to a prior art, and FIG. 13B is a schematic view explaining a method for detecting an object by using an ultrasonic wave, according to the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] An ultrasonic sensor 100 according to a preferred embodiment of the present invention is shown in FIGS. 1A and 1B . FIG. 1B shows the sensor 100 mounted on a circuit board K. The sensor 100 includes one transmission device S 1 and four reception devices R 1 -R 4 , which are integrated on the same semiconductor substrate 10 . FIG. 2A shows an ultrasonic element 90 for providing each of the transmission device S 1 and the reception device R 1 -R 4 .
[0031] The ultrasonic element 90 is similar to the MEMS type ultrasonic element 90 R as the reception device shown in FIG. 13A . The transmission device S 1 of the ultrasonic element 90 has the same construction of the reception device R 1 -R 4 of the ultrasonic element 90 .
[0032] The ultrasonic element 90 is formed of a SOI (i.e., silicon-on-insulator) semiconductor substrate 10 . The substrate 10 includes a first semiconductor layer 1 a as a supporting layer, an embedded oxide layer 1 b , a second semiconductor layer 1 c and a protection oxide film 1 d . A membrane M as a thin portion of the substrate 10 is formed by using a semiconductor micromachining method. A piezoelectric vibrator 20 is formed on the membrane M to cover the membrane M. The piezoelectric vibrator 20 includes a piezoelectric thin film 2 and a pair of metallic electrodes 3 a , 3 b . Specifically, the piezoelectric thin film 2 is sandwiched by a pair of the metallic electrodes 3 a , 3 b , which are formed of a metallic film.
[0033] When the ultrasonic element 90 is used as the transmission device S 1 , alternating voltage is applied to the metallic electrodes 3 a , 3 b of the piezoelectric vibrator 20 so that the membrane M together with the piezoelectric vibrator 20 is resonated with a predetermined ultrasonic frequency. Thus, the ultrasonic wave is transmitted. When the ultrasonic element 90 is used as the reception device R 1 -R 4 , the returned ultrasonic wave reflected by the object to be measured resonates the membrane M together with the piezoelectric vibrator 20 so that the returned ultrasonic wave is converted to an electric signal by the piezoelectric vibrator 20 . Thus, the ultrasonic wave is received.
[0034] When the ultrasonic element 90 is used as the transmission device S 1 , it is preferred that a planar area of the membrane M in the transmission device S 1 is comparatively large. This is because it is required to generate large ultrasonic sound pressure outputted from the transmission device S 1 . Thus, it is preferred that the planar area of the membrane M in the transmission device S 1 is larger than that in the reception device R 1 -R 4 . Thus, the transmission device S 1 can transmit the ultrasonic wave having large sound pressure. However, the planar area of the membrane M in the reception device R 1 -R 4 may be comparatively small as long as the reception device R 1 -R 4 has sufficient sensitivity of the ultrasonic wave.
[0035] FIG. 3 shows another ultrasonic sensor 100 a according to the preferred embodiment of the present invention. In this case, the planar area of the membrane Ms in the transmission device S 1 a is larger than the planar area of the membrane Mr in the reception device R 1 -R 4 .
[0036] FIGS. 4A to 8C show other ultrasonic elements 91 - 95 for using as the transmission device S.
[0037] The ultrasonic element 91 shown in FIGS. 4A and 4B includes the semiconductor substrate having SOI structure. The piezoelectric vibrator 21 is formed on the membrane M formed to be a thin portion of the substrate 10 . The piezoelectric vibrator 21 covers the membrane M. The piezoelectric vibrator 21 also includes the piezoelectric thin film 2 and the metallic electrodes 3 a , 3 b . The piezoelectric thin film 2 is sandwiched by the metallic electrodes 3 a , 3 b.
[0038] In the piezoelectric vibrator 21 of the ultrasonic element 91 , the piezoelectric thin film 2 includes a partial cutting pattern 2 a as a groove, which separates the piezoelectric thin film 4 into four parts. This partial cutting pattern 2 a is obtained by removing a part of the piezoelectric thin film 2 , at which a stress caused by radial direction vibration of the membrane M is concentrated. Therefore, rigidity of the part of the piezoelectric thin film 2 as a stress concentration region is reduced, so that the membrane M is easily bent, i.e., the flexibility of the membrane M is increased. Accordingly, the piezoelectric vibrator 21 can transmit, i.e., output the ultrasonic wave having sufficient sound pressure.
[0039] In the piezoelectric vibrator 22 of the ultrasonic element 92 shown in FIGS. 5A and 5B , the piezoelectric thin film 2 includes a partial concavity pattern 2 b as a partial groove. The thickness of the part of the piezoelectric thin film 2 , which is the stress concentration region of the radial direction vibration of the membrane M, is reduced so that the partial concavity pattern 2 b is formed. Thus, the flexibility of the membrane M is increased so that the piezoelectric vibrator 21 can output the ultrasonic wave having sufficient sound pressure.
[0040] The piezoelectric vibrator 23 of the ultrasonic element 93 shown in FIGS. 6A to 6C is formed of multiple layers composed of multiple piezoelectric thin films 2 and multiple metallic electrodes 3 a - 3 c , which are alternately stacked. When the voltage is applied to the piezoelectric vibrator 23 , deformation of the piezoelectric vibrator 23 is increased. Thus, vibration amplitude of the membrane M is increased so that the vibrator 23 outputs the ultrasonic wave having sufficient sound pressure.
[0041] In the piezoelectric vibrator 24 of the ultrasonic element 94 shown in FIGS. 7A and 7B , the piezoelectric vibrator 24 and the membrane Md are cantilevered with the substrate 10 . Thus, the membrane Md can be deformed sufficiently, i.e., no portion of the membrane Md, which prevents the membrane Md from deforming, exists in the membrane Md. Thus, when the voltage is applied to the piezoelectric vibrator 24 so that the piezoelectric vibrator 24 is deformed, the membrane Md is also deformed largely. Accordingly, the vibrator 24 outputs the ultrasonic wave having sufficient sound pressure.
[0042] In the piezoelectric vibrator 25 of the ultrasonic element 95 shown in FIGS. 8A to 8C , the membrane Me is formed in such a manner that a part of the embedded oxide layer 1 b of the substrate 10 is hollowed, i.e., cut from a top surface side of the substrate 10 by a sacrifice etching method. A hole H for the sacrifice etching method is formed around the membrane Me and a beam Ha. Accordingly, the periphery of the membrane Me is partially supported on the substrate 10 through the beam Ha. Thus, the interference part of the membrane Me, which prevents the membrane Me from deforming, becomes small. When the voltage is applied to the piezoelectric vibrator 25 so that the membrane Me is deformed, distortion of the beam Ha is generated and the beam Ha is deformed largely; and therefore, the membrane Me is largely deformed. Thus, the vibrator 25 outputs the ultrasonic wave having sufficient sound pressure.
[0043] Since each ultrasonic element 91 - 95 can output the ultrasonic wave having sufficient sound pressure, the element 91 - 95 can provide the transmission device S 1 of the ultrasonic sensor 100 having high detection accuracy. Here, the element 91 - 95 may also provide the reception device R 1 -R 4 of the ultrasonic sensor 100 .
[0044] Next, a method for detecting the object by using the ultrasonic sensor 100 is explained with reference to FIGS. 9A to 9C . In FIGS. 9A to 9C , the substrate surface of the ultrasonic sensor 100 is disposed to be perpendicular to the ground. Specifically, the surface of the transmission device S 1 is perpendicular to the ground. Here, a X-Y plane in FIG. 9A is parallel to the ground. A Z-axis in FIG. 9B is perpendicular to the ground. FIG. 9A shows the reception devices R 1 , R 2 of the ultrasonic sensor 100 and the reception ultrasonic wave in the X-Y plane. Specifically, the ultrasonic wave transmitted from the transmission device S 1 is reflected by the obstacle 50 , and then the reflected ultrasonic wave is received by the reception device R 1 , R 2 as the reception ultrasonic wave. FIG. 9B shows the reception devices R 1 , R 3 of the ultrasonic sensor 100 and the reception ultrasonic wave in the Z-X, Y plane. Here, the Z-X, Y plane in FIG. 9B is perpendicular to the ground. ΔL represents difference of a path of the reception ultrasonic wave. FIG. 9C is a timing chart showing an alternate pulse signal of the ultrasonic wave outputted from the transmission device S 1 and four alternate pulse signals of the ultrasonic wave received by four reception devices R 1 -R 4 .
[0045] In FIG. 9A , Dx represents a distance between the center of the ultrasonic sensor 100 and the obstacle 50 in the X-Y plane. The distance Dx is calculated on the basis of a S signal No. 1 outputted from the transmission device S 1 , a R signal No. 1 received by the reception device R 1 and a R signal No. 2 received by the reception device R 2 . The reception devices R 1 , R 2 are disposed on an upper side of the sensor 100 in FIG. 1 . Specifically, the distance Dx is calculated from an average time difference ΔTx between reception times (i.e., an arrival time) of the R signals No. 1 and No. 2 and a transmission time (i.e., an output time) of the S signal No. 1 .
[0046] In FIG. 9A , θx represents a direction angle to the obstacle 50 in the X-Y plane. The direction angle θx is measured from the X-axis as a reference axis. The direction angle θx is obtained on the basis of the R signals No. 1 and No. 2 from the reception devices R 1 and R 2 . Specifically, the direction angle θx is calculated from a phase difference ΔPx between the R signal No. 1 and the R signal No. 2 .
[0047] In FIG. 9B , Dz represents a distance between the center of the ultrasonic sensor 100 and the obstacle 50 in the Z-X, Y plane, which is perpendicular to the ground. The distance Dz is calculated on the basis of the S signal No. 1 from the transmission device S 1 , the R signal No. 1 from the reception device R 1 and a R signal No. 3 received by the reception device R 3 . The reception devices R 1 , R 3 are disposed on a left side of the sensor 100 in FIG. 1 . Specifically, the distance Dz is calculated from an average time difference ΔTz between reception times of the R signals No. 1 and No. 3 and the transmission time of the S signal No. 1 .
[0048] In FIG. 9B , θz represents a direction angle to the obstacle 50 in the Z-X, Y plane. The direction angle θz is measured from the X-Y plane as a reference plane. The direction angle θz is obtained on the basis of the R signals No. 1 and No. 3 from the reception devices R 1 and R 3 . Specifically, the direction angle θz is calculated from a phase difference ΔPz between the R signal No. 1 and the R signal No. 3 .
[0049] On the basis of the distances Dx, Dz and the direction angles θx, θz, the distance between the obstacle 50 and the sensor 100 and the direction to the obstacle 50 are determined. Thus, the sensor 100 detects the obstacle 50 .
[0050] In the sensor 100 , the transmission device S 1 and the reception devices R 1 -R 4 are integrated into the same substrate 10 . Accordingly, the dimensions of the sensor 100 and the manufacturing cost of the sensor 100 are reduced, compared with the sensor 900 shown in FIG. 13B , in which the transmission device S 1 and the ultrasonic allay device A 90 R are independently formed. Further, since the positioning relationship between the transmission device S 1 and the reception device R 1 -R 4 is accurately designed, i.e., determined on the substrate 10 . Thus, even when the sensor 100 is mounted on a bumper of an automotive vehicle, mounting accuracy of the sensor 100 on the bumper does not affect the detection accuracy of the sensor 100 .
[0051] Even when the number of the transmission devices S 1 and/or the number of the reception devices R 1 -R 4 are increased or reduced, and/or even when the dimensions of the transmission device S 1 and/or the dimensions of the reception device R 1 -R 4 are changed, the sensor 100 can be formed only by changing a mask. Thus, the manufacturing cost of the sensor 100 is almost the same.
[0052] Although the sensor 100 includes four reception devices R 1 -R 4 , the obstacle 50 can be detected by using three reception devices R 1 -R 3 . Specifically, the distance Dx in the X-Y plane and the direction angle θx measured from the X-axis are obtained by using two reception devices R 1 , R 2 , which are disposed on the upper side of the sensor 100 . The distance Dz in the Z-X, Y plane and the direction angle θ z measured from the X-Y plane are obtained by using two reception devices R 1 , R 3 , which are disposed on the left side of the sensor 100 .
[0053] However, the distance Dx in the X-Y plane and the direction angle θx measured from the X-axis can be obtained by using two reception devices R 3 , R 4 , which are disposed on a lower side of the sensor 100 . The distance Dz in the Z-X, Y plane and the direction angle θz measured from the X-Y plane can be obtained by using two reception devices R 2 , R 4 , which are disposed on the right side of the sensor 100 . Thus, the obstacle 50 can be detected by three reception devices R 2 -R 4 .
[0054] Accordingly, in the sensor 100 , two different distances and two different direction angles to the obstacle 50 are obtained. By comparing these two data of the obstacle 50 , operation failure of the sensor 100 is judged. Specifically, when two data of the obstacle do not coincide, the operation failure of the sensor 100 occurs. Accordingly, the sensor 100 has operation failure detection function.
[0055] If the sensor 100 determines that only one reception device R 1 -R 4 acts up the operation failure, the sensor 100 can detect the obstacle 50 by using other three reception devices R 1 -R 4 . Accordingly, the sensor 100 has fail safe function.
[0056] Further, even when the sensor 100 includes only three reception devices R 1 -R 3 , the sensor 100 can have the operation failure detection function. Specifically, the distance Dx and the direction angle θx are obtained from two reception devices R 1 , R 2 , and the distance Dz and the direction angle θ z are obtained by using two reception devices R 1 , R 3 . Accordingly, the obstacle 50 is detected on the basis of two combination data, one of which is obtained from the reception devices R 1 , R 2 , and the other one of which is obtained from the reception devices R 1 , R 3 . The other combination data obtained from the reception devices R 2 , R 3 can be used for checking the calculation of detection of the obstacle 50 . Thus, even when the sensor 100 includes three reception devices R 1 -R 3 , the sensor 100 can have the operation failure function.
[0057] Thus, when the sensor 100 includes three or more reception devices R 1 -R 3 , the sensor 100 has the operation failure function. When the sensor 100 includes four or more reception devices R 1 -R 4 , the sensor 100 has the fail safe function. Thus, if the operation failure of the sensor 100 is occurred by waterdrop or dust, which is attached to the sensor 100 , the sensor 100 can avoid the operation failure.
[0058] The sensor 100 can output two or more different ultrasonic waves having different frequencies, which are transmitted from one transmission device S 1 by controlling the frequency of the alternate pulse signal in terms of time, the pulse signal being applied to the transmission device S 1 . By using two different ultrasonic waves, the sensor 100 can detect the obstacle 50 with humidity compensation function. Here, the input voltage is controlled to have a frequency range other than the resonant frequency of the membrane M so that the ultrasonic waves having two different frequencies are transmitted.
[0059] FIG. 10 explains the method for compensating the humidity. In FIG. 10 , the transmission device S 1 outputs two different ultrasonic waves having two different frequencies f 1 , f 2 . The transmission device S 1 transmits the first ultrasonic wave having the first frequency f 1 , and then, the device S 1 transmits the second ultrasonic wave having the second frequency f 2 . The first and the second ultrasonic waves are periodically, i.e., with a predetermined time interval, outputted. In four reception devices R 1 -R 4 , the first R signal No. 1 corresponding to the first ultrasonic wave and the second R signal No. 1 corresponding to the second ultrasonic wave to the first R signal No. 4 corresponding to the first ultrasonic wave and the second R signal No. 4 corresponding to the second ultrasonic wave are detected. The relationship among the first R signals No. 1 - 4 and the first S signal No. 1 corresponding to the first ultrasonic wave in FIG. 10 is the same as that in FIG. 9C . Further, the relationship among the second R signals No. 1 - 4 and the second S signal No. 1 corresponding to the second ultrasonic wave in FIG. 10 is the same as that in FIG. 9C .
[0060] In FIG. 10 , the height of the alternate pulse signal of the first S signal No. 1 of the first frequency f 1 is equal to that of the second S signal No. 1 of the second frequency f 2 . However, the height of the first R signal No. 1 of the first frequency f 1 is higher than that of the second frequency f 2 , i.e., the second R signal No. 1 of the second frequency f 2 is largely attenuated, compared with the first R signal No. 1 of the first frequency f 1 . Similarly, the second R signals No. 2 - 4 are largely attenuated, i.e., reduced.
[0061] Here, attenuation loss P, i.e., absorption loss of the ultrasonic wave is obtained by the following formula.
[0000]
P
∝
-
mr
(
F
1
)
m
=
(
33
+
0.2
T
)
f
2
×
10
-
12
+
Mf
k
/
2
π
f
+
2
π
f
/
k
(
F
2
)
k
=
1.92
×
(
G
0
G
×
h
)
1.3
×
10
5
(
F
3
)
[0062] Here, m represents absorption coefficient, r represents transmission distance, M represents a predetermined coefficient, f represents a frequency, T represents a temperature, GO represents a saturated vapor pressure, G represents a total air pressure, and h represents a humidity.
[0063] From the above formula F 1 , the attenuation loss P depends on the frequency f. As the frequency f of the ultrasonic wave becomes larger, the attenuation loss becomes larger. Further, the attenuation loss P depends on not only the frequency but also the temperature T and the humidity h of the transmission environment. The frequency f of the ultrasonic wave is preliminarily determined. The temperature T of the environment can be detected by an external temperature sensor or the like. When the sensor 100 is mounted on the vehicle, the temperature T, i.e., the external temperature can be detected easily. However, the humidity h of the environment, i.e., the external humidity h is not detected easily by a humidity sensor. This is because there is no appropriate humidity sensor for detecting the external humidity around the vehicle.
[0064] However, since the received ultrasonic waves having two different frequencies f 1 , f 2 are measured, the humidity h can be calculated on the basis of the difference of two attenuation losses P obtained from two different frequencies f 1 , f 2 . This calculated humidity h is used for compensating the standard humidity, which is preliminarily determined and memorized in the sensor 100 . Thus, the sensor 100 has the humidity compensation function. In this case, the detection accuracy of the sensor 100 is much improved regarding the humidity change.
[0065] Although the sensor 100 includes only one transmission device S 1 , it is preferred that the sensor 100 includes two or more transmission devices S 1 . When the sensor 100 includes two transmission devices S 1 , each transmission device S 1 can output the ultrasonic wave having different frequency with high Q value, the device S 1 outputting the wave by using different resonant frequency of the membrane M.
[0066] FIG. 11 shows an ultrasonic sensor 101 having two transmission devices S 1 , S 2 . The sensor 101 can output two ultrasonic waves having different frequencies f 1 , f 2 simultaneously by using two transmission devices S 1 , S 2 for outputting two different ultrasonic waves. Thus, no compensation for compensating motion of the vehicle is necessitated. Here, since the ultrasonic waves having different frequencies f 1 , f 2 have the same transmission velocity, the reflected ultrasonic waves are arrived at the sensor 100 at the same time. Accordingly, frequency analysis for decomposing the reception ultrasonic waves into the component having the first frequency f 1 and the component having the second frequency f 2 is required.
[0067] FIG. 12 shows an ultrasonic sensor 102 having the transmission device S 1 and eight reception devices R 1 -R 8 . The transmission device S 1 is surrounded with eight reception devices R 1 -R 8 . In this case, it is preferred that two reception devices R 1 -R 8 are arranged to be symmetrically with respect to the transmission device S 1 . Specifically, a pair of the reception devices R 1 , R 8 , a pair of the reception devices R 2 , R 7 , a pair of the reception devices R 3 , R 6 , and a pair of the reception devices R 4 , R 5 are arranged to be symmetrically with respect to the transmission device S 1 so that each pair of the reception devices R 1 -R 8 surrounds the transmission device S 1 .
[0068] In this case, since each pair of the reception devices R 1 -R 8 is symmetrically disposed, the reflected ultrasonic wave outputted from the transmission device S 1 is returned to the pair of the reception devices R 1 -R 8 in such a manner that the sound pressure of the received ultrasonic wave received by one of the pair of the reception devices R 1 -R 8 is almost the same as the other one of the pair of the reception devices R 1 -R 8 . Accordingly, the detection accuracy of the obstacle 50 is improved.
[0069] Thus, each sensor 100 , 100 a , 101 , 102 has small dimensions and low manufacturing cost, and the detection accuracy of the sensor 100 , 100 a , 101 , 102 is not affected by mounting accuracy of the sensor on the vehicle. Further, the sensor 100 , 100 a , 101 , 102 has high detection accuracy, even if the waterdrop or the dust is adhered to the sensor 100 , 100 a , 101 , 102 and even if the humidity around the sensor 100 , 100 a , 101 , 102 changes.
[0070] Although the sensor 100 , 100 a , 101 , 102 includes one transmission device S 1 and four or eight reception devices R 1 -R 8 , the sensor may includes one or more transmission devices S 1 and two or more reception devices. When the sensor includes multiple transmission devices and multiple reception devices, the information from the sensor is increased. Further, when the sensor includes two or more transmission devices, the sound pressure of the ultrasonic wave becomes larger, and the directivity of the ultrasonic wave is controlled.
[0071] Alternatively, the reception devices in the sensor may be arrayed so that a transmission signal is received by multiple reception devices in order to cancel the transmission signal, since the transmission signal may cause noise of the sensor. Specifically, when the transmission device and the reception device are integrated into one substrate, the transmission signal may input into the reception device so that the transmission signal may cause the noise of the sensor. Thus, by canceling the inputted transmission signal, the noise of the sensor is reduced. Accordingly, when the obstacle is disposed near the sensor, the S/N ratio of the signal is improved for detecting the obstacle.
[0072] Although the reception device includes the piezoelectric thin film so that the reception device provides a piezoelectric type device, the reception device may be a capacitance type device for detecting a capacitance change between electrodes. Further, the reception device may be a piezo type for detecting an output of a gauge generated by pressure. Furthermore, the sensor may include a combination of these different type reception devices.
[0073] While the invention has been described with reference to preferred embodiments thereof, it is to be understood that the invention is not limited to the preferred embodiments and constructions. The invention is intended to cover various modification and equivalent arrangements. In addition, while the various combinations and configurations, which are preferred, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the invention. | An ultrasonic sensor for detecting an object includes: a substrate; a transmission device for transmitting an ultrasonic wave; a plurality of reception devices for receiving the ultrasonic wave; and a circuit for processing received ultrasonic waves, which are received by the reception devices after the ultrasonic wave transmitted from the transmission device is reflected by the object. The transmission device and the reception devices are integrated into the substrate. The dimensions of the sensor are minimized, and detection accuracy of the sensor is improved. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. provisional application Ser. No. 60/806,920, filed on Jul. 10, 2006, incorporated herein by reference in its entirety, and from U.S. provisional application Ser. No. 60/806,922, filed on Jul. 10, 2006, incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention pertains generally to well-defined colloidal polymeric nanoparticles produced utilizing a microwave methodology that generates narrowly dispersed, intra-cross-linked polymeric nanoparticles, with derivatized surfaces, if desired, at high solids content through a surfactant-free emulsion polymerization process. The nanoparticle size is controlled by using intra-crosslinkers with enhanced reactivity through a one-step microwaving process. The successful size control is realized by confining the generated cross-linking to intra-particle cross-linking rather than inter-particle cross-linking. Additionally, the superheating/dielectric heating effect associated with microwave irradiation is utilized to effectively reduce the nanoparticle size. More particularly, the subject invention discloses polymeric nanoparticles and a method of production of the nanoparticles utilizing a method comprising microwave irradiation of a solution comprised of monomers, an initiator, a cross-linking agent, a hydrophilic solvent, and, optionally, functional group-containing co-monomers.
[0006] 2. Description of Related Art
[0007] Emulsion polymerization is an important industrial process for production of colloidal polymers. Polymeric nanoparticles (NPs) represent an important class of materials that are critical in a wealth of advanced technologies, ranging from colloidal crystals (de Villeneuve, V. W. A.; Dullens, R. P. A.; Aarts, D. G. A. L.; Groeneveld, E.; Scherff, J. H.; Kegel, W. K.; Lekkerkerker, H. N. W. Science 2005, 309, 1231-1233), microelectronics (Magbitang, T.; Lee, V. Y.; Miller, R. D.; Toney, M. F.; Lin, Z.; Briber, R. M.; Kim, H.-C.; Hedrick, J. L. Adv. Mater. 2005, 17, 1031-1035), drug delivery (Ha, C.-S.; Jr. Gardella, J. A. Chem. Rev. 2005, 105, 4205-4232) to immunoassays (Montagne, P.; el-Omari, R.; Cliquet, T.; Cuilliere, M. L.; Dujeile, J. Bioconj. Chem. 1992, 3, 504-509). Among various synthetic strategies for NP preparation (e.g. self-assembly of amphiphilic block copolymers (Harrisson, S.; Wooley, K. L. Chem. Commun. 2005, 26, 3259-3261 and Hawker, C. J.; Wooley, K. L. Science 2005, 309, 1200-1204) and colloidal particles by emulsion polymerization (Wang, Q.; Fu, S.; Yu, T. Prog. Polym. Sci. 1994, 19, 703-753; Elaissari, A. E., Ed. Colloidal Polymers , M-Dekker: New York, 2003; and Jang, J.; Oh, J. H.; Stucky, G. D. Angew. Chem. Int. Ed. 2002, 41, 4016-4019)), surfactant-free emulsion polymerization (SFEP) has emerged as a simple, green process for NP production without addition and subsequent removal of the stabilizing surfactants (Zhang, G.; Li, X.; Jiang, M.; Wu, C. Langmuir 2000, 16, 9205-9207; Mouaziz, H.; Larsson, A.; Sherrington, D. C. Macromolecules 2004, 37, 1319-1323; and Shim, S. E.; Shin, Y.; Jun, J. W.; Lee, K.; Jung, H.; Choe, S. Macromolecules 2003, 36, 7994-8000). It is noted that the traditional emulsion processes typically use a lot of surfactants to enhance colloidal stability of the polymer particles and to reduce the particle size. Unfortunately, the addition of surfactants can change the properties of the polymer particles, especially the surface properties of the polymers. Additionally, removal of the surfactants is a time consuming and costly process. An added value for colloidal polymerization is that the produced polymers are confined in colloidal particles with defined size, which provides opportunities for applications of the polymers in the scale of micrometer and even nanometer ranges. In addition to several additional novel aspects, surfactant-free conditions are utilized in the subject invention in the polymerization of nanoparticles.
[0008] SFEP alone is useful, however, several challenges still exist that cannot be achieved using traditional SFEP to create polymeric NPs (Zhang, G.; Niu, A.; Peng, S.; Jiang, M.; Tu, Y.; Li, M.; Wu, C. Acc. Chem. Res. 2001, 34, 249-256), including the preparation of monodisperse, sub-100 nm NPs at high solids content and the synthesis of NPs incorporating functional groups and cross-links as is found with the subject invention. The incorporation of cross-links is especially important as they maintain structural integrity, preventing the NPs from dissolution in good solvents or matrix materials, greatly expanding their utility (Dullens, R. R. A.; Claesson, M.; Derks, D.; van Blaaderen, A.; Kegel, W. K. Langmuir 2003, 19, 5963-5966 and Dullens, R. R. A.; Claesson, E. M.; Kegel, W. K. Langmuir 2004, 20, 658-664.).
[0009] The subject invention is a facile microwave methodology that overcomes several major challenges associated with SFEP and allows the preparation of narrow dispersity, cross-linked NPs with various functional groups in the critical sub-50 nm range. As an alternative to using a two-stage approach to control the NP size (Song, J.-S.; Tronc, F.; Winnik, M. A. J. Am. Chem. Soc. 2004, 126, 6562-6563), cross-linkers with enhanced reactivity are employed to effect cross-linking through a one-step process without detrimental effects on NP size or dispersity. This successful size control is realized by confining the cross-linking to intra-particle cross-linking rather than inter-particle cross-linking. In addition to this novel one-step strategy, the increased efficiency and control associated with microwave chemistry is exploited to prepare stable 20 nm NPs with included solids content up to about 10 wt %, or greater, which is in direct contrast to the 100+nm NPs that can be prepared at only 5 wt % included solids content using traditional techniques (Mouaziz, H.; Larsson, A.; Sherrington, D. C. Macromolecules 2004, 37, 1319-1323). By combining all of these features a novel method for preparing well-defined nanoparticles is herein disclosed that offers significant advantages when compared to previous methods (Zhang, W. Gao, J.; Wu, C. Macromolecules 1997, 30, 6388-6390; Ngai, T.; Wu, C. Langmuir 2005, 21, 8520-8525; and Bao, J.; Zhang, A. J. Appl. Polym. Sci. 2004, 93, 2815-2820.).
BRIEF SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide a one-step process for microwave preparation polymeric nanoparticles having high solid content utilizing a surfactant-free solution, wherein selected cross-linking agents create intra-particle cross-linking.
[0011] Another object of the present invention is to furnish a one-step method for microwave preparation of sub-50 nm sized polymeric nanoparticles utilizing a surfactant-free solution comprising monomer, initiator, intra-particle cross-linkers, and solvent.
[0012] A further object of the present invention is to supply a one-step method for microwave preparation of sub-50 nm sized polymeric nanoparticles utilizing a surfactant-free solution comprising monomer, initiator, cross-linkers, solvent and functional group-containing co-monomers.
[0013] Still another object of the present invention is to disclose a one-step method for microwave preparation of sub-50 nm sized polymeric nanoparticles utilizing a surfactant-free solution comprising monomer, initiator, intra-particle producing cross-linkers, and solvent.
[0014] Yet a further object of the present invention is to describe a one-step method for microwave preparation of sub-50 nm sized polymeric nanoparticles utilizing a surfactant-free solution comprising monomer, initiator, intra-particle producing cross-linkers, solvent, and functional group-containing co-monomers.
[0015] Yet a further object of the present invention is to disclose sub-50 nm polymeric nanoparticles produced by a one-step microwave process utilizing a surfactant-free solution, wherein included cross-linking agents create intra-particles cross-linking.
[0016] Still an additional object of the present invention is to disclose sub-50 nm polymeric nanoparticles produced by a one-step microwave process utilizing a surfactant-free solution comprising monomer, initiator, intra-particle cross-linkers, hydrophilic solvent, and, if desired, functional group-containing co-monomers.
[0017] Specifically, disclosed are intra-cross-linked polymeric nanoparticles (NPs) and the method for producing these NPs. The subject invention provides an efficient, surfactant-free process for the preparation of these sub-50 nm particles from a surfactant-free solution comprising monomer, initiator, intra-particle producing cross-linkers, solvent, and, if selected, functional group-containing co-monomers.
[0018] By way of explanation concerning the basis of why the subject invention is such a vast improvement over previous nanoparticle preparation techniques, it is noted that for existing surfactant-free emulsion processes, the particle size is routinely above 100 nm and it has been a challenging issue to prepare sub-100 nm particles with high solid content, especially for cross-linked particles. In surfactant-free emulsion processes, usually polymerization of the monomers is initiated by a water-soluble initiator that initiates the polymerization of monomers in solution. When the polymer chains are long and hydrophobic enough, they collapse to form small polymer particles that are stabilized by the ionic groups generated from the initiator. The initially formed small polymer particles can trap monomers and thus act as nucleation seeds for further particle growth. Depending upon the colloidal stability of the particles, the particles may agglomerate into larger particles to reduce the total surface area when the particles are not stable enough. The subject invention is partially focused on the nucleation step of the process and specifically designed to increase the concentration of the nucleation seeds such that more nanoparticles can be formed and, accordingly, the critical size of the average nanoparticle reduced. As noted below, a carefully selected combination of various steps are used to increase the concentration of the nucleation in the subject invention. Water miscible solvent and more water soluble monomers are utilized to increase the concentration of monomers in solution with the subject invention over past methods. An optimized amount of initiator is used to generate high concentrations of free-radicals and to provide colloidal stability to the nanoparticles. In addition, microwave radiation is employed to facilitate the decomposition of the initiator and accelerate the polymerization process. Also, the choice of appropriate cross-linker is important to render the particle size similar to the particles without cross-linkers. With the subject method, highly monodispersed, cross-linked, sub-50 nm nanoparticles are synthesized with solid content up to about 10 wt % or more. The subject microwave synthesis process improves the efficiency of the overall polymerization by shortening the necessary reaction times. Further, the versatility of the subject approach allows for various functional groups to be incorporated into the nanoparticles by copolymerization and this can lead to a variety of extremely useful and novel functionalized nanoparticles for applications in biological imaging, biomedical immunoassays, controlled release schemes and the like.
[0019] Further objects and aspects of the invention will be brought out in the following portions of the specification, wherein the detailed description is for the purpose of fully disclosing preferred embodiments of the invention without placing limitations thereon.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0020] The invention will be more fully understood by reference to the following drawings which are for illustrative purposes only:
[0021] FIG. 1 is a graph of particle size as a function of reaction time at 70° C. under microwave power of 23±2 W (0.125 M MMA, 9.25 mM KPS) with a) 0 mol % EGDM in water; b) 0 mol % EGDM in 25 wt % acetone/water; c) 0.5 mol. % EGDM in water; and d) 0.5 mol % EGDM in 25 wt % acetone/water.
[0022] FIG. 2 is a graph showing DLS (dynamic light scattering) size of NPs prepared in water with 1 mol % of cross-linkers. Reaction conditions: 70° C., 28±2 W, 1 h, 0.125 M MMA, 9.25 mM KPS.
[0023] FIG. 3 is a graph showing DLS (dynamic light scattering) size of NPs prepared in water with 3 mol. % of cross-linkers. Reaction conditions: 70° C., 28±2 W, 1 h, 0.125 M MMA, 9.25 mM KPS.
[0024] FIG. 4 is a graph showing DLS size of NPs prepared in 25 wt. % acetone/water with 1 mol. % of cross-linkers. Reaction conditions: 70° C., 28±2 W, 1 h, 0.125 M MMA, 9.25 mM KPS.
[0025] FIG. 5 is a graph showing DLS size of NPs prepared in 25 wt. % acetone/water with 3 mol. % of cross-linkers. Reaction conditions: 70° C., 28±2 W, 1 h, 0.125 M MMA, 9.25 mM KPS.
[0026] FIG. 6 is a graph showing particle size as a function of temperature under microwave power of 23±2 W in 25 wt. % acetone/water (0.125 M MMA, 9.25 mM KPS).
[0027] FIG. 7 is a graph showing particle size as a function of microwave power at 70° C. in 25 wt. % acetone/water (0.125 M MMA, 1.5 mol. % MBA, 9.25 mM KPS).
[0028] FIG. 8 shows a microwave profile for temperature (° C.) versus time (min.) for a 25 wt % acetone/water solution at 28±2 W.
[0029] FIG. 9 shows a microwave profile for power (W) versus time (min.) for a 25 wt % acetone/water solution at 70° C.
[0030] FIG. 10 shows a microwave profile of pressure (torr) versus time (min./20) for a 25 wt % acetone/water solution at 70° C. and 28±2 W.
[0031] FIG. 11 shows an AFM image of PMMA NPs synthesized with 0.125 M MMA and 9.25 mM KPS at 70° C. under microwave power 28±2 W for 1 hour in 25 wt % acetone/water and 0 mol % cross-linker.
[0032] FIG. 12 shows a section analysis of the NPs seen in FIG. 11 .
[0033] FIG. 13 shows an AFM image of PMMA NPs synthesized with 0.125 M MMA and 9.25 mM KPS at 70° C. under microwave power 28±2 W for 1 hour in 25 wt % acetone/water and 1 mol % MBA.
[0034] FIG. 14 shows an AFM image of PMMA NPs synthesized with 0.125 M MMA and 9.25 mM KPS at 70° C. under microwave power 28±2 W for 1 hour in 25 wt % acetone/water and 1 mol % EGDA.
[0035] FIG. 15 displays nanoparticle diameter measured in both water and DMF for cross-linked nanoparticles prepared with 0.125 M MMA, 9.25 mM KPS in 25 wt % acetone/water solution and the cross-linker used is either 1 mol % or 3 mol % of EGDM with reaction conditions: 70° C., microwave power 28±2 W, 1 hour.
[0036] FIG. 16 shows nanoparticle diameter measured in both water and DMF for cross-linked nanoparticles prepared with 0.125 M MMA, 9.25 mM KPS in 25 wt % acetone/water solution and the cross-linker used is either 1 mol % or 3 mol % of EGDA with reaction conditions: 70° C., microwave power 28±2 W, 1 hour.
[0037] FIG. 17 presents nanoparticle diameter measured in both water and DMF for cross-linked nanoparticles prepared with 0.125 M MMA, 9.25 mM KPS in 25 wt % acetone/water solution and the cross-linker used is either 1 mol % or 3 mol % of MBA with reaction conditions: 70° C., microwave power 28±2 W, 1 hour.
[0038] FIG. 18 depicts DLS size results for nanoparticles prepared at different temperatures.
[0039] FIG. 19 shows DLS size results for nanoparticles prepared under different microwave power levels.
[0040] FIG. 20 illustrates DLS nanoparticle size as a function of acetone content in the solvent.
[0041] FIG. 21 presents DLS nanoparticle size as a function of the amount of HEMA co-monomer (2-hydroxyethyl methacrylate, a functionalized monomer) in the reaction mixture.
[0042] FIG. 22 shows DLS size results for nanoparticles as a function of KSP (potassium persulfate, an initiator) concentration.
[0043] FIG. 23 presents DLS nanoparticle size as a function of solids content.
[0044] FIG. 24 discloses DLS size results for nanoparticles prepared at different solids content in 40 wt % acetone/water.
DETAILED DESCRIPTION OF THE INVENTION
[0045] Referring more specifically to the drawings, for illustrative purposes the present invention is embodied in the examples and results generally shown in FIG. 1 through FIG. 25 . It will be appreciated that the method may vary as to the specific steps and sequence, without departing from the basic concepts as disclosed herein.
[0046] The subject invention is an emulsifier-free and microwave initiated polymerization process (and the produced nanoparticles) utilized to generate well-defined sub-50 nm polymeric nanoparticles with varying amounts of cross-links, functional groups, and included solids. Depending on the exact nature of the desired polymeric nanoparticle, the composition of the reaction mixture (solution or colloidal suspension) may vary. Comprising the microwave polymerizable subject mixture is a monomer, initiator, cross-linker, hydrophilic solvent, and functionalized co-polymer, if desired.
[0047] As is supported by specific examples further below, the following listing presents illustrative examples, not by way of limitation, but by way of explanation, of suitable chemicals and conditions for practicing the subject invention:
[0048] 1) Monomers (first co-monomer, if employed with a second co-monomer) are selected from chemical species that polymerize via traditional addition polymerization mechanisms and include alkenes (double bond containing molecules) such as the simplest ethene to more complex structures such as vinyl group containing molecules and derivatives such as acrylates or alkyl acrylates like methyl methacrylate, ethyl methacrylate, and similar compounds, and equivalent alkene containing structures having one or more double bonds that are polymerizable via addition polymerization are considered to be within the realm of this disclosure.
[0049] 2) Initiators are water-soluble entities that produce a free radical upon activation and are utilized in the subject invention for initiating addition polymerization. Usually, the concentration of initiator is less than about 20 wt % of the monomers. Subject initiators include persulfates such as potassium persulfate, peroxydisulfates, azo compounds, peroxides, and equivalent compounds. These initiators must be capable of activation (generation of one or more free radicals) by application of microwave radiation.
[0050] 3) Cross-linkers are employed in the subject invention to produce, mostly, intra-particle cross-links within the subject polymeric nanoparticles. Typically, the concentration of cross-linkers is less than about 5 mol % of the monomers. Exemplary cross-linkers include, but are not limited to, ethylene glycol dimethacrylate, ethylene glycol diacrylate, N,N′-methylenebisacrylamide, and other equivalent substances. Under the reaction conditions of the subject invention, these cross-linking agents produce a majority of intra-particle cross-links, as opposed to inter-particle cross-links, which permits the microwave-initiated production of nanoparticles with high percentage yields for sub-50 nm polymeric nanoparticles.
[0051] 4) Solvents are hydrophilic and water-based and range from 100% water to various water/organic compound mixtures, wherein the organic compound is selected from a wide range of candidates such as aldehydes/ketones (e.g.: acetone and the like), alcohols (e.g.: methanol, ethanol, propanol, butanol, and the like), and other equivalent water-soluble solvents.
[0052] 5) Functionalized monomers (second co-monomers if included with a bulk first co-monomer) are chemicals that polymerize into or with the bulk of the nanoparticle that provides useful functional groups within or on a polymeric nanoparticle. The concentration of the functionalized monomers is usually in the range of about 0 mol % to about 20 mol % of the total monomers, depending on the targeted surface functionality density. Exemplary functionalized monomers include acrylic acid, methacrylic acid, itaconic acid, 2-acrylamino-2-methyl-1-propane sulphonic acid, ethylene glycol methacrylate phosphate, N-(hydroxymethyl)acrylamide, poly(ethylene glycol) monomethacrylate, 2-hydroxyethyl methacrylate (HEMA), 2-aminoethyl methacrylate, 1-vinylimidazole, and sugar-based methacrylate or acrylate, to provide carboxylic acid, sulphonic acid, phosphoric acid, hydroxyl, amine, imidazole and sugar surface functionalities.
[0053] 6) The microwave power range is preferably anywhere from about 0 W to about 300 W or higher, which is limited by the maximum power of the microwave.
[0054] 7) The reaction temperature for a subject polymerization reaction is preferably in the range of about 50° C. to about 100° C., but could be lower or higher if a particular reaction requires such variation.
[0055] Specifically, as shown in FIG. 1 , when methyl methacrylate (MMA) was polymerized with potassium persulfate (KPS) in water (letter “a” diamond-symbols in FIG. 1 ) or in 25 wt % acetone/water solution (letter “b” square-symbols in FIG. 1 ), the particles reached their final size (characterized by dynamic light scattering (DLS)) within about 30 min under 23±2 W microwave irradiation. Without cross-linker, the final size was reduced from 155 nm in water to 65 nm in 25 wt % acetone/water. This size reduction in acetone/water solution was attributed to the greater number of nucleating seeds resulting from the increased solubility of the monomer in acetone/water solution. While adding cross-linker ethylene glycol dimethacrylate (EGDM) caused a small increase in NP size in water (letter “c” circle-symbols in FIG. 1 ), 155 nm (0 mol. % EGDM) vs 170 nm (0.5 mol. % EGDM); a dramatic size increase was seen in acetone/water solution (letter “d” triangle-symbols in FIG. 1 ), 65 nm (0 mol. % EGDM) vs 120 nm (0.5 mol. % EGDM), suggesting a different nucleation mechanism involved in acetone/water solution possibly due to inter-particle cross-linking, particularly when the number concentration of the nucleating seeds was significantly increased in acetone/water solution.
[0056] Based on the observed high sensitivity of the NP size to the reaction conditions in the presence of cross-linkers, it is proposed that two factors are critical in determining inter-particle/intra-particle cross-linking and hence the NP size: the concentration of the NP seeds and the propagation rate coefficient k p of the cross-linkers. To confirm this hypothesis, the following experiments were conducted: 1) NP synthesis in water with cross-linkers of different k p , representing conditions of low particle seed concentration and 2) NP synthesis in 25 wt % acetone/water solution with cross-linkers of different k p , representing conditions of high particle seed concentration. Two other cross-linkers, ethylene glycol diacrylate (EGDA) and N,N′-methylenebisacrylamide (MBA), were studied in addition to EGDM. The k p values for the corresponding monomeric methacrylate, acrylate and acrylamide are ˜650-800 M −1 s −1 (50° C.) (Beuermann, S.; Buback, M. Prog. Polym. Sci. 2002, 27, 191-254), ˜11,600-16700 M −1 s −1 (20° C.) (Beuermann, S.; Buback, M. Prog. Polym. Sci. 2002, 27, 191-254) (Beuermann, S.; Buback, M. Prog. Polym. Sci. 2002, 27, 191-254) and ˜20,000-30,000 M −1 s −1 (20° C.) (Ganachaud, F.; Balic, R.; Monteiro, M. J.; Gilbert, R. G. Macromolecules, 2000, 33, 8589-8596), respectively. Therefore, the k p values for the corresponding cross-linkers should follow the order of MBA>EGDA>EGDM.
[0057] As shown in FIGS. 2 and 3 , when prepared in water, the particle size (˜155 nm) was not affected by the type and amount of cross-linkers, indicating that inter-particle cross-linking was negligible due to the low particle concentration (˜4.9×10 12 ml −1 ). However, in 25 wt % acetone/water ( FIGS. 4 and 5 ), the particle concentration increased by ˜25 times (particle concentration was calculated from the mass of the monomer and the particle diameter, assuming spherical NP and 100% monomer conversion), resulting in significantly enhanced inter-particle cross-linking for cross-linkers with lower k p . In 25 wt % acetone/water, for 1 mol % cross-linker ( FIG. 4 ), EGDM with the lowest k p led to larger particle size (˜115 nm) than NPs without cross-linker and with 1 mol % EGDA/MBA (˜55 nm); while for 3 mol % cross-linker ( FIG. 5 ), particles with EGDA started to increase (˜100 nm) and particles with EGDM displayed a further enlargement (˜230 nm), consistent with the corresponding k p order of the crosslinkers. In all cases, the NP size (55-60 nm) was well controlled with MBA, the cross-linker with the highest k p and this is attributed to the decreased occurrence of inter-particle cross-linking. The cross-linked NPs showed narrow polydispersity and maintained their integrity in N,N-dimethylformamide (DMF). In addition, NPs prepared under thermal heating conditions displayed no control for cross-linked NPs, resulting in poorly defined systems.
[0058] In contrast to thermal heating reactions, one of the advantages of microwave systems is the ability to control other facets of the reactions. In this respect, microwave polymerization was examined in the superheated state of the solution by increasing the temperature from 65° C. to 78° C. (azeotropic point of 25 wt. % acetone/water is 68° C.) which showed a significant reduction in NP size from 180 nm at 65° C. to 23 nm at 78° C. ( FIG. 6 ). In addition, for polymerizations performed at the same temperature (i.e. 70° C.), an impressively wide range of diameters (100 to 30 nm) could be obtained by varying the microwave power (11 to 36 W) ( FIG. 7 ). Control reactions without KPS did not produce any colloidal NPs or polymers, indicating that polymerization was not initiated by just microwave irradiation, without an initiator. The dramatic reduction in NP size suggests enhanced radical influx in the solution, which further implies that microwave can dielectrically couple with the persulfate anions to accelerate the decomposition of the initiator.
[0059] Having positively demonstrated the ability to prepare cross-linked NPs with diameters less than 50 nm, the versatility of this technique was further established by increasing the solids content and by the inclusion of functionalized monomers, such as 2-hydroxyethyl methacrylate (HEMA) into the polymerization system. After a high-throughput analysis of various reaction parameters (see below), it was found that decreasing the solvent polarity to 40 wt % acetone/water while increasing the reaction temperature (80° C.) and microwave power (50±2 W) allowed the preparation of cross-linked, HEMA functionalized NPs at unprecedented solids content, from 14 nm at 5.6 wt % to 41 nm at 12.6 wt % solids (molar ratio of MBA:HEMA:MMA:KPS=1.0:1.6:30.7:1.6). In each case, the monomer conversion was essentially quantitative (96-100%) and stable colloidal solutions without any agglomeration were obtained.
[0060] Clearly, a novel strategy for controlled preparation of cross-linked polymeric NPs is disclosed herein. Key to this development is the use of crosslinkers with enhanced reactivity and controlled microwave reaction procedures. The subject invention proves to be a powerful tool for the synthesis of cross-linked, functionalized, if desired, NPs under high solids content and surfactant-free conditions. In addition, these findings based on exemplary PMMA data (e.g.: in one case, narrow dispersity, cross-linked PMMA NPs with hydroxy functional groups in the critical sub-50 nm range were prepared in high yield) can be easily extended to other polymers and other emulsion polymerization techniques.
DETAILED EXPERIMENTAL EXAMPLES
Example 1
Synthesis
[0061] All chemicals were purchased from Aldrich and were used as received except for the monomers which were vacuum distilled before use. The polymer nanoparticles were prepared with a 2.45 GHz microwave reactor having a maximum power of 300 W (Initiator Eight, Biotage). In an example synthesis of PMMA nanoparticles, 0.01 g (37.0 μmol) potassium persulfate was added to a vial, followed by the addition of 4 ml of deionized water (Millipore, 18 MΩ·cm) pre-purged with nitrogen for about 20 min and 0.05 g (0.50 mmol) methyl methacrylate. The vial was then sealed, pre-stirred to dissolve the initiator before being subjected to microwave irradiation. The microwave reactions were carried out under nitrogen cooling at a fixed temperature for a desired reaction time (all reactions were allowed to heat for one hour for final size comparison, except for the particle size versus time studies). The desired temperature was typically reached within about one minute, depending on the reaction conditions. The microwave power was adjusted by tuning the cooling nitrogen flow and was limited by the achievable pressure of the cooling nitrogen for a given reaction. The stability of the microwave power can affect the size distribution of the nanoparticles and it is important to keep the microwave power stable to get narrow size distribution. Typical microwave reaction profiles are shown in FIGS. 8 , 9 , and 10 .
[0062] Nanoparticle synthesis was also performed under similar conditions to microwave reactions with conventional oil bath heating for comparison. Briefly, sealed vials with the desired amount of reactants and solvent were prepared similarly as in microwave reactions, immersed into 70±2° C. oil bath and heated while stirring for about 12 hours. When reactions by thermal heating were carried out in water without cross-linkers, serious flocculation was observed; while reactions by thermal heating in 25 wt % acetone/water gave stable colloidal solutions. The size of the nanoparticles prepared under microwave and thermal heating conditions is summarized in Table 1. It is clear that thermal heating did not have the same ability to control the particle size as did microwave heating.
Example 2
Nanoparticle Characterizations
[0063] The hydrodynamic diameters of the nanoparticles were determined by dynamic light scattering (DLS) technique on a Zetasizer Nano-ZS (Malvern Instrument) using a 633 nm laser and the scattered light was collected at 173°. The as-prepared colloidal solutions were diluted with Millipore water until the size was no longer concentration dependant and a well-defined correlation curve was obtained. All measurements were performed at 25±0.1° C. Z-average diameter and polydispersity were automatically analyzed in the cumulant mode by the Malvern Zetasizer software and was reported as the average of three measurements.
[0064] Atomic force microscope (AFM) images (see FIGS. 11 , 12 , 13 , and 14 ) were obtained using a Dimension 3000 (Digital Instruments) scanning force microscope in the tapping mode. AFM samples were prepared under ambient conditions by evaporating diluted colloidal solutions on clean silicon wafer. Particle size was determined from height analysis. The particle size analyzed from AFM was generally smaller than that determined from DLS.
[0065] The representative AFM images ( FIGS. 11 , 12 , 13 , and 14 ) of PMMA NPs synthesized with 0.125 M MMA and 9.25 mM KPS at 70° C. under microwave power 28±2 W for 1 hour in 25 wt % acetone/water contain: 0 mol % cross-linker ( FIG. 11 ) (with section analysis of NPs in FIG. 11 shown in FIG. 12 ); 1 mol % MBA ( FIG. 13 ); and 1 mol % EGDA ( FIG. 14 ).
Example 3
Nanoparticle Swelling Studies
[0066] The incorporation of cross-linkers into nanoparticles was qualitatively characterized by swelling the nanoparticles in DMF. Briefly, 2˜3 drops of the as-prepared colloidal solutions were mixed with 1 ml DMF to form a uniform solution and size measurement was performed after 1˜2 hours of swelling in DMF. The refractive index of DMF was used as the refractive index of the dispersant. FIGS. 15 , 16 , and 17 show the relative size of the corresponding cross-linked nanoparticles measured in both water and DMF, and the nanoparticle diameter and swelling ratio (diameter measured in DMF/diameter measured in water) are summarized in Table 2. FIGS. 15 , 16 , and 17 present cross-linked nanoparticles prepared with 0.125 M MMA, 9.25 mM KPS in 25 wt % acetone/water solution and the cross-linker used was either 1 mol % or 3 mol % of EGDM ( FIG. 15 ), EGDA ( FIG. 16 ), and MBA ( FIG. 17 ). Reaction conditions for all three: 70° C., microwave power 28±2 W, 1 hour.
Example 4
Nanoparticle Characterizations
[0067] FIGS. 18-24 present various DLS size results for nanoparticles prepared under different conditions.
[0068] FIG. 18 relates DLS size results for nanoparticles prepared at different temperatures (superheating at 70° C., 75° C. and 78° C.) with 0.125 M MMA, 9.25 mM KPS in 25 wt % acetone/water under microwave power of 23±2 W.
[0069] FIG. 19 presents DLS size results for nanoparticles prepared under different microwave power at 70° C. with 0.125 M MMA 1.5 mol % MBA, 9.25 mM KPS in 25 wt % acetone/water.
[0070] FIG. 20 depicts nanoparticle size as a function of acetone content at 70° C. under microwave power of 23±2 with 0.125 M MMA, 9.25 mM KPS. At least two factors were identified that affect the particle size upon addition of acetone: 1) solubility of the monomers and 2) solvation of KPS residues on the particle surface. Addition of acetone increases monomer concentration but decreases dielectric constant of the solution. Increased monomer concentration leads to reduced particle size; while decreased dielectric constant gives rise to less stable particles leading to increased particle size. FIG. 20 shows the complex interplay of these two factors on the particle size.
[0071] FIG. 21 discloses nanoparticle size as a function of the amount of HEMA co-monomer (an exemplary functionalized co-monomer) at 70° C. under microwave power of 23±2 W with (MMA+HEMA) total concentration 0.125 M, 9.25 mM KPS in 25 wt % acetone/water.
[0072] FIG. 22 depicts nanoparticle size as a function of KPS concentration at 70° C. under microwave power of 23±2 W with 0.125 M MMA in 25 wt % acetone/water.
[0073] FIGS. 23 and 24 related nanoparticle size variation with solids content. FIG. 23 presents DLS nanoparticle size as a function of general wt % of solids and FIG. 24 displays DLS size results for nanoparticles prepared at different solids content in 40 wt. % acetone/water under microwave power of 50±3 W at 80° C. (MBA:HEMA:MMA:KPS=1:1.6:30.7:1.6).
[0074] Although the description above contains many details, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”
[0000]
TABLE 1
Comparison of nanoparticle diameter for the nanoparticles prepared
under microwave and thermal heating conditions with 0.125 M MMA
and 9.25 mM KPS.
Microwave conditions: 70° C., microwave power 28 ± 2 W, 1 hour.
Thermal heating conditions: 70° C., 12 hours.
Nanoparticle diameter (nm) and polydispersity
Microwave heating
Thermal heating
25 wt %
25 wt %
Solvent
water
acetone/water
water
acetone/water
No cross-
155 ± 0.8
56.4 ± 0.1
flocculation
122 ± 1
linker
1.3 ± 1.0%
4.7 ± 0.7%
10.2 ± 0.6%
1 mol. %
158 ± 2.5
54.6 ± 0.5
175 ± 0.4
220 ± 1.8
MBA
0.9 ± 0.2%
4.4 ± 0.7%
2.2 ± 1.2%
0.9 ± 0.3%
[0000]
TABLE 2
Comparison of nanoparticle diameter and swelling ratio for cross-linked
nanoparticles prepared with 0.125 M MMA, 9.25 mM KPS in 25 wt %
acetone/water solution and the cross-linker used is either 1 mol % or 3 mol %.
Reaction conditions: 70° C., microwave power 28 ± 2 W, 1 hour.
Diameter (nm) and polydispersity
EGDM
EGDA
MBA
1 mol %
3 mol %
1 mol %
3 mol %
1 mol %
3 mol %
Water
113 ± 1.6
231 ± 3.3
54 ± 0.5
99 ± 0.7
55 ± 0.6
60 ± 0.3
5.7 ± 0.4%
4.4 ± 2.3%
3.5 ± 0.8%
8.3 ± 0.6%
4.4 ± 0.7%
7.8 ± 1.5%
DMF
163 ± 1.1
322 ± 1.9
102 ± 0.2
144 ± 0.8
533 ± 76
135 ± 0.8
7.9 ± 0.9%
2.3 ± 2.7%
11.0 ± 1.3%
6.2 ± 1.5%
15.9 ± 5.4%
18.4 ± 1.2%
Swelling
1.44
1.39
1.89
1.45
9.69
2.25
ratio | Disclosed is a microwave preparation method for producing polymeric nanoparticles in which a mixture is made that contains a monomer, an optional functionalize co-monomer, a polymerization initiator that is activated by microwave irradiation, a cross-linker that preferentially creates intra-particle cross-links during polymerization, and a water-based solvent which is then irradiated with microwave radiation to facilitate polymerization of the nanoparticles into sub-50 nm size range nanoparticles. | 2 |
[0001] This application claims the benefit of the Korean Patent Application No. 58561/2005, filed on Jun. 30, 2005, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a liquid display device, and particularly, to a backlight unit and a liquid crystal display device having the same that minimize image quality degradation when light emitting devices are employed as a backlight lamp in the liquid crystal display device.
[0004] 2. Background of the Invention
[0005] Various portable electronic devices, such as mobile phones, personal digital assistants (PDA), notebook computers, etc., have been continuously developed. As such, there is a demand in developing flat panel display devices, such as liquid crystal displays (LCDs), plasma display panels (PDPs), field emission displays (FEDs), and vacuum florescent displays (VFDs) to provide necessary characteristics such as compact construction, light weight, and low power consumption. Among these flat panel devices, LCDs are extensively used due to the ease with which they are driven and their superior ability to display images.
[0006] An LCD device displays images on a screen by adjusting an amount of light being transmitted through a liquid crystal layer using refractive anisotropy. In order to display images in the LCD device, a back light (i.e., light source) is required to supply light to a liquid crystal layer of the LCD device. In general, the backlight may be divided into two types depending upon the light source (or lamp) location, namely, a lateral (side or edge) type backlight and a direct type backlight.
[0007] In the lateral type backlight, a lamp is disposed at a lateral side of the LCD panel to supply light to the liquid crystal layer, while in the direct type backlight, the lamp is disposed at a lower portion of the LCD panel to directly supply light to the liquid crystal layer. Also, the lateral type backlight is disposed at the lateral side (or edge) of the LCD panel to supply light to the liquid crystal layer through the use of a reflector and a light guide plate. Hence, the lateral type backlight can be employed in notebook computers or the like which requires thin display devices.
[0008] However, because the lamp is disposed at the lateral side of the LCD panel, it is difficult to employ a lateral side backlight to a large sized LCD panel. Moreover, it is difficult to obtain high level brightness because the light is supplied through the light guide plate. Thus, the lateral type backlight cannot be applied to an LCD panel for a large size LCD TV.
[0009] On the contrary, the direct type backlight can be applied to large LCD panels because light is directly supplied from the lamp to the liquid crystal layer, thereby obtaining high level brightness. Thus, the direct type backlight can be used for LCD TVs.
[0010] For a backlight lamp, a light emitting device that spontaneously emits light, such as a light emitting diode (LED) can be used instead of a fluorescent lamp. Such a light emitting device emits R, G and B monochromatic (i.e., single color) light. Accordingly, upon using such light emitting devices as a backlight, a high color reproduction rate can be advantageously obtained with a minimal driving (operation) power.
[0011] FIG. 1 illustrates a structure of the related art LCD device employing light emitting devices as a backlight lamp. As shown in FIG. 1 , an LCD device 1 includes an LCD panel 3 and a backlight 10 installed at a rear surface of the LCD panel 3 . Images can be displayed on the LCD panel 3 , which includes a lower substrate 3 a and an upper substrate 3 b that are both made of a transparent material, such as glass, and a liquid crystal layer (not shown) interposed therebetween. Particularly, although not shown in the drawing, the lower substrate 3 a is often referred to as a thin film transistor (TFT) substrate because driving devices such as thin film transistors and pixel electrodes are formed thereon. The upper substrate 3 b is often referred to as be a color filter substrate because a color filter layer is formed thereon. A driving circuit unit 5 is provided at a lateral (side or edge) surface of the lower substrate 3 a to apply electronic signals to the thin film transistors and the pixel electrodes formed on the lower substrate 3 a.
[0012] Further, the backlight 10 includes a plurality of light emitting devices 11 , installed at a lower lateral (side or edge) surface of the LCD panel 3 , that emit and provide light to the LCD panel 3 , a light guide plate 15 to guide the light emitted from each of the light emitting devices 11 to the LCD panel 3 , and a reflector 17 to reflect the light emitted from each of the light emitting devices 11 , to thereby improve luminance efficiency.
[0013] In addition, a diffusion plate (not shown) can be provided at an upper portion of the light guide plate 15 to diffuse the light and to provide a uniform distribution of the light to the LCD panel 3 .
[0014] The light emitting devices 11 , which are R, G, and B light emitting devices to emit the R, G and B monochromic light, are provided in plurality at a lateral (side or edge) location of the backlight 10 with certain intervals between each light emitting device 11 . The plurality of light emitting devices 11 are aligned in two or more lines (i.e., two or more rows or columns). R, G, and B monochromic (single color) light is respectively emitted from each of the R, G and B light emitting devices. Each of the R, G and B monochromic light is mixed (combined) together to form so-called white light, and thereafter the white light is supplied to the LCD panel 3 via the light guide plate 15 .
[0015] However, the related art backlight having the above-described structure may have the following problems. As illustrated in FIG. 2 , the light emitting devices 11 are arranged in multiple lines (e.g., only two lines shown in FIG. 2 for simplicity) at the lateral (side or edge) wall 12 of the backlight 10 . Here, the R, G and B light emitting devices are mounted in sequential order. Each of the R, G and B monochromic (single color) light emitted from each of the light emitting devices 11 is directed to be incident directly onto the light guide plate 15 or upon being reflected by the reflector 17 at the lower portion thereof.
[0016] When the monochromic light emitted from each of the R, G and B light emitting devices 11 is reflected by the reflector 17 , an intensity of the monochromic light particularly reflected at a portion near or adjacent to each light emitting device 11 is greater than that of other emitted or reflected light. Accordingly, all the monochromic light provided to the LCD panel 3 is not completely converted into white light due to the differences in the intensities of each type of monochromic light (i.e. R, G, B light being provided directly to and reflected to the LCD panel 3 ), which ultimately causes undesirable degradation in the quality of images shown on the LCD panel 3 .
SUMMARY OF THE INVENTION
[0017] Accordingly, the present invention is directed to a backlight unit and a liquid crystal display device having the same that substantially obviate one or more problems due to limitations and disadvantages of the related art.
[0018] An object of embodiments of the present invention is to provide a backlight unit and a liquid crystal display device having the same that supply uniformly mixed white light to an LCD panel by disposing a side-emission light emitting device which scatters and emits light towards the LCD panel.
[0019] Another object of embodiments of the present invention is to provide a backlight unit and a liquid crystal display device having the same that minimize the amount of R, G and B monochromic light from being supplied to an LCD panel without being properly mixed into white light.
[0020] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0021] To achieve these and other advantages and in accordance with the purpose of embodiment of the present invention, as embodied and broadly described, a backlight unit for a liquid crystal display device includes a plurality of light emitting devices emitting light and a reflector disposed below the light emitting devices to reflect the light towards a liquid crystal panel, the reflector having grooves with side walls having an inclined angle.
[0022] In another aspect of an embodiment, a liquid crystal display device includes a liquid crystal display panel, a plurality of light emitting devices to supply light to the liquid crystal display panel from a lateral surface of the light emitting devices, and a reflector disposed below each light emitting device, and inclined at a lower surface of each light emitting device to reflect the light emitted from each light emitting device to the LCD panel.
[0023] In another aspect of an embodiment, a backlight unit for a liquid crystal display device includes one or more light emitting devices emitting a plurality of monochromatic light to a liquid crystal display panel and first and second reflectors respectively attached on first and second surfaces of the light emitting devices to reflect the light emitted from the light emitting device to a lateral surface of the light emitting devices, the first surface facing the liquid crystal display panel and the second surface facing a direction opposite to the liquid crystal display panel.
[0024] In a further aspect of an embodiment, a liquid crystal display device includes a liquid crystal display panel having a first and second substrates, one or more light emitting devices emitting a plurality of monochromatic light to the liquid crystal display panel, and first and second reflectors respectively attached on first and second surfaces of the light emitting devices to reflect the light emitted from the light emitting device to a lateral surface of the light emitting devices, the first surface facing the liquid crystal display panel and the second surface facing a direction opposite to the liquid crystal display panel.
[0025] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the present invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. In the drawings:
[0027] FIG. 1 is a schematic view showing a structure of the related art liquid crystal display device;
[0028] FIG. 2 is a partially enlarged schematic view showing a reflection of light from a backlight having light emitting devices at a lateral surface thereof according to the related art;
[0029] FIG. 3 is a schematic view showing an exemplary structure of a liquid crystal display device having a backlight unit according to an embodiment of the present invention;
[0030] FIG. 4 is an enlarged view of a region A of FIG. 3 ;
[0031] FIG. 5 is a view showing a reflection of R, G and B monochromic light at a reflector adjacent to a light emitting device when the reflector is formed in a parallel manner; and
[0032] FIG. 6 is a view showing a backlight unit structure according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Reference will now be made in detail to preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0034] FIG. 3 is a schematic view showing an exemplary backlight unit of a liquid crystal display device according an embodiment of the present invention. As shown in FIG. 3 , a liquid crystal display device 101 includes a liquid crystal display (LCD) panel 103 and a backlight unit 110 to supply light thereto. The LCD panel 103 may include a lower substrate 103 a and an upper substrate 103 b , both made of a transparent material, such as glass, and including a liquid crystal layer (not shown) interposed therebetween. The lower substrate 103 a may be referred to as a thin film transistor (TFT) substrate because thin film transistors and pixel electrodes are formed thereon. The upper substrate 103 b may be referred to as a color filter substrate because a color filter layer is formed thereon. A driving circuit unit 105 can be provided at a lateral (side or edge) surface of the lower substrate 103 a to apply appropriate signals to each thin film transistor and each pixel electrode formed on the lower substrate 103 a.
[0035] The backlight unit 110 , which can be mounted (or otherwise attached or provided) underneath (or below or at a lower portion of) the LCD panel 103 to supply light thereto, may include a plurality of light emitting devices 111 (such as light emitting diodes) disposed underneath the LCD panel 103 , a light guide plate 115 appropriately installed between the light emitting devices 111 and the LCD panel 103 to guide light towards the LCD panel 103 . Also, a reflector 117 may be appropriately installed underneath (or below or at a lower portion of) each light emitting device 111 to reflect light emitted from each light emitting device 111 toward the LCD panel 103 , resulting in improved luminance efficiency.
[0036] Although not shown in the drawing, various optical members such as a diffusion plate and a diffusing sheet to diffuse light at an upper portion of the light guide plate 115 and to allow a uniform distribution of light to the LCD panel 103 may be further included in the backlight 110 unit.
[0037] A plurality of light emitting devices 111 can be disposed underneath of the LCD panel 103 to emit R, G, and B monochromic (single color) light. Unlike the related art backlight structure as shown in FIG. 1 in which the light emitting devices are installed at the lateral (side or edge) portion of the backlight assembly, the light emitting devices 111 are arranged underneath (or below or at the lower portion of) the LCD panel 103 in an embodiment of the present invention. In other words, lateral-type light emitting devices are installed in the related art backlight, whereas direct-type light emitting devices 111 are arranged in the backlight unit according to an embodiment of the present invention.
[0038] The light emitting device 111 of an embodiment of the present invention can be considered as a side-emission light emitting device. As shown in FIG. 4 , each light emitting device 111 may be formed to have curved shapes (portions or regions) to allow certain side surface portions thereof to have a particular curvature. Accordingly, when the R, G and B monochromic light is emitted from each light emitting device 111 , the light is scattered at the surfaces having such a curvature. Thus, since the R, G and B monochromic light is emitted from the side surfaces of each light emitting device 111 , the light emitting device 111 of the present invention can be referred to as a (direct-type) side-emission light emitting device.
[0039] One or more direct-type light emitting devices 111 according to an embodiment of the present invention has a specifically shaped profile or cross-section, which substantially improves the way that light is emitted from the light emitting device 111 . As can be explained with reference to FIGS. 3 to 6 , the specifically shaped profile or cross-section of the light emitting device 111 can have opposing inwardly pinched portions (i.e., grooves with at least one concave curved wall). As such, the overall shape resembles a cross-section of a typical loaf of bread or slice of toast. Additionally, one or more reflectors 117 , 118 (which will be described in more detail hereafter), that also have particular shapes (as shown in FIGS. 4, 5 , and 6 ) may be additionally attached or otherwise provided at (or adjacent to) one or more light emitting devices 111 to further improve light emission efficiency.
[0040] As shown in FIG. 4 , a reflecting body 118 may be formed at (or attached to) an upper surface of one or more side-emission light emitting device 111 . In order to minimize the amount of light being emitted to portions other than the curved side surfaces of the light emitting device 111 (such as to the flat top surface of the light emitting device 111 ), the reflecting body 118 reflects all R, G and B monochromic (single color) light that may be emitted towards the upper surface of the light emitting device 111 , to thus scatter and emit such light back towards the side surfaces thereof.
[0041] Hence, because all of the R, G and B monochromic light are emitted from the side surfaces of the light emitting device 111 according to an embodiment of the present invention, each of the emitted R, G and B monochromic light can be more easily mixed together (combined) as compared to that of the related art light emitting device structure. As a result, white light can be supplied more to the LCD panel 103 than that of the related art backlight structure.
[0042] Additionally, a reflector 117 may be formed underneath (or below or at the lower surface of) one or more light emitting devices 111 . The reflector 117 can have a shape that further reflects the R, G and B monochromic light emitted from each light emitting device 111 towards the light guide plate 115 , thereby to additionally improve luminance efficiency of the LCD panel 103 . As shown in FIG. 4 , the reflector 117 can be formed to have inclined portions that form an angle θ with respect to the lower surface of the light emitting device 111 . Referring back to FIG. 3 , the inclined portions of the reflector 117 may be formed underneath (or below) all light emitting devices 111 . Accordingly, the reflector 117 may have a zigzagged or corrugated cross-section when viewed from its profile.
[0043] Thus, the corrugated reflector 117 can have inclined portions at angles with respect to the lower surface of the light emitting device 111 or in an incident surface of the LCD panel 103 onto which light is directed to be incident. This feature can minimize the amount of R, G and B light that is reflected (from portions near each light emitting device 111 ) directly toward and directed to be incident to the LCD panel 103 without being properly mixed (combined) to form white light.
[0044] In other words, the corrugated reflector 117 has peaks and valleys, and each light emitting device 111 is located at the peaks. With respect to one peak, the opposing walls of two adjacent valleys (i.e., the opposing sides of two adjacent grooves) slope downward away from the peak. Namely, the walls of the grooves are formed at particular angles to allow improved reflection of light being emitted from the light emitting device 111 . Thus, some of the light emitted from one light emitting device 111 travel into the grooves and is reflected at the angled portions thereof. Such corrugated reflector 117 results in improved luminance performance when compared to the related art reflector 17 of FIG. 1 .
[0045] FIG. 5 shows an example of a reflector 517 that has a parallel, flat or plate-like shape which corresponds to the lower surface of each light emitting device 511 or which is incident to the surface of the LCD panel 103 . By using such a flat reflector 517 , each R, G and B monochromic light reflected from the portions adjacent to each light emitting device 511 can have stronger intensity than that of the corrugated reflector 117 in FIG. 4 . Accordingly, upon mixing (combining) each R, G and B monochromic light with other R, G and B monochromic light, the amount of white light that is formed may not optimal, and such non-optimal white light (and/or R, G, B monochromic light that have not been properly combined) is directly supplied to the LCD panel 103 . That is because the intensity of the reflected R, G and B monochromic light becomes weaker than that of the related art backlight having lateral-type light emitting devices (as shown in FIG. 1 ). Thus, the R, G and B monochromic light provided (reflected) in an embodiment of the present invention allows improved mixing (combining), thereby to allow more advantageous formation of white light. However, even if the flat reflector 517 is mounted to be substantially parallel to the lower surface of each light emitting device 111 or parallel to the incident surface of the LCD panel 103 , the R, G and B monochromic light or light having a particular color (both having a constant intensity) other than the white light may still be undesirably made incident onto the LCD panel 103 .
[0046] Referring back to FIG. 4 , because the corrugated reflector 117 has grooves with certain angled portions, the R, G and B monochromic light, which is emitted from one light emitting device 111 toward the reflector 117 , may not be immediately reflected as in the case of a flat reflector 517 . The R, G and B monochromic light from one light emitting device 111 ultimately gets reflected by opposing inclined portions of adjacent grooves next to adjacent light emitting devices 111 of the corrugated reflector 117 . However, the intensity of the R, G and B monochromic light is weak enough to allow more proper mixing (combining) with other monochromic light. As such, the R, G and B monochromic light can be properly combined into white light and supplied to the LCD panel 103 more effectively.
[0047] As explained above, an embodiment of the present invention, by employing a corrugated reflector 117 having grooves with walls inclined at an angle θ, the R, G and B monochromic light emitted from each light emitting device 111 can be improved. Hence, the inclined angle θ of the reflector 117 can be formed to have any appropriate angle as long as the R, G and B monochromic light emitted from each light emitting device 111 is reflected in an improved manner.
[0048] However, the reflector in the backlight unit 110 according to an embodiment of the present invention does not have to be formed with inclined sloped (grooves) as described above with reference to FIG. 4 . As shown in FIG. 6 , a corrugated reflector 617 having stepped portions may be provided underneath (or below) one or more light emitting devices 611 . In such a case, the stepped reflector 617 may be positioned underneath (below) the light emitting devices 611 in direct contact with (as shown in FIG. 6 ) or to have a gap (distance) therebetween. In such a structure, the rate in which the R, G and B monochromic light emitted from the backlight 110 that is reflected by the stepped reflector 617 is decreased, and thus the intensity of the light becomes weaker than that of the related art. Accordingly, the R, G and B monochromic light can be mixed (combined) in an improved manner and thus supplied to the LCD panel 103 as the white light more efficiently.
[0049] FIGS. 7A and 7B show another embodiment of present invention. As shown in FIGS. 7A and 7B , a plurality of protrusions 717 a and 717 b are formed on the surface of the reflector 717 near the light emitting device 711 . The monochromic light emitted from the light emitting device 711 is scattered by the protrusions 717 a and 717 b to be mixed with other monochromic light emitted from the other light emitting devices. As a result, the resultant white light can be provided with the liquid crystal display panel. The protrusions 717 a and 717 b may be formed integrally with the reflector 717 as a single body. In other words, the protrusions 717 a and 717 b are formed of the same reflective material as the reflector 717 . Further, the protrusions 717 a and 717 b may be formed independently from the reflector 717 . That is, the reflective protrusions 717 a and 717 b are attached onto the reflector 717 .
[0050] The protrusions 717 a and 717 b are disposed at the region where the monochromic light emitted from the light emitting device 711 and reflected by the reflector 717 is not mixed with the light from the neighboring light emitting devices 711 . Thus, the region which the protrusions 717 a and 717 b are disposed may be dependent upon the gap between the neighboring light emitting devices 711 and the distance between the reflector 717 and the liquid crystal display panel. Although the protrusions 717 a and 717 b may be formed in the shapes of the FIGS. 7A and 7B , for example, they may be formed in various shapes as long as they function to produce uniform white light.
[0051] FIG. 8 is a view showing yet another embodiment of the present invention. In this embodiment, a scattering member 820 is disposed at the region near the light emitting device 811 where the monochromic light emitted from the light emitting device 811 and reflected by the reflector 817 is not properly mixed with the light from the neighboring light emitting devices 811 . The monochromic light from the light emitting device 811 is scattered by the scattering member 820 to be mixed with other monochromic light from the other light emitting devices. By such a scattering member, the monochromic light is mixed with the monochromic light from the other light emitting devices, thereby providing the white light with the liquid crystal device. Although the scattering member 820 is flat on the reflector 817 as shown in FIG. 8 , a shape of the scattering member 820 is not limited to this particular shape. For example, the scattering protrusion having various shapes may be used in this embodiment to scatter the monochromic light.
[0052] As described above, concerning the backlight unit of embodiments of the present invention, a plurality of side-emission type light emitting devices are provided underneath (below) the LCD panel and a corrugated reflector (such as 117 , 617 ) with appropriate grooves (i.e., peaks and valleys) and the scattering member may be provided underneath (below) the light emitting devices, so as to improve the reflection of the R, G and B monochromic light from being emitted from the light emitting devices. Therefore, more efficiently generated white light can be supplied to the LCD panel, which thus results in minimal degradation in the quality of images being displayed on the LCD panel.
[0053] It will be apparent to those skilled in the art that various modifications and variations can be made in the backlight unit and the liquid crystal display device having the same of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A backlight unit for a liquid crystal display device includes one or more light emitting devices emitting a plurality of monochromatic light to a liquid crystal display panel, and first and second reflectors respectively attached on first and second surfaces of the light emitting devices to reflect the light emitted from the light emitting device to a lateral surface of the light emitting devices, the first surface facing the liquid crystal display panel and the second surface facing a direction opposite to the liquid crystal display panel. | 6 |
BACKGROUND OF THE INVENTION
As pipes became more costly and expensive, pipe repair and assembling of pipes becomes a more important job that requires more efficiency.
In gas and oil wells, deteriorating well casings often require repairing and insertion of new pipes to prolong the productive life of the well. Hydraulic swages like those disclosed in U.S. Pat. Nos. 3,540,224 and 3,555,831 have radial acting deforming tips that are used to repair casings or interconnect pipes which are greater than 7 inches (17.78 cm) in diameter. The problem now is that of repairing small pipes, i.e. pipes or tubes of less than 7 inches. The disclosed swages are 31/2 inches (8.89 cm) in diameter for repairing and for connecting small pipes. Two typical small coaxial pipes or tubes to be connected have their abutting ends positioned internally of a third short tube therearound, FIG. 1. The invention is used here for connecting one of the abutting tube ends to an end of the third short tube telescopically positioned therearound. Then the invention is used again in connecting the other abutting tube end to the other end of the short tube telescopically positioned therearound.
OBJECTS OF THE INVENTION
Accordingly, a primary object of this invention is to provide a few methods for forming or assembling a few swages for the repair of, or connecting of, two small pipes, pipes or tubes, for example which are less than 7 inches in diameter.
Another primary object of this invention is to provide a few different swages assembled or formed by the above methods for repairing or connecting small pipes together, as small oil and gas well casings or production tubes with increased efficiency.
Still another object of this invention is to form at least three different swages with indentation tips thereon, two of which having the features which with increased pivotal movement of an arm and link combination therein, a gain results in the mechanical advantage and indentation force.
A further object of this invention is to provide a swage for forming contiguous indentations in the walls of two small telescopic tubes that is easy to operate, is of simple configuration, is economical to build and assemble, and is of greater efficiency for the repair and interconnecting of the two tubes.
Other objects and various advantages of the disclosed methods for forming three swages and three swages made by the above methods will be apparent from the following detailed description, together with the accompanying drawings, submitted for purposes of illustration only and not intended to define the scope of the invention, reference being made for that purpose to the subjoined claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings diagrammatically illustrate by way of example, not by way of limitation, three forms of the invention wherein like reference numerals designate corresponding parts in the several views in which:
FIG. 1 is a schematic diagrammatic front view of a swage internally of a tube that has been connected to another abutting tube with a short tube around both;
FIG. 2 is a schematic sectional view of an elevation of one modification of the swage illustrated in dimpling position in solid lines and in retracted position in broken lines with parts cut away for clarity of disclosure;
FIG. 3 is a schematic section view taken at 3--3 on FIG. 4 of a second modification of the swage illustrated in retracted position;
FIG. 4 is a sectional view taken at 4--4 on FIG. 3;
FIG. 5 is an enlarged portion of the sectional view of the swage of FIG. 3 shown in deforming position internally of two tubes to be interconnected;
FIG. 6 is a sectional view taken at 6--6 on FIG. 3;
FIG. 7 is a schematic elevation of a third modification of the swage;
FIG. 8 is a sectional view taken at 8--8 on FIG. 7;
FIG. 8A is a modification of FIG. 8; and
FIG. 8B is another modification of FIG. 8.
The invention disclosed herein, the scope of which being defined in the appended claims is not limited in its application to the details of construction and arrangement of parts shown and described, since the invention is capable of other embodiments and of being practiced or carried out in various other ways. Also, it is to be understood that the phraseology or terminology employed here is for the purpose of description and not of limitation. Further, many modifications and variations of the invention as hereinbefore set forth will occur to those skilled in the art. Therefore, all such modifications and variations which are within the spirit and scope of the invention herein are included and only such limitations should be imposed as are indicated in the appended claims.
DESCRIPTION OF THE INVENTION
This invention comprises three methods for assembling of forming a swage for joining together two small telescopic pipes, and three different swages which may be assembled or formed by the methods and which may be assembled by other methods, as by hand.
While the two pipes to be repaired or connected together may be any suitable pipes desired, this invention is particularly useful in an oil or gas well for connecting together, in an emergency for example, two small joints of casing in a string of casing or two small joints of production tubing in a string of tubing. Thus the term "tube" or "tubing" recited hereinafter may pertain to any desired pipe.
BASIC METHOD FOR ASSEMBLING OR FORMING A SWAGE
A method for forming a swage (10 of FIG. 1, 10a of FIG. 3, or 10b of FIG. 7, for examples) for joining the ends of two small (less than 7 inches or 17.78 cm) telescopic pipes or tubes (12 and 14 or 13 and 14 of FIG. 1) of about a diameter of 31/2 inches (8.89 cm), comprises basically the following steps:
(1) mounting a piston (16, 16a, and 63 of FIGS. 1, 3, and 7) in one end of a cylinder (15, 15a, and 64 of FIGS. 1, 3, and 7) and placing an end element at the other end of the cylinder (21, 53, and 60 of FIGS. 1, 3, and 7),
(2) pivotally connecting one end of an arm (22, 22a, and 74 of FIGS. 1, 3, and 7) to the piston,
(3) fixing indentation tip means (18, 18a, and 76 of FIGS. 1, 3, and 7) to the other end of the arm, and
(4) forming biasing means (31, 54, and 80 of FIGS. 1, 3, and 7) for pivoting the arm outwardly transversely of the cylinder responsive to the piston for deforming two contiguous depressions or dimples (48-50 and 48a-50a of FIGS. 1 and 5) in the two small telescopic tubes for forming a swage for efficiently joinint together two small tubes.
METHOD FOR FORMING THE SWAGE OF FIG. 1
The above basic method may be modified to assemble or form a swage as disclosed in FIG. 1 by adding the following steps,
(5) pivotally connecting one end (25, FIG. 2) of a second arm (23 of FIG. 2) to the piston (16),
(6) crossing the first and second arms (22 and 23), and
(7) pivotally connecting an end (29, 28) of each of two biasing means (22, 23) to the respective other ends (33 and 34) of the two crossed arms for forming an efficient swage having increasing mechanical advantage and indentation force with increased indentation movement for deforming two contiguous dimples (48, 50 of FIG. 1) in the ends of both small telescopic tubes (12, 14) for efficiently joining two small tubes (12 and 13) together.
More detailed method steps for forming the swage of FIG. 1 comprise,
(1) mounting a piston (16 of FIG. 2) in one end of a cylinder (15) and closing the other end of the cylinder with a cradle (21),
(2) pivotally connected one of the ends of each of first and second arms (22, 23) to the piston,
(3) crossing the free ends (29, 28) of the first and second arms with each other,
(4) pivotally connecting one of the ends of first and second links (31, 32) to the cradle in the other end of the cylinder,
(5) pivotally connecting the free ends (29, 28) of the first and second arms to the respective free ends (33, 34) of the first and second links forming two pairs of free end connections intermediate the piston and cradle, and
(6) fixing indentation tips (17, 18) to one of the free ends of each pair forming each connection for forming an efficient swage having increased mechanical advantage and indentation force with increased pivotal movement of the arms so that movement of the piston towards the cradle actuates the two indentation tips outwardly for forming two contiguous dimples in two small telescopic tubes (less than 7 inches in diameter) for efficiently and effectively joining together the two small telescopic tubes.
METHOD FOR FORMING THE SWAGE OF FIG. 3
The above basic method may be modified further to assemble or form a swage as disclosed in FIGS. 3-6 by adding the following steps,
(5) forming a guide means (51 of FIG. 3) fixed to the cylinder (15a), and
(6) shaping the guide means into an arcuate form (54) for causing the indentation tip means to engage and deform the two contiguous dimples (48a, 50a) in both small telescopic tubes for forming a swage for efficiently and effectively joining together two small telescopic tubes.
METHOD FOR FORMING THE SWAGE OF FIG. 7
The above basic method may be modified and enlarged further to assemble or form a swage as disclosed in FIGS. 7-8B by adding the following steps,
(a) forming the piston (63 of FIG. 7) slideable around a guide arm (62), and
(b) connecting biasing means (74) to the piston being actuated outwardly for forming a swage having increasing mechanical advantage and indentation force with increasing longitudinal movement of the piston outwardly of the cylinder for efficiently and effectively joining the two small telescopic tubes together.
Besides the above methods for assembling or forming a swage, this invention comprises a mechanism assembled by the above methods and for being assembled by other methods.
SWAGE OF FIGS. 1 AND 2
While various double acting swages may be made or assembled by the above methods, FIG. 1 illustrates one embodiment of the invention.
FIG. 1 is an elevational view illustrating a swage 10 in a well being raised by support cable 11 to the surface after connecting two elongated, small diameter, less than 7 inches (17.78 cm) tubes 12 and 13 with a shorter circumscribing telescopic tube 14.
FIG. 2 illustrates in section the double acting swage 10 comprising basically a cylinder 15 with a piston 16 operable therein, the piston being connected through arms and links to the lower end of the cylinder for extending and retracting depression or dimple forming indentation tips 17 and 18 for interconnecting the two small coaxial tubes 12 and 13, FIG. 1, with telescopic tube 14.
In greater detail, cylinder 15, FIG. 2, has a slot 19 and 20 on each side thereof and a cradle 21 closing the lower end of the cylinder. Two crossed arms 22 and 23 have their upper ends 24 and 25, respectively, pivotally connected to piston 16 with the respective pins 26 and 27. Depression of dimple forming indentation tips 17 and 18 are fixedly attached to the lower ends 28 and 29 of the respective arms 23 and 22. Cable 11 is attached to a conventional eye 30 in the top of the swage 10 for support thereof. Links 31 and 32 have outwardly curved upper ends 33 and 34, respectively, pivotally connected to the respective arm lower ends 29 and 28 with pivot pins 35 and 36 for biasing the indentation tips 17 and 18 outwardly for deforming the telescopic tubes.
While the indentation tips 17 and 18 are shown mounted on the lower ends 29 and 28, respectively, of the upper arms 22 and 23, they could be mounted on the upper ends 33 and 34 of the lower links 31 and 32 if so required for intrinsically economical engineering design. Lower ends 37 and 38 of links 31 and 32, respectively, are pivotally connected to the cradle 21 with respective pivot pins 39 and 40.
While the solid line position of the internal parts of the swage 10 illustrated in FIG. 2 is the tube deforming or dimpling position, the broken line position illustrated is the indentation tip retracted position. While various power means may be used to make the swage 10 double acting as DC motors, or the like, the preferred power means is a hydraulic system comprising a smaller piston 41 operable in a smaller cylinder 42 in the upper portion of the swage housing above the swage cylinder 15.
While only one retracting piston and cylinder are shown, and any number may be utilized, the preferred number is three as illustrated in FIG. 6 of the modification of FIGS. 3-6. A piston rod 43 is fixedly connected at its free end to the swage piston 16, as by being screwed into a threaded hole in the piston. Conventional O-rings 44 and 52 are mounted around the pistons 41 and 16, respectively, to insure a fluid tight fit. Line 45 supplies high pressure hydraulic fluid to cylinder 15 when called for, for actuating swage piston 16 and the connected linkage to the deforming solid line position. Line 46 supplies high pressure hydraulic fluid to the underside of small piston 41 in small cylinder 42 for raising the piston for raising the swage internal parts to the broken line, retracted position illustrated in FIG. 2.
An important feature of this linkage is that the outwardly curved links or biasing means 31 and 32 position their interconnecting intermediate pivot pins 35 and 36 outboard of their line of centers or line of their respective pairs of pivot pin centers 27-39 and 26-40. Accordingly, with increased outward or deforming movement of the arms and indentation tips, increased mechanical advantage and increased indentation force results, particularly after the line connecting the pivot pins 35-26 and 27-36 of arms 22 and 23 have passed the 45° position to the cylinder longitudinal axis. Attaching and supporting eye 30a, FIG. 2, permits lowering of the swage 10a to the desired level in the small tubes.
Briefly in operation hydraulic fluid under high pressure is supplied by a suitable controlled source (not shown) through line 45 illustrated in FIG. 2 to cylinder 15 for actuating swage piston 16 from the broken line position to the solid line position. As depression forming indentation tips 17 and 18 are actuated radially outwardly of the cylinder 15 through slots 19 and 20, respectively, they contact the two small telescoped sleeves or tubes 12 and 13 at a particular predetermined location. Upon the indentation tips reaching the solid line position, a pair of opposite dimples 47, 48, in tube 12, FIGS. 1 and 2, are formed contiguous with dimples 49 and 50 in tube 14, FIGS. 1 and 2, for example. Finally, the fluid in line 45 is vented to a return sump (not shown) and high pressure hydraulic fluid is supplied through line 46 to cylinder 42 for raising piston 41 for retracting the indentation tips. Then the swage 10, FIG. 1, may be rotated 90°, lowered one dimple diameter and two more oppositely positioned contiguous dimples formed in the two telescopic tubes. Any desired pattern of contiguous dimples may be formed as illustrated in FIG. 1 for securely and efficiently interconnecting the two small coaxial tubes 12 and 13 together with the third and telescopic tube 14.
SWAGE OF FIGS. 3-6
FIGS. 3-6 are sectional views illustrating a modified swage 10a made by one of the above methods for lowering into a well internally of the casing, and particularly inside small casing, as a casing having a diameter of less than 7 inches (17.78 cm) for interconnecting two tubes 12 and 13, FIG. 1, with a short telescopic tube 14, FIGS. 1, 4, and 5, therearound and contiguous therewith.
FIG. 3 illustrates a sectional view of an elevation of the modified swage 10a comprising basically a cylinder 15a having a piston 16a operable therein, the piston surrounding and being slideable on a shaft 51 for extending and retracting an arm 22a carrying a dimple forming indentation tip 18a for interconnecting the two small coaxial tubes 12, FIGS. 4, 5, and 13, FIG. 1, with telescopic tube 14, FIGS. 1, 4, 5.
In more detail, the shaft 51, FIG. 3, protrudes up through the middle of cylinder 15a and piston 16a for being fixedly secured in the top of the cylinder with screw threads. A lower end 53 of shaft 51 radiates out to a diameter substantially equal to that of the cylinder and has a plurality of arcuate surfaces thereon, one surface for each indentation tip carrying arm, as arcuate surface 54 for biasing or forcing outwardly arm 22a carrying dimple forming indentation tip 18a secured with screw 56, for example. The upper end of arm 22a is pivotally connected to the lower portion of piston 16a with pivot pin 26a.
The deforming piston actuation system of FIG. 3 is similar to that of FIG. 2, wherein smaller piston 41a, operable in cylinder 42a, has piston rod 43a fixedly connected to large deforming piston 16a by screw threads, for example. O-rings 44a and 52a-52b seal pistons 41a and 16a, respectively, in their respective cylinders 42a and 15a. High pressure hydraulic line 45a supplies high pressure fluid to the cylinder 15a and line 46a supplies high pressure fluid to cylinder 42a as required and controlled with suitable valves (not shown).
Outwardly biasing movement of deforming indentation tip 18a, FIG. 5, forms contiguous dimples 48a and 50a in the telescopic tubes 12a and 14a, respectively. As many additional contiguous dimples are formed around the two tubes and spaced at various distances from the peripheral edges of both tubes as deemed required before the swage is lowered to secure the second coaxial tube 13 to the overlying telescopic third tube 14 with a similar pattern of dimples made by the new method and apparatus of FIGS. 3-6.
While any number of pivotal arms may be used, FIG. 4, a sectional view at 4--4 on FIG. 3, illustrates the preferred number of arms to be three, all equally spaced radially about shaft 51 and similar to pivotal arm 22a.
FIG. 5, an enlarged view of a portion of FIG. 3, illustrates the swage 10a after having formed the two contiguous dimples 48a and 50a in the telescopic tubes 12a and 14a.
FIG. 6, a section at 6--6 on FIG. 3, shows a top view of the hydraulic system for extending and retracting the deforming indentation tip 18a. High pressure hydraulic fluid is supplied from line 46a, FIG. 6, to the three similar retracting cylinders 42a, 42b, and 42c for actuating their respective piston rods 43a, 43b, and 43c.
Briefly, in operation of the modification of FIGS. 3-6, high pressure fluid is supplied by a suitable controlled source (not shown) through line 45a, FIG. 3, to cylinder 15a for actuating swage piston 16a from its retracted position of FIG. 3 to its extended position of FIG. 5. Thus as dimple forming indentation tips 18a, 18b, and 18c, FIG. 4, are actuated radially outwardly of the cylinder 15a, FIG. 5, through a slot 19a, they contact the two small telescoped tubes 12a, 14a at a particular predetermined location. As the indentation tips on arm 22a reach the extended position illustrated in FIG. 5, a pair of contiguous dimples 48a and 50a is formed by each indentation tip. Then the high pressure fluid is valved over from line 45a to line 46a for actuating retracting piston 41a up to retracted position illustrated in FIG. 3 to retract the arm 22a, FIG. 5, with its indentation tip 18a to the retracted position of FIG. 3. Then the swage may be raised or lowered and rotated for forming any desired pattern of contiguous dimples for securing the ends of telescopic tube 14a around and to the juxtapositioned ends of tubes 12 and 13, as illustrated in FIG. 1.
SWAGES OF FIGS. 7-8B
FIG. 7 is an elevation of another basic modification of a small diameter (less than 7 inches or 17.78 cm) swage 10b comprising basically a motor for extending depression forming indentation tips mounted on pairs of interconnected links.
More specifically, the swage 10b, FIG. 7, comprises a head 60 having a support eye 61 and being fixedly connected to rigid conduit 62 of the main body, which in turn includes a piston and cylinder 63, 64, respectively, driven by a hydraulic gear pump 65 connected to a hydraulic fluid reservoir 66 with a bank of conventional reversible DC motors 67 connected to a common drive shaft for driving the gear pump, and a stabbing guide 68 for including ballast, if so desired. Support and wire line and electrical cable 30c connected to eye 61 supplies the electrical current for the DC motors 67 for driving the gear pump 65 for actuating piston 63 longitudinally in its cylinder 64.
A linkage system connected to the piston actuates the deforming or dimpling means of swage 10b, FIG. 7. Two pins 69 and 70 pivotally connect upper projections 71 and 72 on the piston 63 to the lower ends of actuating links 73 and 74. Depression forming indentation tips 75 and 76 are fixedly mounted on the upper ends of the actuating links 73, 74, respectively, and extending radially outwardly. Pivot pins 77 and 78 pivotally connect upper links 79 and 80 to the respective lower actuating links 73 and 74, while pivot pins 81 and 82 pivotally connect the upper ends of the upper links to lower projections on the underside of the swage head 60. Compression springs (not shown), or the like, may be positioned between the rigid conduit 62 and links 79 and 80 for biasing the indentation tips 75, 76 outwardly.
FIG. 8, a section at 8--8 on FIG. 7 of swage 10b illustrates the two radially oppositely positioned actuating lower links 73 and 74 pivotally connected to piston projections 71 and 72 for being actuated upwardly to extend and retract deforming indentation tips 75 and 76, respectively, as for forming contiguous dimples in the ends of the two telescopic small tubes 12 and 14 or 13 and 14, FIG. 1.
FIG. 8A, a view similar to that of FIG. 8, illustrates a modified swage 10c in which three circumferential equally spaced actuating links 83, 84, and 85 are pivotally connected to the piston projections 87, 88, and 89, the piston being operable in cylinder 86 for extending and retracting the deforming indentation tips for forming contiguous dimples in the ends of the two small telescopic tubes 12 and 14 or 13 and 14, FIG.1.
FIG. 8B, a view similar to FIG. 8, illustrates another modified swage 10d wherein four circumferentially equally spaced actuating links 90, 91, 92, and 93 are pivotally connected to the piston projections 94, 95, 96, and 97 for extending and retracting the deforming indentation tips for forming contiguous dimples in the ends of the two small telescopic tubes 12 and 14 or 13 and 14, FIG. 1.
Briefly, in operation of the modification of FIGS. 7 and 8, the swage 10b is lowered down internally of the ends of two telescopic tubes to be connected to each other with the forming of contiguous dimples therein. Reversible DC motors 67, FIG. 7, connected to power line 30c, drive hydraulic gear pump 65 for raising and lowering the piston 63 for actuating outwardly the dimple forming indentation tips 75 and 76 on the linkage for forming the two opposite pairs of contiguous dimples 48 and 50, FIG. 1, in the ends of the small telescopic tubes 12 and 14 and 13 and 14.
As in the first modification of FIGS. 1-2, with increased outward or deforming movement of the indentation tips of this modification of FIGS. 7-8, increased mechanical advantage and increased indentation force results, particularly after the links forming the pairs 73-79, FIG. 7, and 74-80 pivot to less than 90° to each other.
While the above swages are illustrated and described in vertical position in vertical pipes, obviously they may be positioned at any other angle with the vertical for interconnecting two pipes at any angle with the vertical.
Thus accordingly, it will be seen that the present methods for forming a swage and the various swages operate in a manner which meets each of the objects set forth hereinbefore.
While only three basic embodiments of the invention have been disclosed, it will be evident that various other modifications are possible in the methods and in the arrangement and construction of the disclosed swages without departing from the scope of the invention, and it is accordingly desired to comprehend within the purview of this invention such modifications as may be considered to fall within the scope of the appended claims. | Three methods for forming three different, double acting, self-contained swages for joining two small diameter tubes are disclosed. Likewise three double acting small diameter (31/2 inch) combination hydraulic-mechanical swages assembled by the methods are disclosed using hinge arms with indentation tips thereon for deforming and connecting together two small (less than 7 inches or 17.78 centimeters diameter) telescopic tubes for casing repair or a flow line connection, for example. Two of the modifications have links connected to the swaging arms so that with increased pivotal movement of the arm and link, a gain results in the mechanical advantage and indentation force. | 4 |
This is a continuation of application Ser. No. 08/458,511 filed on Jun. 2, 1995, now abandoned.
TECHNICAL FIELD OF THE INVENTION
This invention relates to a thermostat assembly and in particular to a thermostat assembly for a cooling circuit of an internal combustion engine.
BACKGROUND OF THE INVENTION
It is well known to provide a thermostat assembly for the cooling circuit of an internal combustion engine to restrict the flow of cooling water through the radiator when the engine is started from cold.
A common problem with such assemblies is that they allow warm coolant from the bypass to flow straight out of the outlet. Another problem is that there is no control over the mixing of warm and cold coolant.
It has become increasingly popular in recent years to use a combined bypass and thermostat assembly located in the supply between the bottom of the radiator and the circulation pump rather than in the return between the engine and the top of the radiator. This change in practice has been primarily encouraged by the need to more accurately control the coolant temperature of the engine and to eliminate the large temperature oscillations which can occur when a top mounted thermostat is used.
However, it is a problem with such supply line located bypass and thermostat assemblies that they can lead to the thermostat being unduly influenced by the temperature of the relatively cold coolant entering from the bottom of the radiator. In extreme cases this can lead to the thermostat restricting the flow of cold coolant from the radiator to such an extent that boiling of the coolant within the engine occurs. It is a further problem with such prior art bypass and thermostat assemblies that the unregulated flow regime within the valve chamber can lead to inconsistent operation due to random impingement of hot fluid from the bypass or cold fluid from the radiator upon the temperature sensitive part of the thermostat.
Breeden (GB 2241301) addresses these problems by ensuring that warm coolant from the bypass must pass by the bulb of the thermostat thereby ensuring that it senses the temperature of the recirculated bypass flow. This invention has three disadvantages: firstly it utilizes all new components and so cannot be easily incorporated into an existing design, it is more expensive to produce than a conventional thermostat and thirdly it is doubtful whether the sliding seal 29 could be made to work reliably.
However, Breeden is relevant because it shows the need to produce a stable and controlled flow within the valve chamber.
It is an object of this invention to overcome the disadvantages associated with known supply line or bottom hose bypass and thermostat assemblies.
SUMMARY OF THE INVENTION
According to a first aspect of the invention there is provided a combined bypass and thermostat assembly for a cooling circuit of an internal combustion engine comprising a housing defining a valve chamber and a bypass and thermostat valve assembly mounted in the valve chamber, the housing having a first fluid inlet to connect the valve chamber to a source of cooled fluid, a second fluid inlet to connect the valve chamber to a bypass flow from the engine and a fluid outlet to connect the valve chamber to a return supply to the engine, the bypass and thermostat valve assembly having a temperature responsive valve actuating means connected to a first valve member to regulate the flow of fluid from the first inlet to the outlet in response to the sensed temperature of the fluid in contact with a temperature sensitive part of the temperature responsive valve actuating means and a second valve member to regulate the flow of fluid from the second inlet to the outlet wherein flow control means are attached to part of the wall of the valve chamber to direct the fluid entering the housing through the second inlet over the temperature sensitive portion of the temperature responsive valve actuating means so that the position of the first valve member is determined primarily by the temperature of the fluid entering the valve chamber through the second fluid inlet.
Preferably, the flow control means may include a tube connected to the second inlet to form an inner valve chamber encircling the temperature sensitive portion of the temperature responsive valve actuating means.
Advantageously, the first valve member is plate like and acts so as to deflect flow from the first inlet away from the temperature sensitive portion of the temperature responsive valve actuating means.
The first valve member may be attached to the temperature sensitive portion of the temperature responsive valve actuating means so that between 10% and 20% of the outer surface area of the temperature sensitive portion is exposed to fluid entering through the first inlet.
The temperature sensitive portion may be a wax filled temperature responsive actuator.
The housing may comprise of two separate housing parts connected together to define the valve chamber.
The tube may be formed as an integral part of one of the two housing parts.
According to a second aspect of the invention there is provided a cooling circuit for an internal combustion engine comprising a radiator having a top tank and a bottom tank a supply line between the bottom tank and the engine, a combined bypass and thermostat assembly interposed in the supply line, a coolant circulation pump to circulate coolant through the engine and return it via a return line to the top tank and a bypass line connected between the return line and the combined bypass and thermostat assembly to allow a controlled flow of coolant from the return line to pass back into the engine wherein the bypass and thermostat assembly comprises a housing defining a valve chamber and a bypass and thermostat valve assembly mounted in the valve chamber, the housing having a first fluid inlet to connect the valve chamber to the supply line from the bottom tank, a second fluid inlet to connect the valve chamber to the bypass line and a fluid outlet to connect the valve chamber to the supply line to the engine, the bypass and thermostat valve assembly having a temperature responsive valve actuating means connected to a first valve member to regulate the flow of fluid from the first inlet to the outlet in response to the sensed temperature of the fluid in contact with a temperature sensitive portion of the temperature responsive valve actuating means and a second valve member to regulate the flow of fluid from the second inlet to the outlet, the flow control means being attached to part of the wall of the valve chamber to direct the fluid entering the housing through the second inlet over the temperature sensitive portion of the temperature responsive valve actuating means so that the position of the first valve member is determined primarily by the temperature of the fluid entering the valve chamber through the second fluid inlet from the bypass line.
Preferably, the flow control means may include a tube connected to the second inlet to form an inner valve chamber encircling the temperature sensitive portion of the temperature responsive valve actuating means.
Advantageously, the first valve member is plate like and acts so as to deflect flow from the first inlet away from the temperature sensitive portion of the temperature responsive valve actuating means. The first valve member may be attached to the temperature sensitive portion of the temperature responsive valve actuating means so that between 10% and 20% of the outer surface area of the temperature sensitive portion is exposed to fluid entering through the first inlet.
The temperature sensitive portion may be a wax filled temperature responsive actuator.
The housing may comprise of two separate housing parts connected together to define the valve chamber.
The tube may be formed as an integral part of one of the two housing members.
The outlet from the bypass and the thermostat assembly may be connected to the inlet side of the coolant circulation pump.
The attractiveness of the present invention is that the majority of the parts are completely standard and so have been used for many years. The implementation of the invention therefore only requires a small change to standard parts in order to be made. Although the terms hot and cold are used it will be appreciated that when the engine is up to normal operating temperature there may be very little difference between the temperature of the coolant in the bypass and that from the radiator. It would appear that provided the cold coolant cannot disturb the fluid surrounding temperature sensitive element and there is sufficient warm coolant surrounding the temperature sensitive portion of the invention is enabled. It is therefore possible that the tube could have apertures in it.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawings of which:
FIG. 1 is a cross section through a combined bypass and thermostat assembly according to a first embodiment of the invention showing the thermostat valve in a closed position with the bypass valve fully open;
FIG. 2 is a cross section similar to that of FIG. 1 but showing the thermostat valve partially open;
FIG. 3 is a cross section similar to that of FIG. 1 but showing a first modification;
FIG. 4 is a cross section through a combined bypass and thermostat assembly according to a second embodiment of the invention showing the thermostat valve in a closed position and the bypass valve in an open condition;
FIG. 5 is a schematic drawing of a cooling circuit for an internal combustion engine incorporating a combined bypass and thermostat according to the first embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 5 there is shown an engine 11 having a coolant circulation pump 12, a radiator 13 having a top tank 16 and a bottom tank 17 and a combined bypass and thermostat assembly 14 interposed in the supply line between the bottom tank 17 and the coolant circulation pump 12.
The bypass and thermostat assembly 14 is connected to the bottom tank 17 of the radiator 13 by means of a bottom hose 18 and to the circulation pump 12 by means of a supply hose 15. The bypass and thermostat assembly is connected to a top or return hose 10 connecting the engine 11 to the top tank 16 of the radiator 13 by means of a bypass hose 22.
In use, the cooling circuit operates as follows, initially, when the engine is cold, the thermostat part of the assembly 14 is in a closed position preventing the passage of coolant from the bottom tank 17 into the engine 11 via the bottom hose 18 and the supply hose 15.
To prevent local overheating of the engine 11 when the thermostat valve is closed the bypass valve part of the assembly is open allowing a controlled flow of coolant from the return hose 10 through the bypass passage 22 to the supply hose 15.
When the temperature of the coolant passing through the bypass and thermostat assembly 14 reaches a predetermined temperature the thermostat part of the assembly 14 is operative to allow coolant to gradually be admitted from the bottom tank 17 through the bottom hose 18 to mix with the coolant already circulating through the engine 11.
When the engine is at its normal running temperature, coolant passes freely from the bottom tank 17 through the bypass and thermostat assembly 14 and into the circulation pump 12, through cooling passages (not shown) defined within the engine 11 and then back to the top tank 16 via the return hose 10 to be cooled for recirculation from the bottom tank 17.
As the temperature of the coolant approaches the normal running temperature the bypass valve part of the assembly closes so that flow through the bypass hose 22 is effectively shut off ensuring that virtually all of the coolant circulates through the radiator 13 before returning to the engine 11.
With particular reference to FIGS. 1 and 2 there is shown in greater detail the combined bypass and thermostat assembly 14.
The assembly comprises first and second plastic housings 25, 26 secured together by friction welding defining a valve chamber 20 in which is mounted a combined bypass and thermostat valve assembly 30.
The first plastic housing 25 has the form of a tubular inlet member, a cylindrical outer surface 25A for engagement with the bottom hose 18, and an internal surface which defines a first inlet passage 27 and part of the valve chamber 20.
The second plastic housing 26 has an internal cavity which defines the major portion of the valve chamber 20, a first cylindrical portion defining a second inlet passage 26A to connect the bypass hose 22 to the valve chamber 20 and a second cylindrical portion defining an outlet passage 26B to connect the valve chamber 20 to the supply hose 15. The first and second inlet passages 27, 26A are on a common axis whereas the axis of the outlet means 26B is inclined with respect to the common axis of the first and second inlet passages 27, 26A.
The bypass and thermostat valve assembly 30 is conventional in construction and comprises a temperature responsive valve actuating means 31 formed by a temperature sensitive wax filled body 32, an end cap 35 and a reaction rod 33. The reaction rod 33 extends away from the wax filled body 32 towards the first inlet passage 27 where it abuts against an end plate 34 of the valve assembly 30.
A first valve member 36 is attached to the end cap 35 and the wax filled body 32 near to the end from which extends the reaction rod 33. The first valve member 36 extends radially outwardly from the wax filled body 32 for co-operation with an inwardly extending lip 40 formed on a flange plate 41 connected to the end plate 34. The first valve member 36 and the extending lip 40 form, in combination, the thermostat valve part of the valve assembly 30 to regulate the flow of coolant from the first inlet passage 27 to the outlet passage 26B.
The first valve member 36 is biased towards the lip 40 against the action of the valve actuating means 31 by a spring 29 interposed between the first valve member 36 and a reaction plate 28 connected to the end plate 34 by means of a pair of longitudinally extending limbs 28A.
The flange plate 41 is used to support and locate the valve assembly 30 within the valve chamber 20 and is clamped around its outer periphery between the first and second housings 25, 26. A sealing ring 42 is interposed between the first housing 25 and the flange plate 41 to provide a seal between the first and second housings 25, 26.
At the end of the bypass and thermostat valve assembly 30 facing the second inlet passage 26A there is formed a spring biased second valve means in the form of a bypass flow valve 50. The bypass flow valve 50 has a valve member 51 for abutment against an end wall 52 of the second plastic housing 26 to regulate the flow of coolant from the second inlet 26A to the outlet passage 26B.
A tube 38 attached to the end wall 52 of the second housing member 26 extends away from the second inlet means 26A to define a cylindrical inner chamber encircling the majority of the wax filled body 32 of the bypass and thermostat valve assembly 30.
The tube 38 prevents coolant from flowing directly from the second inlet means 26A to the outlet means 26B without passing over the wax filled body 32. This ensures that the wax filled body 32 is primarily influenced by the temperature of the coolant within the inner chamber formed by the tube 38 and not by the temperature of the coolant entering through the first inlet passage 27.
The first valve member 36 deflects coolant entering the thermostat assembly through the first inlet passage 27 outwardly and way from the temperature sensitive wax filled body 32 which, in combination with the tube 38, ensures that it is very difficult for cold coolant entering through the first inlet passage 27 to impinge directly upon the main part of the wax filled body 32.
To further shield the wax filled body 32 from the cold coolant entering the bypass and thermostat assembly 14 through the first inlet 27 a small flow of relatively hot coolant is allowed to reach the wax filled body 32 even when the valve member 51 is in abutment with the end wall 52.
When the engine 11, shown in FIG. 5, has reached its normal running temperature the reaction rod 33 is virtually fully extended causing the first valve member 36 to be fully open and the bypass flow valve 50 is closed thereby restricting the flow of coolant passing between the second inlet 26A and the outlet 26B. The closing of the bypass valve 50 ensures that the majority of the coolant passes through the radiator before being returned to the engine thereby achieving maximum cooling.
With reference to FIG. 3 there is shown a combined bypass and thermostat assembly which is in most respects identical to that shown in FIG. 1 with the exception that the first valve means 36 is attached to the outer surface of the wax filled body 32 further along the wax filled body 32 towards the bypass valve 50. This modification allows between 10% and 20% of the outer surface of the wax filled body 32 to be exposed to the flow from the first inlet passage 27.
This modification prevents the thermostat from opening too soon when the ambient temperature of the coolant from the radiator is very low thereby allowing the engine to attain a higher temperature before relatively cold coolant is admitted from the radiator.
With reference to FIG. 4 there is shown a second embodiment of the invention in which the first plastic housing is substantially as described above but in which the second plastic housing is replaced by a number of cavities and passageways formed as an integral part of the cylinder head or cylinder block of the engine.
The bypass and thermostat assembly 214 is in most respects identical to that previously described and also utilizes a conventional bypass and thermostat valve assembly 230 located in a valve chamber 220. However, instead of the tube 238 which forms the inner valve chamber being formed as an integral part of one of the housings it is in this case a separate component that is press fitted into a bore 278 in the cylinder head 200 which defines part of the valve chamber 220.
In use, coolant will enter the valve chamber 220 from the first inlet 227 which is connected to the radiator, or from the second inlet 226A, depending on the operating conditions. In either case the coolant returns via the outlet passage 226B to the coolant circulation pump via a hose (not shown) connected to the pipe connector 226C.
If the bypass valve 251 is closed the majority of coolant from the engine passing along the passageway 279 which is connected to other passageways (not shown) will go directly back to the radiator via a hose (not shown) connected to the pipe connector 279A.
Although the invention has been described by way of example with reference to a water cooling circuit for an internal combustion engine it will be appreciated that it could be similarly used in an oil cooling circuit for an internal combustion engine or other fluid cooling systems.
Furthermore it will be appreciated that the invention is not limited to the embodiments specifically described herein, for example, the first and second housings could be made of any suitable material, and the bypass and thermostat assembly could be incorporated into the housing of another component forming part of the cooling circuit such as the circulation part of the radiator.
It will also be appreciated that the tube which forms the inner valve chamber could be formed as an integral part of the housing as described with respect to the first embodiment or could be a separate component as described with respect to the second embodiment. | A cooling circuit for an internal combustion engine is disclosed in which the bypass and thermostat assembly includes means to prevent relatively cold coolant entering the thermostat assembly from a bottom hose to impinge upon a temperature sensitive valve actuating means. The bypass and thermostat assembly is therefore unaffected by relatively colder coolant entering the assembly as the temperature sensitive part of the thermostat remains immersed in relatively warm coolant entering the assembly through a bypass hose even when the bypass is closed. | 5 |
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